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On-demand webinar: Unlock Greater Efficiency by upgrading to the new CoroCut® 2
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Good morning, good afternoon everyone. Hope you all can listen to me very well. Great guys. Today, I think we are here to talk about, you know, our latest upgrade within Party and Grooving, which is Corocut 2, which is soon going to replace everything within Corocut 1.2 platform. So, let's unlock some greater efficiency with the new upgrade. So, we are going to go through this as such. If you have any questions, please utilize the chat. We have the chat platform, so you can post it in the chat. We will take it at the end of the presentation as such. So, before we start, let's look at safety first. As you know, Sandvik objective is zero harm to our people, the environment we work in, and our customers and our suppliers. And safety is always a top priority for us. Make sure that you know your emergency routines wherever you are located today. One thing I would like to emphasize is obviously psychological safety. Today, it is our webinar where we are sharing some information. So, feel free to ask questions. As I said, utilize the chat platform so we can have a very good interaction today. So, let's continue. So, who are the presenters? Myself, Harish Manur. I am currently responsible for offer implementation, turning products within Asia. As such, I have my colleagues here, Samik, who is responsible for working as a product solution specialist for turning products within India, and also Aris Khusnaryadi from SEAO. So, any questions, any kind of support you need, hands-on at your shop floor, at your place, these two guys can help you guys along with our, you know, sales specialists. So, I think today, I think we all know what the situation across the manufacturing industry, or not limited to manufacturing industry, but all the kinds of industry where we see, we have certain challenges, industry which is changing very fast. And I believe you can relate to this in your deal, in your work, or in the industry, what you're working in today. You know, sustainability is at a very high focus. Everybody is looking for sustainable solutions. We need to keep the climatic environment and everything in consideration. So, energy efficiency is in focus. There is very high targets on reducing emissions as such, and a need for circularity. It's very important that we have a circular economy within our moving forward. The second aspect, I think, which we all can relate to is the digitalization, which is increasing at a rapid pace. We need to navigate it. The technology is developing within digitalization. We need to upgrade ourselves there. So, that also keeps us in a more challenging environment moving forward. Cost pressure, I think we all can associate with this. Everywhere there is a cost pressure. We need to improve, improve, be more efficient. There is more complex components with different kinds of exotic materials. And obviously, the material cost is increasing with the geopolitical situation, what we have around the world. And there is a constant drive for efficiency doing that. And the other challenge, what you see, is obviously the skills gap. So, do we have enough people to do it? No. Today, the manufacturing technology is facing one of the biggest challenges, where we have less number of people interested in manufacturing, and therefore, a lack of skills and competence. So, automation takes much more precedence than before in this kind of a setup. And partnerships, even more important to grow and move into a win-win situation for all of us as such. So, how do we see this challenge? I mean, for us, it's very important that, you know, we support our customers, you know, with the technology and the knowledge to overcome these challenges within their businesses as such. And, you know, and move their businesses into the more, you know, healthy manufacturing environment. And this is where, in the changing industry, manufacturing wellness is essential. When I say manufacturing wellness is essential, what is manufacturing wellness? It's a mindset, simplifying complexities, taking leaps and mastering processes, you know, flattening costs. And obviously, a relentless pursuit towards the future, you know, improving the future, but then much more and testing new things, new ideas as such, appreciating new ideas as such. And, of course, you know, a way of looking at the challenges in a holistic view. And we need to drive this very calmly with a purpose as it is. And all this, it's a set of healthy habits that enable all the companies to do this successfully and create value for today, at the same time, you know, gearing up for the future. So, it is our belief within Sandvik Coruman or within Sandvik that manufacturing wellness is a key. And that is where we follow in our shock flows also. So, I mean, if you look at today, I mean, Sandvik Coruman, our brand promise is manufacturing wellness, has always been our core. I mean, we have been doing this. I mean, we have been reaching out to customers, supporting them in their developments, in their upskills, at the same time in the knowledge sharing and productivity, improving their productivity within the shop flows. We have been doing this very much consistently for all through over the 80 years. And we continue to do so. And our intention with