Webinar
Webinar SRT (MEA and TR) 30 May 2024.mp4
33 views
And also, you will have CoroChuck 930: Achieve maximum precision with the CoroChuck 930! This high-precision hydraulic chuck is the key to uncompromising milling, drilling, and reaming operations, ensuring stability and reliability every step of the way.
Machining demonstrations it's conducted from our Sandvik Coromant Center in Halesowen, United Kingdom
View transcript
Hello and welcome to this Coromel Dura presentation. My name is Ben Lodge, I'm the Solid Round Tools Product Manager for Samvik Coromant and I'm going to be talking about the Coromel Dura milling cutters today. As always we start with safety. Safety is our first priority at Samvik Coromant. So we ask that you view this presentation in a safe area, be aware of your emergency exits and assembly points and if you do need to leave the meeting, should there be an emergency, then please do so in a safe manner. If you have any questions then please put them into the chat function and we'll do our best to answer them as quickly as possible. So we're going to start off talking about the Coromel Dura. So the Coromel Dura in this introduction, this was reintroduced in 2022 and this is our new family of high performance versatile solid end mills. OK, these are developed for both roughing and finishing applications in a wide range of materials. So it is both a multi material cutter as well as a multi application cutter and this is the new family within our versatile offer. OK, and we launched this, you know, to give a higher performance and we're going to talk a little bit more about the product in some later slides. But, you know, we've really made a step increase both with the performance, but also with the stability that we've got with this product. And hopefully it's going to make it easier to use and also to choose the correct tool for the applications. As we look at the product itself, you know, we can see here we've got our wear resistant grade, the GC 1730. This is a grade that we've previously had on our Coromel Plura, our optimized products, and we're now utilizing that with the Coromel Dura. So it's a really reliable grade that we've got that can work in all these different material groups. And we can see in the bottom corner there, you know, the ISO application areas, the P, M, K, N and S. When we look at the options with the cutter, we've got a number of radiuses and necks as well as chip breaker options available for the longer tools. We have products with up to seven fluches should there be requirements to do so. And we're also able to have the ramping capabilities of around 20 degrees. We have cylindrical and welding shank available. And we can see there at the bottom this whisper cut technology. You know, the whisper cut technology is what makes the cutter perform at its best. So when we look at it, you know, we spoke around the two to seven flute options, one to four times D cut lens, so with or without the chip divider. We've got this robust and light cutting geometry to work in these many different applications. And it's, you know, making sure it's a plug and play product that is easily to define which product you require for the milling applications. One other thing is our reconditioning offer. And we offer reconditioning up to three times to the as new specification. So you can ensure that when we recondition a product, you have a reliable product when it comes back. And now we look a little bit into this whisper cut technology. So whisper cut technology is an advanced unequal helix concept where each flute is orientated at a different helix angle. So we can see there from the illustration, you know, we've got this varying helix, this unequal helix concept. As well as that, we have a differential pitch, which you can see in the illustration in the in the bottom right hand corner. OK, so on every level of the cutting edge, each flute is unequally spaced from the others, reducing the constant harmonics typically produced with conventional end mills. So this enables us to have very good stability and low vibrations. It helps eliminate the vibration that we can have. And it means that we can do heavy cuts with this product. And we're going to see a demonstration showing the capabilities of the product today. And the result of that, you know, safe, silent and efficient machining. As we look at the assortment, you know, we can see here a wide range of assortment available to us from, you know, two flute all the way up to seven flute options. One times D all the way up to four times D. And we can see there the different options when it comes to both the neck, the chip breaker, the radius and the chamfer. So, you know, we've got a wide range of products available within the product portfolio to meet customer needs. And as we look at application areas, you know, I touched on it a little bit at the beginning of this presentation. No, but the the Coromel Dura is suited for roughing and finishing applications with different engagements in multiple material conditions. And I think, you know, the picture on the right hand side really does show the capabilities of the Coromel Dura and what it can achieve. So one versatile tool concept for all applications and materials. And when we look at the industry area, you know, general