Product category:
Toolholders
News Release from: Sandvik Coromant UK | Subject: CoroTurn TR
Edited by the Manufacturingtalk Editorial
Team on 30 November 2007
Ensuring that indexable inserts are
fixed
How is it possible to make sure that indexable inserts remain fixed exactly in their position - use a precision interface between the insert and tool holder, said a tooling manufacturer.
Any type of instability between a tooling insert and toolholder has a negative effect on machining, said Sandvik Coromant Until now, measures against instability have focused on major instability issues such as machinery, fix-turning, tool holding, tool design, insert geometry, tool paths and overhang
This article was originally published on Manufacturingtalk on 12 Apr 2007 at 8.00am (UK)
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* Micro-movements highlighted - turning operations often include various tool paths that put extra radial strain on an insert, giving rise to the tendency for micro-movements of the insert in its seat.
These movements are often only in microns.
However, when they are continually repeated and when they move the cutting edge out of position, they can result in unsatisfactory performance, especially in finishing operations.
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Dimensional accuracy, tool life and chip control can suffer because of insert movement.
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Sandvik told manufacturingtalk.com that profiling operations are especially prone to insert micro-movement because longer D- and V-shaped inserts are usually used.
Sandvik's T-rail design positions the insert precisely in the tool holder seat and maintains the cutting-edge position with high stability.
The profiling inserts usually change the direction of the tool path frequently during machining and have to cope with varying depths of cut during turning, facing, profiling and recess cutting.
Inserts with the T-rail interface ensure that there is no micro-movement that can affect the dimensional accuracy and surface finish of even precision-machined components.
The accurate T-rail engages the insert almost below the cutting edge.
So the only task of the insert-clamping screw is to draw down and hold the insert against the T-rail.
* Milling: high-speed machining - the positioning and locking of inserts in milling cutters is becoming more and more important as spindle speeds rise to high-speed machining (HSM).
The security and precision of the insert clamping plays a critical role in achieving satisfactory performance.
The radial run-out of a milling cutter affects the balance of the tool, a property that grows in importance as the cutting speeds/spindle speeds increase to high levels.
A balanced tool is a prerequisite for HSM, as even small amounts of run-out can affect performance and safety.
A basic requirement is that, by design, tools are balanced with minimal run-out, complemented by exact positioning and uncompromising insert clamping.
Locking the insert in such a way that it cannot move at all provides security for these operations.
* iLock for milling cutters - the Sandvik CoroMill 790 has an iLock interface.
The contact surface in the insert seat is serrated, providing a precise and tightly secured location for inserts.
High precision is accommodated through ground inserts, and the serration reduces the effect of the insert tolerance by about half.
Cutting forces are taken up from all machining directions, and feed rates do not have to be compromised.
The open chip space has provided room for the huge amounts of chips produced in these operations and for the chips to be evacuated from the machining zone.
The accurate, firm location of inserts minimizes tool run-out and counters high centrifugal forces at high spindle speeds.
The iLock interface provides high insert stability and location accuracy, making the CoroMill 790 a highly productive cutter for HSM performance in aluminum and other non-ferrous materials.
The CoroMill Century facemill for non-ferrous materials has also been designed with an iLock interface for high spindle speeds (the cutter has HSM security by design).
It also has built-in precision and features micro-precision axial setting of inserts.
The serrated iLock interface in the balanced milling cutter body is a guarantee of the performance and quality that the CoroMill Century offers.
In addition, chip and coolant flow have benefited from the iLock interface, leaving the chip space free of obstacles.
* About Sandvik Coromant - Sandvik Coromant is a world-leading supplier of cutting tools and tooling systems for the metalworking industry, represented in more than 60 countries by its own sales staff and specialists.
In addition, there is an established distributor network.
21 state-of-the art Productivity Centres located around the world provide customers and staff with continuous training in tooling solutions and methods to increase productivity.
Sandvik Coromant is part of the Tooling business area of the Sandvik Group.
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