Aluminum machining knowledge
Welcome to your one-stop source for knowledge and information on machining automotive and e-mobility aluminum components. Explore tooling and component solutions, watch films and knowledge sessions or read articles. You will also find downloadable product publications and discover more about our digital offering and services.
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Component Solutions
With your specific component as a starting point, we can recommend a complete machining solution for the component features. Optimizing tools and providing machining methods that guarantee the highest quality results. We work globally, with a strong focus on R&D. This means that you benefit from Sandvik Coromant's collective competence when you meet one of our experts.
Machining solutions for aluminum automotive components
Automotive manufacturers are facing a big transformation. New environmental legislation and expectations from more environmentally conscious consumers are pushing manufacturers towards new low- and zero-emission vehicles.
Aluminum may offer a solution to the component challenges the manufacturing industry is facing. Aluminum is one of the lightest metals in the world – almost three times lighter than iron but very strong and corrosion-resistant. Aluminum can also be reused over and over again. It can be melted and reused without any harm or change to its mechanical properties. Thanks to effective recycling, approximately 75% of all aluminum produced is still in use today, which is great news for a more sustainable future.
Electric vehicles are on the rise, but it will take time until the internal combustion engine is completely out of the picture. In the current drive to use cleaner energy, employing lightweight materials in internal combustion engines becomes imperative as it results in greater fuel efficiency and thus reduces pollution.
The power train of a European passenger car typically contains around 80 kilograms of aluminum, which means these parts – the engine, gearbox, suspension parts, housings – are an obvious area of interest for lightweighting measures. Replacing the conventional cast iron with aluminum alloys can reduce the weight of the engine block by up to 40–55%, even accounting for the lower strength of aluminum compared to gray cast iron. Several transmission components, particularly gearbox housings, electrification devices/components, suspension arms and rear axles, are prime examples of driveline applications where aluminum is a preferred material.
Sandvik Coromant offers solutions and tools for aluminum components, backed up with in-depth application know-how. We have a global presence with dedicated engineering teams supporting the automotive industry with several high-quality solutions.
Here, we share a selection of productive solutions for some of the challenging features of aluminum machining.
M5Q90
Roughing tangential milling cutter, designed to clean the surfaces in the first machining stage on newly cast aluminum parts in a single operation without burring
M5R90
A first-choice solution for roughing to semi-finishing in shoulder milling operations of aluminum automotive components such as cylinder blocks, cylinder heads and transmission housings
M5C90
Face milling concept for high-speed direct finishing of aluminum automotive parts with wide cutter engagement. This can replace the need for both roughing and finishing, which means that only one operation is needed
M5B90
An engineered face milling cutter that offers outstanding surface quality, minimized cycle times, close component tolerances and high-volume production
M5F90
Machining parts without burring, scratching or chipping, M5F90 is a concept face-milling cutter that enables roughing and finishing in a single operation
CoroTap® 100
Superior tool life and high productivity are just two of the benefits offered by this exceptional tool. Suitable for both through and blind holes
CoroTap® 200
CoroTap® 200 features spiral point taps for through holes designed to push chips forward. The range includes versatile taps for various materials and optimized taps for specific materials and applications. Tailor Made and Advanced Engineered tools are available within the Customized solutions range
CoroTap® 300
CoroTap® 300 is a range of spiral flute taps suitable for tapping in blind holes up to 3 × D. There are different helix angles suitable for different applications. The range features versatile taps for various materials and optimized taps for specific materials and applications. Tailor Made and Advanced Engineered tools are available within the Customized solutions range
CoroTap® 400
CoroTap® 400 is a high-speed, chip-free forming tap suitable for both through and blind holes in steel, stainless steel, aluminum and HRSAs. Versatile and optimized forming taps are available, with and without oil grooves, in an assortment of diameters, grades, coatings and thread forms to suit a range of applications