everything we do, including today's presentation, is to enhance the, you know, our customers' manufacturing wellness. So, to give you even more information, even more new solutions for you to improve your manufacturing environment. And the eight habits outlined here are integral to our approach and reflect our commitment to this mission. If you look at the first one, which is take a holistic perspective, everything in manufacturing consists of various interconnections. So, everything has to follow in, fall in harmony. If something doesn't work, then it's a challenge for the whole chain. So, it is very important that we keep that in perspective whenever we do things. Embrace new technology is one area, you know, is also very much important in the rapidly evolving manufacturing landscape changes. I think the front runners are the ones who are able to adapt to this technology and able to take it forward and implement it in the shop floors. So, that is why it is very critical. And today, we are going to look into how our new products or new solutions can help in doing this as such. The other one, sustainable path. I think, to the sustainability, is very much key in the world today. And our industry needs to become part of the solutions as such. And we are working towards more sustainable and innovative solutions, you know. Eliminate waste. I think this is a key element for efficient and sustainable manufacturing to eliminate anything which is undue waste as such. So, uncovering the waste along the value chain is very much important and gives you new ideas to improve the processes. Unlock potential data. I think you all know data is the currency today. And we need to unlock that. So, there is large amount of data within the shop floor. If you create more transparency as such and create more awareness and accelerate the utilization of data for improving cross efficiency, it even helps better. And the benefit from strong partners, I think, is very much key. Partnerships and collaboration will drive the future much more because you can't develop everything on your own. And that is where we would also like to support you guys in your development, in your growth journey as such. And we would like to be the strong partner in your growth as such. Develop your people, which is very much key. As I said, I think one of the challenges, what you have seen is lack of skills and skill gaps, what we have today. So, develop your people becomes even more essential. You know, people are the backbone for the technology and also the growth of the organization. So, we need to empower them, continuously learn, give them the knowledge and upskill them as such. And in that sense, you won't just, you know, lead the market. You will create the standards, you know, with the developing of the people. The final one, automate for success. I think production setups may vary. There might be manual interventions, but automation will help you to be more, you know, resistant to that. At the same time, be more consistent in delivering of the quality and reduce the need for rare expertise and also accelerate your success as such. So, this is, you know, this is the manufacturing habits, you know, that we believe it's very important for us moving forward in the current manufacturing landscape environment. Thank you. So, just quick. So, let's go through a quick video. Uh... Imagine a workday where complex doesn't mean complicated. Securing high quality to low costs. Machining advanced components. Difficult grooves with high precision demands. And making it more efficient while maintaining process security. Delivering on time, continuous improvements, and troubleshooting and... Wait. Pause for a moment. Don't get blinded by the challenges or consumed by chasing quick fixes. Embrace new technology and advance confidently. Tap into the accelerating pace of change with new tooling solutions. Fine-tuned to remove machining obstacles in new, efficient ways. Because a new tool is more than an upgrade. It's a gateway to new possibilities. We drive true progress together when innovation meets grounded experience and expert knowledge. It's this winning combination that paves the way to manufacturing wellness. Creating value today while gearing up for the future. Thank you. So, the video has given you a short glimpse on how the new technology can help in manufacturing wellness. As such. So, today I think... What are the main manufacturing needs? You know, what you guys are looking for as such within... Everywhere is obviously increased output. You know, you want to see more output. We need to facilitate it. We need to make machine utilization even more efficient. And need to minimize unplanned stops and fix the machining problems, which we all know. Process security is another key aspect. I think reliable and predictable machining processes is needed of the hour today to avoid any unexpected interruptions. And thus, the consequences towards, you know, stoppages and the tool breakages or anything related to that kind of problems. Component quality. We have to be right quality on each part right from the start. So, it is critical for all the manufacturers to have that. And producing components according to the qualities is the key for us, you know, to moving forward. Or even in the current today as such. Cost reduction, I think, which remained all through and will remain all through in the future, is obviously