Webinar
Beyond the surface - CoroCut 2
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Welcome to our knowledge session. My name is Paul Campbell, Turning Specialist at Sandvik Coromant and I'm delighted to have you join us today. In this session we'll explore transformative impact of selecting high quality tools for enhancing manufacturing processes, boosting both machining, security and productivity. We will focus on Sandvik Coromant's latest innovation, the Corocut 2 concept, designed specifically for part and grooving applications. As you know process security and productivity are crucial for cost effective and profitable business. Especially in part and grooving, the setup and the choice of tools is so important. So Corocut 1-2 has been our most versatile part and grooving concept since 1999. With a wide range of geometries to cover all different applications for part and grooving. Grades to cover different workpiece materials and tools to cover the machine interfaces that are available in the market. Now we are updating our offer with more customer value. The updated product family name will be Corocut 2. It's been developed to meet specific needs for part and grooving applications. Corocut 2 offers now a new level of process security and productivity for your machining. With the versatile tool concept you'll get the stability you need, while keeping your cost per component down and your metal cutting efficiency up. Upgraded inserts offer cost efficient machining. The Corocut 2 inserts are produced with a unique in-house developed painted technology, resulting in improved edge line quality for increase in tool life. The smaller inserts now have featured the rail interface, which offers a more stable insert, better location on the rail and the insert to give better performance. The wiper design on all part and geometries ensures an excellent surface finish. All new inserts are compatible with the old holders. Corocut 2 features a well-established rail interface for all insert sizes. The rail design provides a more precise insert position and minimizes the insert movement for improved stability, especially when applying side forces to the inserts. All new inserts will be compatible with old tool holders. But you get the benefit of a more precise insert location and minimized insert movement with the new holders. You need to convert now to the new holders with the rail design to get all the benefits we have to offer with the new Corocut 2. Corocut 2 inserts are produced with a unique in-house developed painted technology, which results in higher quality edge line. The results superior tool life with better blanks from the painted technology. We can achieve a better control of the ER on the insert, which means we can reduce the tolerance and have the same quality on both edges. In the picture, you can see clearly the new insert edge line is much cleaner and much more intact. There are no lumps and bumps down to the new technology. The wiper design is on all part and geometries. Wiper inserts let you machine components at higher feed rates without compromising on a good surface finish and excellent swarf control. A general guideline is two times a feed rate will give you the same surface finish as a non-standard wiper insert, or the same feed rate with twice as good surface finish. New and updated high performance grades. The new first choice grade for Corocut 2 will be GC 1225. This offers superior flank wear resistance and edge line toughness. It's perfect for all part and grooving and turning operations in good conditions. We have the grade GC 4425. It offers excellent combination of high wear resistance and good edge line security. The application area is grooving, turning and parting off operations in stable conditions. Let's have a look at 1225 compared to our existing 1125. The new 1225 has improved flank wear resistance and higher edge line security. This means if the limiting wear mechanism is flank wear, you can expect around a 50% longer tour life. The increase in edge line security means you will have a more secure process. The GC 4425. In this introduction, this grade will be available in Corocut 2. The parting off geometries in Corocut 2 will have an optimised coating for the parting off application to make it more secure. For turning, the TF and the profiling geometry RM are using the same coating process as in general turning. Use high surface speeds and stable setups to get the benefits of this grade. The grade 1225 provided a 36% increase in tool life compared to the existing grade 1125. So clearly it's a winner over our own 1125 grade. The improved clamping design and the precision coolant in our tools. This is a key advantage. The Corocut 2 parting blades are upgraded with internal coolant and improved clamping finger design. Which ensures a higher clamping force and better stability. Corocut 2. Corocut 2 holders with precision coolant are updated with a screw clamp solution. This will replace the former spring lock mechanism. The screw clamp solution and the rigid rail insert seat make machining more reliable than ever. Keep an insert movement to a minimum without any clamping force lost. Ultimately this new solution will prolong tool life, increase performance and help reduce costs. When compromising the new tools with all the updates in Corocut 2, the insert movement has been reduced by 50% of a load of 500Nm. This gives us a much more secure clamping of the insert, less movement, better performance. The updated blades have improved clamping finger design. The shorter clamping finger provides higher clamping force and better side stability. This results in better performance when making chamfers when parting off. The new blades also comes with internal coolant that increases the tool life and helps chip evacuation. Looking at the parting off test with the Corocut 2 versus the old Corocut 1-2, both tool life and surface finish are improved with the Corocut 2. This again is due to better stability and the internal coolant. We've had some new product additions to the Corocut 2 family. The new GL geometry for grooving in low alloyed steels, in particularly difficult to chip materials. One very important area is swarf control when grooving. This new geometry eliminates poor swarf control. That can cause machine downtime and machine stoppages. This insert is available in widths of 2 to 6mm with our full grade portfolio offer. Also the new profiling insert that gives superior swarf control, just like the GL geometry. This profiling insert has exceptional swarf control and superior surface finishes. Its flawless edge line offers surface quality, validated according to aerospace standards. This new geometry is called the RF geometry. Which brings us to another product that is perfectly positioned for aerospace applications. And the new HRSA grade GC1205. This has superior edge line strength that delivers constant tool life with every edge. It's a PVD coated insert which allows for significant increase in both cutting speed and gives us extra tool life. Another key area that we need to look at is tool holding and tool interfaces. We have a large portfolio of specific holders that can be used with the different machine interfaces. Current Capto, VDI and HSKT for connecting QS shanks and parting blades in turning centers. QS stops for connecting QS shanks and Swiss tools for machine specific adapters. Rectangular shank tool holders and boring bars are also included in this release. Plug and play adapters for easy coolant connection. Coroturn SL cutting heads enable a wide range of tool combinations from a small inventory. The versatility of Corocut 2 is exceptional. We have all the latest geometries covering all parted and grooving applications. Grades for a wide range of workpiece materials and tool holders available for all common machine tools. We'll take a look at a Corocut 2 demo. Parting and profiling with Corocut 2. The upgraded Corocut 2 shows how secure parting and grooving operation can be achieved. And when profiling with Corocut, the swarf control is excellent. With total confidence with the insert location, even in tougher applications like face grooving. First choice for cost efficient machining in applications where it is possible to use double ended inserts. Two edges offer longer tool life per insert compared to a single edge concept designed for one specific application. Secure and efficient machining, process security and productivity are crucial in parting and grooving. The correct setup, the choice of tools will prevent problems. A wide range of geometries and tools with precision coolant enables optimisation for different machining conditions. Please do not hesitate to contact us for any support or contact your local Coromant engineer. We're here to support you with your new Corocut 2. Thank you for attending the webinar. Good luck with all your machining applications.