Hello and welcome to this Solid Round Tools knowledge session. During this series we will cover features, strategies and products relating to Solid Round Tools. As always we start with safety. Safety is our top priority at Sandvik Coromant. Please ensure you are watching this in a safe environment. Be aware of the safety procedure, exits and assembly point at the building that you are viewing this. My name is Ben Lodge and I am the Solid Round Tools product specialist and today I am joined by Tony Bryan. Hello Ben, my name is Tony Bryan and I work as Solid Round Tools sales driver in the UK. Today we will be looking into the topics of Coromill. Sandvik Coromant have a total milling offer, indexable and solid round tools covering the four main product areas for milling. We have face milling, we have shoulder milling, slot and groove milling, high feed and profile milling. In all of these product areas we do have a Solid Round Tool offer. Ben, why don't you tell us where we can use Solid Round Tools in each of these areas? So we would use Solid Round Tools depending on different situations that we might see within the customer. Okay, so normally this could be dependent on the feature, either the size, the tolerance or the material that the operation is being done in. But usually we see Solid Round Tools as having a tighter tolerance on the finished component. So we may see a reduction in any secondary operations that might need to be made. So why don't you tell us a little bit more about our range as it sits? Certainly Ben. So currently we split our Solid Round Tool offer into three different product areas. We have Versatile Solutions which is a complete range of high performance products that offer excellent flexibility and cost efficiency. We have Optimized Solutions which is a unique line of refined tools, material specific designed to optimize and give the best value for money. And we also offer a customized solution. These can either be tailor made or they can be advanced engineered specials. So as we previously said, we do have a Solid Round Tool offer for all of the four main milling categories. Here you can see our range of tooling for shoulder milling, full slot milling, profile milling and high feed face milling and plunge and chamfer. So we do have an offer both versatile and optimized in each of these product areas. Why don't you go into a bit more detail Ben about the Versatile offer? Okay. So our Versatile offer, this is designed for high performance and secure machining in a variety of materials, applications, component sizes and shapes, allowing maximum machine utilization. For the highest machine utilization in various components and variable production, you need tools with the highest precision, robustness and versatility. When precision, stability and cost efficiency is paramount, a caramel pleura versatile end mill is the first choice. So we would be looking at the Versatile product offer where a customer is swapping materials, where they're operating in small batch work, so they can get the most productivity from a single tool. Absolutely. That's the best environment for this kind of product. Okay. And we can see with that Versatile range, you know, we've got a lot of applications available to us, you know, like you split them up into the different areas. We can see here, you know, with the slot milling, shoulder, pocket, profile milling, we can also helically interpolate with these products as well as ramping. We have plunge milling, we have plunge milling, chamfers inside and outside of the material as well. That's a really comprehensive versatile range, Ben. Yeah, it's quite a wide range that we've got. So if we look at it as a portfolio itself, we can see here, you know, the first up we've got this heavy roofing, this U30. So these are products with either a 30 or a 35 degree helix in there. So we see them in the two, three and four flute options available. And we can see from the illustration there, the areas where they come into play and where they perform the best. So for example, the two flute, you know, we see this coming into play when we're machining slots. So full slotting applications where we need a lot of chip space from a two flute product. Then as we look into our U45, so these products are a 45 degree helix in the main. And as it says there, you know, medium roughing operations. So this is why we see the three and four flute products there. And we can see there, you know, the fourth flute predominantly looking at profiling operations. To complement that, we also have our roughing with a chip breaker, as well as our profile milling ball nose cutters and our chamfer mills as well. That's great, Ben. Thank you. So we've spoken around the versatile offer. We're now going to move on to the optimized offer. What can you tell us about the Coramil Plora optimized offer? So the optimized offer that we have within our range, you know, these are a perfect combination of specific high quality grades and geometries for specific materials and applications. OK, so here we're matching, you know, the product features with either the material that it's machining or the application that we might be looking at. And we see a similar picture when it comes to the application areas. You know, we're covering all the application areas that we spoke about previously, but with a more focused approach to these products. So if we have a customer that's looking to optimize the productivity in a specific material group, Plora optimized is where we should be recommending a tool. Absolutely. And we can see that from this chart here where we've got products for specific applications and materials. So we're defining the product design. So as we look at that there at the top one, certainly we've got our heavy duty milling. So this is for, as we can see there, full slotting, but it also works in shoulder applications. So that could be either small engagement, but also lends itself to large engagements as well because of the design. So that's a really comprehensive product range, Ben, both in versatile and optimized. Why don't we dig now a little deeper into our first choice