Optimisation Through Insight: New Technologies For Turning & Machine Monitoring

In addition to releasing an industry first for turning, Sandvik Coromant is expanding its offerings for Industry 4.0. APMEN was in Sweden to cover the company’s latest developments. By Jonathan Chou

Cutting tool and tooling systems provider Sandvik Coromant has seen multiple changes in its 75-year history. Recently, the company developed a methodology called PrimeTurning, which the company states is the industry’s first true “all-directional turning” solution.

Unlike conventional turning operations which have remained relatively unchanged for decades, using new programming techniques and a suitable tool, longitudinal (forward and back), facing and profiling operations can be made with a single tool.

New Approach

The methodology is based on the tool entering the component at the chuck and removing material as it travels towards the end of the component. This allows for the application of a small entering angle, higher lead angle and the possibility of machining with higher cutting parameters. Furthermore, conventional turning (from part-end to chuck) can be performed using the same tools.

The company believes that some applications could see productivity increases in excess of 50 percent when compared to conventional techniques. Some of these improvements are due to the small entering angle and higher lead angle, which creates thinner, wider chips that spread the load and heat away from the nose radius.

In addition, as cutting is performed in the direction moving away from the shoulder, there is no danger of chip jamming (a common and unwanted effect of conventional longitudinal turning). Higher machine utilisation due to reduced set-up time and fewer production stops for tool changes also enhances overall productivity.

Big Batch Savings

The new methodology could mean expedited processes to manufacturing industries where there is a need to perform external turning operations in big batch productions or where multiple set-ups and tool changes are often required, such as for the automotive and aerospace sectors.

“Experienced operators know that a small entering angle allows for increased feed rates,” said Hakan Ericksson, global product specialist at Sandvik Coromant.

“However, in conventional turning they are restricted to using entering angles of around 90 degrees to reach the shoulder and avoid the long, curved chips that a small entering angle characteristically delivers.”

He added that the new methodology is able to circumvent these problems by combining a reach at the shoulder and the application of 25-30 degree entering angles with chip control and maintained tolerances.

The new methodology is initially supported by the introduction of two turning tools and the company worked with Mastercam to develop the PrimeTurning code generator, which supplies optimised programming codes and techniques compatible with various CNC systems.

Improving Productivity Through Data

The company also presented a suite of IIoT solutions, known as the CoroPlus concept. It aims to improve the control of productivity and costs through a combination of connected machining as well as access to manufacturing data and expert knowledge.

The suite consists of tools and software that can send and/or receive data. Using connected technology and machining knowledge from the company, the suite makes it possible to reduce data waste and improve manufacturing processes in design and planning and in-machining.

With access to product and application data along with sensor-equipped tools, users can adjust, control and monitor machining performance in real time. The suite connects into existing software environments through open Application Programming Interfaces(APIs).

Optimisation To Avoid Breakages

The main benefit of such a concept is the ability to optimise manufacturing through better understanding and insight into what is happening in the workshop and machining environment. Some examples would be the CoroBore, which makes use of embedded sensors to remotely set up the boring tool, and the company’s line of Silent Tools, which provides in-cut monitoring for tools using connected, damped adapters for the internal turning of deep features.

The company’s Promos 3+ data collector can monitor tools and operations in real time. Developed by Prometec, the data collector receives signals from sensors that monitor parameters such as force, structure-borne noise, or active power against limit values. This can work to prevent collisions before they happen, or stopping a machine if a tool breaks.

APMEN Metal Cutting