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CoroPlus® ProcessControl

Increase cutting tool performance

Tool guard enables the operator to monitor the machining process in real-time and interact with the machine tool. The solution will detect tool force overload and can be programmed to take different types of actions. Cutting tool breakage or missing tool indications will automatically stop the machining.

The result is extended machine capacity and more reliable processes.

Key benefits

  • Increased productivity by improved process security and consistent component quality
  • Savings in fixture repair cost and downtime for resetting
  • Optimized cutting tool life and lower total cutting tool costs
  • In-cut traceability enable improvements of future processes

Contact a sales representative to get started with CoroPlus® ProcessControl


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Limit comparison with dynamic limits

In difficult machining processes, for example when making the first cut in cast iron, sensors are integrated to measure the machining force on all dimensions. Dynamic limits are continuously adapting to the measured signal and therefore tolerate slow signal changes. Adjustments of the dynamic limits take place within cycles of less than one millisecond, thus occurring several times within a single workpiece rotation.

If the signal passes through one of the dynamic limits at breakneck speed, the limits are maintained and additional analysis is performed to decide if this was an insert breakage event. Total breakages or cavities are reliably differentiated, allowing unexpected extreme signal peaks to be tolerated.

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Tool wear detection with static limits

Tool wear increases the dynamics of cutting edge vibration. The acquisition of the acceleration with a vibration sensor enables the comparison of the signal with static limits. When the overload limit is reached, the system will react and stop the machine after the machining has finished or automatically trigger a change of the worn tool.

Example applications

Tool breakage detection in turning of cast and forged parts (initial cut)

The workpiece has an undulating material surface with pronounced hardness fluctuations in its outer surface and can only be clamped off-centre.

With Tool guard it is possible to tolerate hard spots or cut interruption and to quickly react if a tool breakage happens.

Tool wear detection when machining spiral bevel gears

There is a need to detect wear on a milling cutter and to detect its end of life.

With Tool guard it is possible to announce the tool's end of life early to avoid tool overload and danger of a total breakage.

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