for all the manufacturers to lower the production cost. And for that to happen, you need to have reliable solutions and processes that drives the lower component manufacturing cost as such. Sustainability is one important aspect which has recently developed and recently, you know, taken a larger scale in terms of manufacturing landscape. Is obviously the world needs to be more sustainable. So, the importance and the criticality of it is very high. And we need to support that journey towards moving that sustainable goals as such. And the other aspect, I think, which is very much key, I think, which we firmly believe in is service and support. I mean, we need to have, we need access to the services, not just digital or online, but at the same time, physical, you know, in person. So, that is where we in Sandvik Coleman, we firmly believe. I mean, we have the low quotes, we have our sales guys reaching out to you guys as such. So, we firmly believe that this is the key for us to succeed in terms of improving the manufacturing even further. So, let's talk today a little bit within, you know, the main manufacturing needs as such. So, where do you have the biggest potential for enhancement? What do you think? I believe everybody will agree today that increased output is the key. I think everyone wants higher output within their shop flow as such. So, when you look at the whole manufacturing value chain, you know, the total output is not just happening in missioning or just one machine as such. It's a complete manufacturing value chain where you need to create more valuable output. You need to convert it, you know. So, waste in the industry is huge, right? You know, we all know what are the waste as such. You know, if you look at design, then there is probably suboptimal design. If you look at operations, wrong tooling, toolpath, you know, as such, production logistics, I mean, unscheduled machine time, etc. But today, we are going to talk a little bit about missioning because we are more strong. We come from that background. So, let's look at missioning. I mean, what is the challenge with the missioning and what is the waste? Unproductive machine time. I mean, this is the key. I mean, we don't want any unproductive machine time. I think we need to address it immediately as such. And we need to look at how do we make this happen. And by focusing on the new technology, by focusing on, you know, new innovative solutions, we are able to do this. And that is where CoreCut2 comes into picture. You know, where we have higher output, managing the same surface finish with the wiper design for all parting geometries. So, we have come out with a new design, which can help you to keep the same surface finish, which can run at higher feed rates and gives you much better results. So, you get the productivity. At the same time, you also get the surface finish quality compliance as such. This is just one example of it. And then, of course, you do have the clamping part of it, where we have created a rail design, rail design for stability to improve productivity as such. And this, the good part is this gives you even more stable stability within the process. And it also ensures there is minimum movements of the insert, you know, when it is locked and it is doing the machining process. So, as you know, in parting and grooving or parting and facing or profiling, you have a lot of side forces. And that can also help, you know, disturb the movement. So, it's very important the clamping is rigid and stable. And this is where we have. And we have come out for the two, 2.5, 3 millimeter insert size, where we have the rail insert design as such. So, it's even more stronger now. And stable. And, of course, I mean, it's not just the product or the product design as such within the concept. It's also the grades that will enhance. So, every aspect, every feature will add on to the better performance. And that is where grades will help that, which we are looking for. And whatever I'm presenting today, the GC205, the new grade, which in HRSA, nickel-based alloys, I think these are very much higher speed, you know, capable grades. So, GC205, which is our latest PVD grade, which we have come out with, which helps you to run at higher cutting speeds. And the feeds with much more wear resistant as such. 44 are the CVD grade, which also runs at higher cutting speeds, gives you much better. So, what we clearly are mentioning it here is that it can give you higher productivity, higher output, at higher cutting conditions. So, that is what comes out with the Corocut 2. So, here is one example of the success case that we have from one of our customers who produces medical components, medical screws, so which you can associate small screws. And here, you can easily see the cutting conditions, which has been there. You know, you can see the cutting speed, which is 25, feed rate of 0.03 from competitor, and depth of cut of 4 millimeters with a cutting time of approximately 2 seconds. Whereas, when we use Corocut 2, we were able to increase the cutting speed, as I said, with the tool 25 grade, 35, feed rate of 0.08, depth of cut of 4, and cutting time of 1.06, so which reduced the cutting time. So, at the same time, you can look at the productivity here in a tool life, which is double the tool life. So, the result is plus 87% productivity, cost per part reduced by 22%. At the same time, the sustainability