engineering in all industry segments. You know, we've had a lot of success in a lot of different materials and a lot of different applications. So we can have confidence in the product and the capabilities that we've got within the application areas. And as we look at the, you know, the tool selection, you know, we're already aware of our Coromel Plura range where we have our Coromel Plura HD, as well as our Coromel Plura high feed side milling. So the Coromel Dura is a stable solution for a large variety of materials. And we still have our complementary products to the Dura when we look at our Coromel Plura. So we have our Plura HD when we're looking at optimized solutions for ISO-P and ISO-M when we're doing heavy duty applications, as well as our Coromel Plura high feed side milling. So this is designed for high productivity and tool life inside milling applications, predominantly looking ISO-P, M and S. So, you know, if we've got applications that are more material specific, then we'd be looking at the Plura range. But when we look at the Dura, this is where we see multi-material, multi-application areas. And that's where it starts to come into its own and perform the best. And as we can see, you know, this first choice, the plug-and-play solution is our four-flute solution, both in the 2xD and the 1.5xD options. And we can see there, you know, if you need something more specific within the Dura range, we can see we've got options available when it comes to the key slot solutions, medium to large engagements. So this is where we're looking at introducing the 5-flute, the dynamic milling, small engagements. So we may introduce the 3 or 3.5xD and looking at semi-finishing or finishing applications. And that's where we can see, you know, the 2 to 4xD and the 7-flute option becoming available and being the first choice within this area. And I think this is a really good illustration of the capabilities of the product portfolio. You know, we spoke before on the left-hand side, we've got this 4xD, 7-flute option available to us. Okay. And we can see the percentage when it comes to the AE, so up to 5%. But as we start to increase our engagement, then we can see the changes that we have within the portfolio. So going to the shorter tool, when we're seeing the larger full slotting engagements that we've got for this product. And we can be confident that we've got a wide range of products to cover all the different applications that we may see out there in the different materials. If we're looking at cutting data, then this is where, you know, our website is a really good place to start with the cutting data. And as well as having our standard Coramil Jura tool selector available. So if you are wanting just a recommendation for the Coramil Jura products, you can visit our website, type in Coramil Jura, and it'll take you to the homepage of the Jura products. You're then able to access the Coramil Jura tool guide for Jura from that link, and you'll get the recommendations just for the Coramil Jura cutting data. And it's a really good way of getting start values for applications that you may be looking at with the Jura range. As well as the Coramil tool guide and the Jura tool selector, we also have other services available. So we can see here, you know, we've got our tailor-made and tailor-made web options, as well as our recycling offer. And we've already touched on our reconditioning offer when it comes to the Coramil Jura range. So we are able to recondition these products up to three times with the as new performance levels once it comes back from reconditioning. And I also want to touch on some success cases that we've had with the products and seeing the applications that we've been using this in. So here we can see this is an injector clamp. We're using the 12mm diameter tool for flute. And we can see here, you know, we kept the cutting data the same, 226m per minute, 0.06. But we can see that increase in the tool life from the competitor that was used on this. So with that, we've seen a 15% tool life increase and a 17% cost reduction from this application. But what we've also been able to do, and it isn't documented here, is that, you know, we've talked and had conversation with the customer around our reconditioning offer. So we've even been able to further reduce the costs down to 38% because we've been able to have a reliable tool where that's been able to recondition this product again to the as new performance and to give a further cost saving to the customer. As we look at our second example, this is a mandrel extension shaft, EN26. Again, we're utilizing the four flute cutter, a 16mm diameter in this case. And we can see here we've changed the cutting data. We've gone from 90m up to 130m per minute, as well as an increase in our feed per tooth. OK, so that means that we've got a cycle time reduction. And we can see there 78% reduction in cycle time due to the higher cutting data. And also we've got an increase in our tool life as well. So a 67% increase in tool life. And, you know, we actually run out of components when we were doing this trial. So, you know, we believe that we can go even further with the cost savings that we could have with this customer. And then lastly, we've got the end cap. So this is a shoulder roughing application. We