M610
Stand-alone milling cutter for finishing milling of bi-metal materials such as aluminum and GCI. It requires no set-up and no adjustment, and results in high feed rates with no chipping, burring or scratching of parts
B685
The B685 cylinder boring bar is designed to combine roughing and semi-finishing in a single operation. The solution provides excellent roundness and cylindricity and allows for a smooth finishing operation thanks to the integrated Silent Tool dampener
B687
The B687 cylinder boring bar is designed for productive and stable finishing. The cutter is available in different designs depending on the operation. Use the three-cartridge design for reliable performance in under-coolant applications
B681
B681 is designed and developed for roughing in cylinder boring operations. The solution produces excellent roundness and cylindricity, allowing for a smooth semi-finishing operation due to the integrated Silent Tools™ damped adapters
B683
B683 is designed and developed for semi-finishing in cylinder boring operations. The solution produces excellent roundness and cylindricity, allowing for a smooth finishing operation due to the integrated Silent Tools™ damped adapters
CoroDrill® 400
The straight flute CoroDrill® 400 is optimized to provide highly productive hole-making in aluminum and cast iron components for the automotive industry
CoroDrill® 430
The spiral flute CoroDrill® 430 is optimized to provide extreme efficiency, reliability and durability during hole-making in aluminum and cast iron components for the automotive industry
CoroDrill® 880
CoroDrill 880’s optimized center and periphery geometries, combined with dedicated diamond-coated grades for each insert position, deliver not only outstanding tool life and productivity but also an impressive ability to handle sticky non-ferrous metals
CoroMill® Century
Face mill concept with an aluminum or steel body for high-speed machining. The tool is designed with a serrated insert interface for safe performance and reduced run-out
Films and knowledge sessions
The best way to get to know a tool is to see it in action. View our compilation of product and component demo films or our films offering tips for aluminum machining to get inspired.
Solid round tools knowledge session – machining aluminum
Do you want to learn more how to optimize your strategies using drills, taps and reamers in aluminium. Welcome to view this knowledge session with our yellow coat specialists.
Tip film #43 - Optimizing tapping operations in aluminum
Reduce the total cost per hole when tapping. We will demonstrate proven methods that will help you meet your customers’ demand for efficiency.
Metal cutting in automotive – improve your production
The automotive and metal cutting industries are demanding sectors. You need to improve your production and reduce your cost per part while maintaining quality. Sandvik Coromant has the expertise and experience to map the processes that will thrust your business forward. We would like to talk to you about component solutions.
Milling cutters for aluminum automotive machining
The complete series of M5 milling cutters dedicated to machining aluminum automotive and e-mobility components, offers everything from first-stage roughing machining to super finishing.
M5Q90 milling cutter – for first-stage roughing operations in aluminum
Demo film presenting M5Q90. This milling cutter cleans the surfaces of newly cast aluminum cylinder heads and engine blocks in one smooth operation, without burring.
M5R90 milling cutter – for roughing and semi-finishing of aluminum automotive parts
Demo film presenting M5R90. This is our first choice for roughing to semi-finishing in shoulder milling operations of aluminum automotive components such as cylinder blocks, cylinder heads and transmission housings.
M5B90 - Super finishing face milling cutter for aluminum
Demo film presenting M5B90, finishing face milling concept developed for aluminum automotive components such as cylinder heads, blocks, housings, covers and all components with a wide material engagement.
M5F90 milling cutter – one shot roughing and finishing
Demo film presenting M5F90. This is a concept face-milling cutter that enables roughing and finishing of thin wall aluminum automotive components in a single operation.
M5C90 milling cutter – one shot face milling, high-speed direct finishing for aluminum
Demo film presenting M5C90. This is a concept face milling tool for high-speed direct finishing of aluminum automotive parts such as cylinder heads, cylinder blocks, and all aluminum parts with wide cutter engagement.
CoroDrill® 880 CVD diamond-coated insert grades for ISO N machining
Making holes in aluminum can be a challenging task. CVD diamond-coated insert grades N124 and N134 feature an insert coating with the super-hardness of a real crystalline diamond. Together with chip breaker designs and a unique geometry the inserts guarantee superior drilling.