aspect is also taken care of, which is our savings within the machine, due to the productivity, higher productivity is 38%, carbon emissions reduced by 49%. So, this is one example of the upgrade in the new technology, what we have invested in, really works as such. The second aspect, as I spoke of, one was the increased output, one is the process security. Especially when you're talking about new upgrade solutions with the new technologies, then obviously there is a high concern on the old one was performing well, how the new one will work well. So, process security is key, which we have, which we consider it very highly when we are doing these kind of upgrades. So, here we come out with much more, and you all know, when it comes to process security, you know, process security is something when all the processes are running as expected, so no disturbances. So, that is when you have an expected process, so you don't have any deviations, so you're secure. When you have deviations, then you have a challenge, because that means the process is not stable, there is unexpected interruptions, it can be tool breakage, it can be machine issues, it can be anything else. But, at the same time, the consequence is less output. So, it's not only about the tools, a misplaced comma or wrong number in the machining input can change, can give you a stoppage, so it's as simple as that. So, it's very important that we make sure that the process security is taken care of from all the aspects, what we have, and that is where, you know, we also know that any small deviations that you see today, or small issues, you need to address it right away, or else it's going to create much bigger problems for tomorrow. So, it can be, you know, late derivative to our customers, or, you know, higher product cost, as such. And, of course, I mean, rapid firefighting instead of proactive improvements. So, with that, adds the extra time you can save. If you are really proactive, if you are really looking at the process security part right from the beginning, or else it takes a longer part, consuming more time. So, you reduce the extra time from that. So, in that way, you can secure the process. So, that's what we are coming out with, also, within CoreCut2, where we understand what are the common process security issues, which is, and these are pretty common in the shop floor, what you see. Wrong tool assembly setup. So, what do you do with it? You need to look at the tooling solutions. Core production logistic planning, you need to look at better software management. What we are going to talk a little bit about is unpredictable tool life today. You know, so, because whenever we change to new upgrade or new insert, you feel like, is the tool life will be the same or double, or will it perform consistently stable? So, we are assuring you that it will perform when you have the right tools and the cutting data for your component feature and material machine as such. And, for us, the CoreCut2 is an answer to it for your upgrade within the CoreCut1-2. It will work. It works very well. We have tailored chip breakers and grades to take care of diverse range of chip breakers and the same cutting conditions, materials, applications as such. And, at the same time, we also have the best-in-class insert clamping. As I said, I mean, insert clamping is the key to give you the stable and consistent, you know, performance. So, that is what we have secured with the new upgrade, much better than the previous one. And, it's also easy to use. It's not complex. So, you don't have to, you know, result too much with the inserts positioning. Precision coolant, I think coolant is the key. And, with the precision coolant, it's even more better for the increment of the tool life and also the moving away of the chips, you know, during the cutting process. So, that creates reduced friction, at the same time increasing the tool life. So, in this way, the process security is taken care of from a CoreCut2 point of view. And, as I said, the clamping solution is, you know, really, really stable. So, that gives you even better. The rail seat design will ensure that the insert sits perfectly and gives you better stability and also consistency. So, this will ultimately help you in prolonging the new tool life. At the same time, you can increase the performance from previous, if you want, as such. And, we have also made sure that the edge line quality is much better with the new patented technology, what we have within production developed, so that we can get much better quality. Very similar to grounded inserts, because everyone knows today that if you need higher quality, then you need to go for a ground insert. So, we have come out with a technology where we have developed that you can achieve the same quality as a ground insert through direct press with this new technology, what we have within production. So, here is the other success case, which ensures, you know, if you look at from on the extreme left side, then you can see that it's a CoreCut1-2, where you're running at certain cutting conditions, which is 120 cutting speed, 0.05 feed rate, approximately 1.15 millimeters of depth of cut. And, when you use a CoreCut1-2 holder and a CoreCut2 inserts, because our inserts can fit in the old holders. So, that is also one way of looking at it. So, with that, you get a performance of approximately double the tool life. So, from 