product for particular milling applications. Yep. So as I spoke about before, the Plura HD. So this is first choice when it comes to heavy roughing applications, predominantly in ISO P, but also in ISO K materials as well. And we can see there, you know, first choice when it comes to full slotting, but also shoulder milling and pocket milling as well. And we're able to helically interpolate with these products. So even though they're not center cutting, we are able to helically ramp down normally between two and five degrees we'd recommend with this kind of product. So it works in a lot of different applications. We have a lot of different options available to us. As we look at the expansion of the range, we can see here as well, our first choice when it comes to ISO M materials. But also secondary materials within ISO S, predominantly nickel based alloys. So we are able to utilize the HD design in most material groups that we see out there in the market. And if the customer is looking to have a milling tool with a corner radius, is this an option on the Plura HD? Absolutely. You know, we've got corner radiuses available within this range, quite a comprehensive selection as well. So now we're going to look at a little bit about the HD design. So as we've said, this is a Plura HD heavy duty machining. And we're able to do this with a four flute and five flute in some examples because of the design of the tool. So we can see there we've got this strong core of the product, but we've also got this specific open flute design as well. And that gives us the ability for the chip evacuation to come out of the flute. And that doesn't cause us any problems when it comes to heavy duty applications. OK, Ben, thank you. So what advantage would a customer see by using an unequal helix or an unequal pitch optimized cutter? So a differential pitch. So here we've got a four degree or three degree when it comes to the five flute. And this allows us to run at higher speeds in the larger engagements that we see within the shoulder milling applications. OK, thank you, Ben. So modern machine tools, machine tools are getting lighter, they're getting quicker. We offer a range of high feed side milling tools. Could you tell us a little bit more about this range, Ben? Yep, absolutely. So as you've said, high feed side milling. This is what we see as first choice when it comes to cam supported high feed side milling operations. They've got a number of different names depending on what software you're using. It's a very similar strategy. You know, it's excellent in intermediate conditions when good surface quality is needed. And obviously it's a stable process, you know, there's low vibrations. So it's about utilizing the full length of the tool, but with a smaller step over. So that means that we can accelerate the data. We can run a much higher VC and also feed per tooth to make sure that we've got a very efficient process in place. So as we look at the design of the high feed side milling tool, you know, we can see here no center cutting, but we are able to ramp as we spoke about before. We're looking at this two to five degree ramp angle that we've got available to us. We've got this radial relief for a tough cutting edge and specific edge rounding as well that we have depending on the material that we're cutting. So we do have some material specific and application specific products when it comes to our high feed side milling portfolio. As we spoke about before this uneven tooth pitch and as well as this core diameter, you know, it's about keeping the strength in the tool. Because on some of our products, we do have a long engagement that we're going to be using a long AP. So we need to have that stability within the tool. We dig a little bit deeper into the design. So we spoke about before this unequal helix, you know, this unequal flute design. So this is a variable angle pitch that we have on there. It's an efficient way of increasing the chatter free material removal rates. And also this conical core shape, you know, we spoke about the stability and this helps improve the chip evacuation capabilities. Whereas a larger core diameter, the AP Max ensures the maximum stability in the product. That's great, Ben. And a really exciting launch for Samovic Coromant when we're looking at machining titanium, deep pockets, long sidewalls. We've launched a new product to market recently. Would you like to tell us a little bit more about that cutter and its capabilities? Yeah, absolutely. Yes. So we've launched a product that's for titanium machining, five times D applications. So this is looking at pocketing applications and long AP Maxes when we're looking at shoulder milling as well. As part of this design, we see a double helix geometry where the helix angle depends on the cutting depth. And we've called this a form control design. So this helps reduce the bending, maximizes stability and also gives us an excellent surface quality as well. And because of the conical core for this increased tool stiffness and the unequal tool pitch, we're also able to operate at high VC levels. So we're looking at a maximum of 230 meters a minute machine entertaining. So we're making a big step change when it comes to the data that we're running at. So as you look at our portfolio when it comes to high feed side milling, we can see here that we've got a number of products for all the main material groups available to us. So we're looking at ISO P and we're able to go up to four times D. Similarly, when it comes to ISO M. Also within ISO K, we see these as a secondary area for our products, but we do have up to four times D available. And then when it comes to ISO S materials, we can see here, we've got the five times D when it comes to titanium machining, but also in nickel alloys as well, we're able to machine up to four times D in a high feed side milling application. That's really impressive Ben. And I think it's plain to see that we do have a fantastic portfolio with a product available to every customer. Yeah, absolutely. And, you know, this is a growing portfolio that we've seen for a number of years. And more and