can see here it's a 25mm indexable tool that we're using on this occasion. And this was actually a plunging application that they were doing with the indexable tool. We replaced this with one of our Coromel duras, the 7 flute, with the longer AP. So we have a 56mm AP, the smaller engagement. But as we can see from changing the machining process, we were able to reduce the time in cut. So it gives a lot more ability with this. So we saw a 266% productivity increase as well as a 67% cost reduction. And it also enabled the customer to reduce the number of tools used from four tools to two tools by changing the strategy as well as changing the product. And this is a really good example for us in relation to what we did with this project. So here we're presented by DLM, which is Digital Live Machining, the technology that we're using today to speak to yourselves. We were able to change the cutting data while the customer was connected to the meeting, try different things to get the best solution and enabled them to, you know, not have any downtime on their machines for us to perform the trials as they wished and be able to see the results live using the technology. And I think, you know, you should be aware that we have this technology in many of our Coromel centers globally. So we do have the ability that if you aren't able to get to one of our Coromel centers, that we can use the digital live machining capabilities to be able to look at projects and for you to join us via meetings and see what we're doing within the Coromel centers. So for now, that concludes my presentation on the Coromel Jura. So I'm now going to hand over to Antonio to introduce himself. Thank you very much. Thank you, Ben. I'm starting to share my screen. So thank you. I'm Antonio Tarallo. I'm the product solution specialist for machine integration. And today I will speak about CoreJAC 930. CoreJAC 930 is our high precision hydraulic chuck for milling, drilling and rimming operation. This solution has several benefits. We can just start to look at it. We have the best in the market pullout security. This means that with this system we can eliminate the vibration for an excellent stability. Then we have a system that is very easy to handle. So it's just using one screw. You can quickly tighten and release the tool inside of the system. And then we have high precision. So there is the tolerance that is on the tool is within micro-dolls. And then we will look more in detail. So here there is an animation that shows the different type of system on this CoreJAC 930. We have three different designs. Inside there is always this system that is the Fulcrum technology. Fulcrum is activated by this screw that you can see on the right. And with this system we have the best pullout security in the market. And very low tolerance. Just in the run out you can see after that is only four microns. We have three of this system. CoreJAC 930. In reality there is another one that is the Slender T that is. It was born for the driven tool holder. So just to have a shorter version of the CoreJAC 930. With pencil we can go from diameter 6 to 20. Then Slender from 6 to 25. And the Slender T is only between 6 and 20. And then we have the HD that is for roughing and heavy roughing. It goes from 20 to 13 at 2. The product range covers everything. We can have with CAPTOL, we can have with HSK, ISO, BIG+, CATB and so on. And if you have something that is outside of this range we can create it via tailor-made. So this gives you the possibility to have to cover everything. So what is inside CoreJAC 930? The heart of this system is the fulcrum. As shown in the animation we have these two areas where the tool is clamped. And this gives the possibility to have very low run out and this pooling system. Here you can see the difference between other systems without the fulcrum technology and CoreJAC 930. Without our system normally the tool is clamped and blocked only in the center. Instead with the fulcrum technologies you have these two areas of clamping. And this gives us big advantages when we do machining. In this video you will see the difference between our CoreJAC 930 and other systems. Using the same mill, so it's a 20mm mill. The depth of cut is 20mm so we are going one time the diameter. Cutting speed is 120, 0.1 feet. This is steel. So the first one is CoreJAC 930. Now we have a competitor. The same condition you can see the red area. So this means that the tool is going out of the chuck. This is another competitor. Here you can see that the red area is longer. You can see that the pullout. There is a big difference in the pullout. So with the CoreJAC 930 it's just 0.01. With this competitor it's 0.33. And with this one it's 1.7. So as I said before, with this system we have a precision run out of 4 microns. These 4 microns are measured at 2.5 times the diameter. with the shorter system. So with LF that is minus than 125mm. If you have this longer version, so this means 190mm. The maximum run out is 7 microns. Less than 7 microns. We can clamp almost every type of pull. But it's important to underline that if the shank is cylindrical, we can clamp without problem. With or without the collet. If the stiff is well done, we can go till diameter 20 without collet. And then we need collet. And you can see