100 components to 200 components. And, if you use a CoreCut2 holder along with a CoreCut2 inserts, it's even better. It's like icing on the cake, that you get even higher tool life to 300 parts, which is three times the tool life than what you are getting. So, there is absolutely, you know, no concerns with respect to the performance side. I mean, you can get the same enhanced performance for sure, based on the, you know, concepts. If you want to run it in the CoreCut1-2 tool holder, you can do that. If you want to run it in the CoreCut2 holder, even better, because that will ensure much stronger performance as such. So, and at the same time, as I said at the beginning, I mean, service and support is our core. I mean, we believe in it. And why, and what can we, you know, provide you in that aspect is, we are a global organization spread across 150 countries with the people like, as I showed at the beginning, we have people sitting in the CAO, India, other markets, so we can reach out. So, the right people with the right skills are there for you to support, for your operations to be supported with. We are experts in machining, and we are more CAM utilization. So, we will, we are using CAM today. I think we are into digitalization. So, we have the expertise within industry-specific component solutions. So, we can help you with that. Machining calculators, I mean, and machining apps, I mean, you all know. And we have the tool guide, which can help you with, you know, all aspects of these as such. And we have a delivery services, which is very much efficient. We have a cross, and it can deliver you within 24 hours, the tools as such. So, having said that, let's quickly have a look at the demo. I think today we have planned a demo for you. So, I'll call my colleague, Mr. Dhaval, to just come and do the demo part for us. Yes. Thank you, Harish. Thank you for the great insights about our product. That will definitely add this value to our customers. And, yes, my name is Dhaval. And I welcome you all for this exciting session that we call it as a machining demonstration. And here in this session, we are going to see our interesting products running action on the machine. Okay. So, let us dive into the first demonstration. So, the very first demonstration, what we have is, of course, of Corocod 2. It's our start product launched recently. And this, we are going to show it on our 4-axis turnmill center. And here, I would like to say, I would like to show a different aspect of our Corocod 2 insert. That is the strength of our insert. So, in order to showcase the strength, we are going to run with the extensive parameters. You can see, we have highlighted this with a cutting speed. You can see the cutting speed is 400 meter per minute. The ideal range for this recommended range lies between 190 to 290 meter per minute. And as well as you can just have a look on the feed rate. So, feed rate we have is quite high. That is 2 mm per ray. The normal recommendation lies between 80 microns to 0.33 mm per ray. So, why we are running this to the extensive limit? Right. So, we want to showcase the strength of our insert. How that performs when it comes to the extensive parameters. So, for that, we have selected an insert of TF geometry. And the grade of insert is 4425. The holder, what we have is, of course, Corocod 2 holder. The specification of holder is C2RCC6LH13CV. And, yes. So, let us see this in action on our machine. Let me switch back to my machine camera. Let us get started with the first demonstration. You can see this is a 4 axis turn mill center. And, yes. We are going about to start this demonstration. The depth of cut we are going to take in this demonstration is 0.4 mm. And, we are going to perform turn milling operation. Sorry. Brew turning operation. It takes a minute. And, we say, Ocean openingleo. Yes that was quite fast when it comes to turning operation with the growing boot. I would like to show the insert condition after this. You can see again I would like to show emphasize on the feed rate it was 2 mm per ray and even though we have run with high parameters the insert condition the cutting edge the security of the cutting edge was good there wasn't significant damage and still we can see with this extensive parameters also because of the features onto the Corocode 2 holder as well as the Corocode 2 insert it can really work robustly on machining conditions like this so you can also see the chip pattern and then yes now let us move to the next demonstration we have for today the next demonstration we have planned is for our Corocode 2 insert again the geometry of insert is RF geometry normally in the machining conditions what happens is if we have lower depth of cut the breaking of the chip is becoming a major challenge and you can see on the right hand side of the screen we have a component generated and this profile when it comes to running with a round insert majorly we get to see a challenges like breaking the chips as well as getting the because of it doesn't get break we have the challenges of surface finish issues right so that is the reason we have come up with a new geometry of insert which we call it as a RF geometry it is a mainly for the finishing operation the grade of insert is 1225 and of course the holder we are going to use is of Corocode 2. the depth of cut you can see it here we have only 0.25 millimeter depth of cut and the cutting