more, you know, customers are coming into this kind of way of thinking when it comes to the strategy for high feed side milling applications. Really, really good. So we've covered HD machining, shoulder milling. We've covered high feed side milling. What products can we offer for high metal removal rate in HRSA materials? So when it comes to HRSA, we have a specific product when we look at our ceramic cutters. So here we're operating at high VC when it comes to nickel-based alloys. So we have both a shoulder milling and a face milling product available for us within this area. And it's really key with this product, certainly looking at a small amount of material, certainly looking at spindle speeds. That's one thing we have to keep in mind because we are operating up to a thousand VC with a ceramic cutter. Obviously, it is a very low engagement that we're going at. But because of that VC, because of the feed per tooth, we are able to have a high metal removal rate with this product. We have a negative rake angle and a unique edge preparation to give it a tough cutting edge. And an optimized core as well for the high stability and excellent chip evacuation. Because that's what's really important, these kind of products, certainly when we're operating at such high metal removal rates. So you spoke about the need for high spindle speeds working at VCs of up to a thousand meters a minute. What would be the minimum VC we could safely operate these tools at? I mean, we'd say the minimum would be around 500 meters per minute. We won't see the same level of performance that we'd maybe see, but we'd realize there are some restrictions when it comes to the spindle speeds required for these products. What I would say is that, you know, currently we have the 10 and 12 millimeters available to us. And that could, you know, restrict some customers when it comes to the RPM that they've got available. But in the next launch of Coropac in October, we will see a new introduction within this area. So we're looking at the 16 and 20 millimeters diameter coming into our portfolio. Really interesting, Ben. Thank you. So when we're looking at automotive, we're looking at aerospace. We have a lot of carbon composite type materials, composite materials. What product range do we offer in order to machine these? So within these engine applications, as we call them, you know, we have a few options available to us. You know, we can see here our three main ones. We have the low helix cutter, the compression, and also we have the composite router as well. So these products are specifically designed for edging applications within composite machining. So with these products, in the main, we have a positive and a negative helix angle. So in our compression router, as we can see in the illustration, we can see the transition point with this negative and positive helix angle. And we normally align that with the middle of the material to ensure that we get the compression of the material together. When we look at the composite router, the positive and negative helix angle are on each tooth. So this is a patented design and gives us a lot more stability with the product. And the benefit of having a compression router would be that we reduce the delamination and separation of the carbon composite layers. Absolutely. And a low risk of the splintering that we might see as well. To complement that, we also have our PCD tip tools that are available as part of Advanced Engineered. So that's part of our customised solutions offer that we spoke about at the beginning. That's great, Ben. I think you've run through and explained a really comprehensive portfolio for SolidRound tools. Do we have any customer real life cases? Yeah, we certainly do. So here we've got our first case. So this is using a side milling operation. And we can see here we're up against an indexable solution. So we're going from a 16mm indexable solution down to a 10mm. And we're utilising this high feed side milling method. So we can see there we've seen some changes when it comes to our AE going from the 1.6 down to the 0.7. But even though we've made that reduction in the step over, we are seeing a higher metal removal rate when it comes to the data that we're running at. So from there, even though we're running at 80m with both products, we are seeing an elevation in the RPM. And we're also seeing an increase in our feed per tooth as well. And we can see there the increases that we've got. So from productivity wise, we're looking at a 482% increase in productivity. But also we're seeing a 33% increase in the tool life as well. So, you know, we're able there to get two full components by utilising the high feed side milling method. Really impressive figures from a customer's point of view. Absolutely. Absolutely. So in this second example, here we're using the Pluri HD. But this time we're using something called high feed side milling power cut. Okay. So with the HD product, we're able to use a similar strategy to high feed side milling, but we're using a larger radial engagement. So we can see there from the slide that we've got a 15 millimetre step over with a 20 millimetre diameter tool. So that's a really big engagement we've got with that. But as long as we've got a smooth process, a smooth tool path with the product, with the cam strategy, then we're able to do these kinds of applications. That's a really valuable cost reduction to the customer as well, Ben. Yeah, absolutely. 51% and as well as the increase in productivity up to 185. So that concludes our session from today. In our next sessions, we're going to continue with the Coramil Plura, but this time we're going to delve a little bit deeper into the strategies that we spoke about a little today. Our next session will be on pocketing strategies, and then that will lead us on to slotting applications as well. So we're going to be looking at lots of different ways that we can machine these two types of features. If you'd like more information about what we've spoken about today, or would like to make contact with us, then please follow the link on the screen or scan the QR code below. Thank you.