in the rest, the whistle notch and ISO 9766. And if you have some tools with the internal coolant like a drill, you can use a sealer collets that allow you to use the coolant through the tool. Otherwise, you can use a normal collet that is with the coolant that is outside. Last point. We introduced some years ago a different collet that is studied for welding shanks. This system allows you to have a perfect mechanical locking interface. This is thanks to this screw that is locking the collet inside the chuck. And this spring that locks the tool on the collet. There is an animation that shows better. So we have the normal CoroChuck 930. Then we mount this screw inside. With the key. Then the tool is locked on the collet with this spring here. And then this assembly is mounted inside the chuck. So we have. With the half movement of 100 degrees, we can lock everything. And you can see here that we have a very good mechanical locking system here on the tool. And of course, here on the surface of the screw. So with this system, it's almost impossible to have a pullout of the tool. So that's all for my side. I give again the stage to Ben that will show you the demo on the machine. Thank you for that, Antonio. So now we're going to see the Coromel Dura demonstration that we've got for you here. So I'm joined by my colleague Joe, who's going to be running the machine for us today. So, yep. So if we take a look at what we're doing, we're utilising the Coromel Dura. This is a 12mm diameter tool for flute with a 2xD depth capability. And the material that we're running it in today is EN 2014. So we're going to be doing a number of operations with this tool. So to start off with, we're going to be doing some slots. So if we make a start, Joe. So here we're running at 130 metres per minute. And 0.05. And this is doing a ramp angle of 10 degrees. So we're ramping into the material during this process. So next up, we're going to do our second slot. So here we are doing a plunging method. So as you can see from the second slide. Again, 130 metres per minute, 0.05. This is a 2.5mm plunge that we're doing each time. And for the third slot, we're going to be utilising our 860 GM project. So this is our high performance multi-material drill. So this is the first choice recommended way that we'd produce a slot. It's drilling a hole there to clear. And then coming back in with the Coromel Dura. So same cutting data again. So now we're going to do a POC kit. So we're helically ramping into the pocket here. 10 degrees ramp angle again. And then we've got a 7mm step over. 10 degrees. Next up is another pocket. Same approach, 10 degree ramp angle. And a 7mm step over. So one of the things that we found with the Coromil Dura is that if we have got an uneven surface, that it cuts quite well with it. So we're going to do some intermittent cutting now. So here we're producing an intermittent cut. We can see the wavy line that we're producing there. And then we're going to come straight through and do a straight shoulder milling application. Again, 130m.05. And we can see and hear that the Dura coats with this really well. So if we have got uneven surfaces, things like castings that we're unsure where the edge of the material may be, we can be assured that the Dura can coat with those kind of cuts. So we're now going to do an open pocket, so some shoulder milling on the back area. So now we're up to a 40% engagement. So this is at 200m per minute and 0.07. So we've seen an increase in our cutting data now. And then we come in with the 860GM again. So, you know, first choice when it comes to producing a pocket would always be to put a hole there for the entry of the milling tool. And we're going to stick to that larger engagement this time. So 200m per minute, 0.07. So we've seen that increase in the cutting data, 40% engagement. So now we're on to some full slotting applications. So this is a 1xD full slot. 130m per minute, 0.05. And then we're going to do some finishing passes in there as well, just to clean it up a little bit. And then lastly, we've got a 2xD full slot. So we're engaging the full AP of the cutter here. And although you can hear a little bit of chip jam in there, you know, the cutter still gets through that full 2xD full slot. So, you know, we're really pushing that to its full capabilities when we're using it in that application, a really challenging application there. And that concludes our demonstration. So I'll just pass over to see if we've got any questions. Ah, is it possible to have the table with maximum engagement AP and AE limits? Yes, absolutely. If there's any information that you do want us to share, then we'll obviously we will share that after the presentation. I think that is a really good side. Thank you for that, Gabriele. It's a really good slide to have as a reference. So we will we will share that afterwards. So, yeah. Is this product in the market in Turkey? Yes, this product is available in Turkey. So, yeah, it's been available since its launch. So, yeah, we do have capabilities in Turkey. Well, if there is any further questions, as I said, please put them in the chat. So I'd like to thank on behalf of myself and Antonio and the team. I'd like to thank you for joining us today. And, yeah, thank you very much. Have a good day. Thank you.