Developing a face milling cutter for aluminum - Passion for innovation
The face milling cutter for aluminum - M5B90 - is a result of true innovation. Meet one of the engineers behind the development of this unique milling cutter and learn about the passion that went into creating it. (including subtitles)
Customer story – Sandvik Coromant and PCI Tongtai - Face milling of cylinder head solution
Face milling operations in cylinder heads place high demand on surface quality. When developing advanced milling cutters, one important success factor is to have strong partnerships based on a shared passion for technology and innovation in metal cutting. PCI is a longtime partner of Sandvik Coromant where that passionate mindset is central. (including subtitles)
Performance in challenging operations - CoroDrill 860 GM
CoroDrill® 860 with -GM geometry is a high-performance multi material drilling solution for short holes.
Edd China explores: Vibration-damping technology by Sandvik Coromant
What’s the similarity between Taipei 101 and a cutting tool? Join Edd China on his journey to Trondheim, Norway, to find out. In the film, you’ll learn about vibrations and how to reduce them in machining operations using a tuned mass damper. Edd talks to experts in vibration-reducing technology for machining and explores the technology behind Silent Tools™ damped cutting tool solutions.
Articles
The use of aluminum in the automotive industry is increasing every year. Its lightweight properties and high strength are perfect for many components. The growth in e-mobility is another driving force behind its increasing use. Here we have collected articles on the trends and challenges you may encounter when machining aluminum.
Ask the expert – aluminum machining
Sandvik Coromant’s Automotive Machining Specialist discusses the challenges of working in aluminum and how proper tooling can help.
Solutions for productive aluminum machining in the automotive industry
The move towards lightweight materials has seen a growth in the popularity of aluminum in the automotive industry. The correct application of optimized milling cutters across the entire range of engine component machining operations can pay significant dividends.
The challenges of working with aluminum
Manufacturing cylinder blocks involves the largest number of machines in automotive component production, using processes that are often complex and involve tight tolerances.
Overcoming e-mobility manufacturing challenges
Electric mobility or e-mobility is more diverse than just pure electric motor-powered vehicles, and this variety means that different components present their own machining challenges.
Optimizing aluminum machining in the automotive industry
Tooling selection is the key to genuine market differentiation in this segment, where the correct application of optimized milling cutters across the entire range of engine component machining operations can pay significant dividends.
Firm steps and decisive actions towards e-Mobility
E-mobility or electromobility is a global goal. We are advancing at different rates but with a clear focus on reaching this goal as soon as possible.
Decarbonizing the world's roads
With climate change a global concern, it’s important that we produce more efficient vehicles that run on greener fuels. Here we explore how material choice and innovations in metal cutting are supporting the transition to more environmentally friendly vehicles.
Productive aluminum machining for automotive powertrains
Sandvik Coromant has the innovation power and committed focus required to offer productive, dedicated solutions for the automotive segment as well as for machine tool builders.
Keeping a clean face
Guaranteeing a stable and burr-free face milling machining process with predictable insert tool life. Solution: Use the Sandvik Coromant M5B90 for predictable tool life.
Beating bi-metal engine block challenges
As demand for lightweight engines increases, more and more customers are requesting tools and methods to process bi-metal engine blocks.
Product publications
Whether you are looking for information about specific milling cutters, drills or taps for machining aluminum components, this is where you can download publications containing information on our solutions.
Services
Time is precious. You can be sure that our range of services is designed to increase efficiency, profitability, sustainability and knowledge in metal cutting. We offer ideas and solutions that will free up your time — in essence, creating a sense of gaining that extra hour.
Digital solutions
CoroPlus® offers digital solutions for the entire manufacturing value chain, all the way from planning and design to in-machining and machining analysis.
CoroPlus® connects preparation and planning processes, making them quicker and more efficient. Perspectives on current machining methods and recommendations are integrated in the workflow. Automation of pre-machining tasks enables increased transparency as well as modern and sustainable production operations.
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