The Road to Success Starts Here

New indexable carbide hobs are designed for higher cutting speeds and feedrates for improved productivity. The high-precision cutter body reduces runout and improves tool life.Sandvik Coromant recently held a Pre EMO 2011 press event in Sandviken, Sweden, in preparation for this year's EMO Show taking place the week of September 19, 2011 in Hannover, Germany. The intent of the event was to provide insights as to what show attendees can anticipate in terms of productivity improvements.

Sandvik Coromant titled the press event, "The Road to Success Starts Here," and according to the Coromant management team, this road to success is based on four key organizational areas: Research and Development; Product and Know-How Development; Training; and Events/Web and Software Solutions. Focusing on these areas also creates a value-chain strategy whereby Sandvik Coromant can provide a comprehensive portfolio of value-added services and solutions that maximize their customer's productivity and profitability.
 

Value Chain Strategy
Since every customer has productivity issues, Sandvik Coromant's goal is to uncover the problems and employ its value chain strategy to devise unique solutions. Truly partnering with the customer, rather than just being a supplier that uses conventional sales techniques, Sandvik Coromant provides a thorough cost savings analysis. For example, Sandvik Coromant specialists will work closely with the customer's staff to identify bottlenecks, tooling requirements, logistical improvements, and process adjustments through their entire value chain of R&D, as well as through production logistics. Assistance is provided to implement changes, document results, and follow them up. Best of all, this service can result in improved productivity and higher profits, without making a major capital investment.
 

Coromant Capto
With more than 5,000 standard products, the Coromant Capto machine tool interface offers unique options for all spindle interfaces.Adding to its value-added services and solutions, Sandvik Coromant will be displaying new product offerings at EMO 2011 for metalcutting industries such as aerospace, automotive, energy, medical, and a host of other areas.

For example, for all types of heavy machining operations of large components, the Coromant Capto size C10 improves performance by allowing higher feeds and greater depths of cut. The C10 has a flange diameter of 100mm, which means a coupling capable of the heavier loads in many milling applications and very high stability in turning applications.

Now an ISO standard, the total Coromant Capto range includes six different sizes (C3 to C10), with a broad selection of basic holders, clamping units, toolholders, integrated cutting tools, adapters, and chucks.
 

Quick Change
In addition, actual machining time can be maximized by reducing downtime – with improved setup and tool changing – efficiency using Sandvik Coromant's quick-change clamping units. Furthermore, the clamping units are equipped to channel high-pressure coolant from the latest CoroTurn HP cutting heads to reduce temperature and improve chip control. Using the Coromant Capto quick-change driven toolholders, all applications can be covered with one clamping unit, reducing the need for additional units – saving turret space and changeover time.
 

Gear Milling
Over the past few years, there has been a growing trend to replace HSS gear milling cutters with carbide insert cutters. Keeping in the forefront of this trend, Sandvik Coromant will be introducing the CoroMill 176 full-profile hob for gear milling at EMO 2011. The full-profile hob is estimated to reduce cutting time by 50%, and more than double tool life when compared to traditional high-speed steel cutters. For roughing, semi-finishing, and finishing, the hobbing tool solution covers gear profile sizes in the range module 4-6. The hob is extremely easy to use with the iLock interface, which insures precision and stability.
 

Silent Tools
Silent Tools boring bars and milling adapters are available in a range of lengths and diameters.Manufacturers involved in milling or boring operations that require an extended tool reach know that vibration during machining can severely limit productivity and affect the required finish. It can also be destructive to both the cutting tool and part being cut. If you are in search of a solution to this problem, Sandvik Coromant's Silent Tools is another avenue to put you on the road to success. Silent Tools boring bars and milling adapters are available in a range of lengths and diameters to obtain proper length-to-diameter-ratios for achieving the required chip evacuation clearance and counter tool deflection. The dampened bars have built-in technology for minimizing vibrations throughout different overhang ranges. They are developed for overhangs exceeding three to four times the bar-diameter, up to which steel bars can be used. At the longer end, carbide reinforced dampened bars can solve boring at overhangs up to 14X the diameter.

For milling with overhangs, a new generation of dampened adaptors has been developed. There are two lengths of adaptors dedicated for milling with overhangs of 4X to 5X the adapter diameter, and 6X to 7X the diameter, respectively. Reach beyond these tool overhangs is covered by engineered dampened adaptors.
 

CoroDrill/CoroMill
When it comes to cutting tools, experiencing Sandvik Coromant's road to success at this year's EMO Show, you will find yourself in a passing lane with no bumps or curves ahead. From new developments in composite holemaking with the CoroDrill 844 and CoroDrill 856 diamond coated solid carbide drills to ceramic inserts for milling and turning of heat resistant super alloys, the focus is on productivity improvements, as well as part quality improvements.

Three new styles of inserts for the CoroMill 316 exchangeable-head milling system are said to guarantee accuracy. The new designs of endmills, each with two cutting edges, provide maximum strength and security and extend the depth-of-cut for the CoroMill 316 range. The new range contains a ballnose for profile milling, aluminum machining, and finishing, equipped with a strong cutting edge for profile roughing.

There is also a corner radius for slot milling, shoulder milling, plunge milling, ramping, and pocketing. In addition, the tools are designed to handle chip evacuation problems when slot milling.

The system of exchangeable endmills is connected to a tool shank with a unique threaded coupling, which provides high-strength as well as accuracy. The tool, based on CoroMill Plura geometries, will be available in the latest PVD grade technology.

These products, coupled with Sandvik Coromant's approach to partnering with manufacturers, are only a sampling of the latest technologies and practices discussed at the Pre-EMO conference.

To learn more about "The Road to Success Starts Here," visit the Sandvik Coromant website sandvik.coromant.com/us.