speed you can see it is a 200 meter per minute so the feed rate we are going to run is 0.25 mm per drive yes and let's get started uh with this demonstration let me switch the machine camera You can see this is a profile that we have created. The challenging operation I would say because the depth of cut is very small, it's a 0.25 millimeter and this is a folder of 4x2 and it's a RF geometry insert which we are mounted on the holder. We have to ramp on this component and just have a look on the tubes. Okay, right, stop. Yes, it was quite fast. That was quite good when it comes to breaking the chips. And I would like to show you some of the chips which we have collected from this operation. Yes, you can see the chips what we have broken down from this operation was very small even though we can say the depth of cut was small. It doesn't have any challenge face any challenges because of the unique geometry what Sandvik Coromant has come up with. And also we have recorded the surface finish from this turning operation that was in terms of RA it was 0.9 micrometers. Yeah, so it was quite, I definitely have a confidence on the RF geometry when it comes to the running this smaller depth of cuts and finishing operation and you must definitely witness that. And with this we are finished with our demonstration part and I would like to again call upon Harish to take us to the next session of our webinar. Thank you. Thank you, Dhav. Thank you. Thank you for the demos. I think the demos has really showcased how good is a new product, you know, how stable is a new product. It can run at high feeds, higher cutting conditions. At the same time with the new geometries as I said, it can help you to solve your problems which is obviously the chip development, chip formations at lower cutting conditions. So just a quick overview of what we have said so far about Corocut 2, you know, as such. So we have seen certain features and benefits of Corocut 2, you know, what has been part of it. One is the patented production technology, which I said, very good quality, edge line quality, what we have got within the insert so that, you know, you get pretty consistent and stable to life as such. And then the second part is obviously the, you know, the coating, which is a great, the 1225, along with the coating, which helps you to even get better to life. Third one is obviously the clamping design, you know, with the finger clamping design on the ring, which helps you to withstand high clamping forces and gives you, keeps things, you know, process stable as such. And then of course, when you look at profiling side of things, then obviously you have the rail seat insert surface along with the chip breakers, you know, design. So, which helps you to, you know, do the profiling in a much faster way. That's not, so you have very short chip formation as such and super surface finish. So that's a short glimpse on what we have gone through within the core cut to not limited to it, but there are a lot more features, but the highlights are this, which has been shared with you. So, so if you want to experience this, I think, please, you know, register now for a free trial with core cut two, and you can feel the change in terms of how it improves the manufacturing efficiency within your shop floor as such. So kindly register this. We'll also share the link in the chat for you. So you will see this available there as such. So I'll give you a little bit time to sort of scan it and register yourself. Please do that. Great. But anyway, don't worry, we will share it. It's already, we will share it in the chat as such. So any questions? Any questions? So I, if you have any questions, feel free to put it out in the chat, as I said at the beginning. So I'm looking at the chat now. So if you have any questions, there is one question, which is okay. Chip breaker specifically in round insert is amazing to see what, what made it possible. I mean, as I said, I mean, with the new technology, what we have developed in the production, you know, as such. Now you can create the chip breaker design more near to the edge. So it's more efficient. It's more, you know, what do you say? Easier to cut the chips in much better rather than before as such. So that's the change part when it comes to Corocut 2. One more question which says is obviously, what is the, what is the difference of rail seat in Corocut 2 and Corocut 1-2? Corocut 1-2, I think we do have the rail seat design, but for higher dimension inserts, about 4 millimeters. Now with the Corocut 2, we are coming in the, in the lower side of it, which is 2 millimeters, 2.53 millimeters, which gives you that. Even in the Corocut 1-2, we had a V-shaped design. Now we have made it even better, you know, to be more stable with the rails, rail insert design as such. Any other questions? No worries. If not, not an issue. We are here to reach out. We are here easily. So you can contact us through web or to our team as such. You know where to go when it comes to these as such. So any questions, any queries, any, any challenges, please reach out to us. We are here to help you and solve you. And as I said, so the, the quicker you upgrade to the new technologies, the better you can use it and the efficient your process becomes. So please try it out today, Corocut 2, as such, and then, you know, let us know the feedback. Thank you. Thank you. Thank you. Thank you. Thank you.