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Stamping dies

Nothing captures the essence of car manufacturing as much as a stamping die. The fact that each and every die represents a huge investment in time, money, and know-how is easy to understand. Just as easy to understand is your need to shorten lead-times and reduce production costs, especially with new model life-cycles getting shorter and shorter.

Making a stamping die requires considerable metal-working skills—straightforward machining and advanced cutting in cast-iron, nodular cast-iron, steel, and hardened tool steels.

 

 

Application overview

 

 

1. Face milling​

CoroMill® 745

Multi-edge concept suitable for large batch productions, flexible transfer lines, and when maximum tool utilization is important. The patented insert positioning system provides the same light cutting action and performance as a positive, single-sided milling cutter, but with 14 cutting edges.

CoroMill® 745

 

CoroMill® 345

CoroMill 345 is a new generation of 45 degree face mills engineered to provide the best cost efficiency on the market. Designed primarily for high performance face milling with small to medium depths of cut in steel, stainless steel, and cast iron, the versatility and far-reaching optimization possibilities of this advanced tool make it suitable for a wide range of applications from demanding roughing operations to mirror-finishing.

CoroMill® 345

2. Shoulder milling​

CoroMill® 390 long edge

Versatile cutter for deep or shallow square-shoulder milling in general machining. Large product program with a wide range of diameters.

CoroMill® 390

3. Profile milling​

CoroMill® 316

Exchangeable-head milling system for greater flexibility and better productivity, plus lower tool and inventory costs. Strong cutting head/shank interface provides high strength for roughing and high rigidity for finishing. The newly introduced solid carbide shank is available in all coupling sizes from 10mm (0.394 in) to 25 mm (0.984 in). Its higher stiffness and less deflection make it possible to machine long overhangs and deep pockets, and it also provides higher accuracy in finishing operations.

CoroMill® 316

 

CoroMill® ball nose

The CoroMill ball nose end mill is now available with integrated Coromant Capto coupling. Coromant Capto improves the modularity of the tool and the coupling’s stiffness.

CoroMill® 216

4. Drilling​

CoroDrill® 880

With up to 100% higher productivity compared to conventional indexable insert drills thanks to step technology, the CoroDrill 880 has four true cutting edges with wiper geometries to create a superb surface finish.Optimized chip channels accelerate chip evacuation and help to avoid production stoppages. The CoroDrill 880 is available in diameters 12.00 mm (0.472 in) to 63.5 mm (2.50 in).

CoroDrill® 880

5. Hard part finishing​

Insert grade GC1010

Optimized for roughing to finishing, the new PVD-coated GC1010 is the perfect complement to existing grade profiles. With superior edge-line toughness, greater wear resistance, and increased cutting speeds in machining of hardened steels, the GC1010 can't fail to boost productivity.

GC1010

6–7. Semi finishing –  
      Roughing​

CoroMill® 300

Round insert cutter for smooth face milling, profiling, and pocketing. Roughing in all material from cast iron to hardened steel. The positive cutting angles take light cuts and make it possible to get high feed rates also in weaker machines and in unstable conditions. Now also in insert size IC20 and cutters in diameters 66 mm (2.598 in)–200 mm (7.874 in).

CoroMill® 300

An auto industry story with a happy ending

It starts in 1956 and ends on Tuesday at 10:15, local time. In that time, auto industry veteran Kenneth Rooth has seen auto industry tooling go from wooden models and plaster molds to CAD manufacturing and efficient 21st century production.
 
But just when it seemed that engineering couldn’t get more sophisticated, Kenneth teamed up with Sandvik Coromant to achieve a full 30% reduction of metalworking times on stamping dies.
 
History being made? Maybe. Money being saved? Definitely.
 
 
 
 


 
 

Automakers typically manufacture over a third of their stamping dies in-house. Making these tools is time-consuming and, with some 750 of them required to build a car, a major production bottleneck. Today, shorter lead times, more models, and tight budgets have made this process even more critical.

Kenneth Rooth knew that much of this cutting and milling work was done by individual operators, with much manual finishing, something that requires great skill and a great deal of time. The result was not only higher costs, but also lower standardization. The quality and fit of a right door could vary from a left door if two different operators were programming the machines.

Sandvik Coromant was given the assignment of finding a way to bring costs and lead times down and quality up. Together, a new process was developed with new tools and machining processes. The results: machining times were cut by more than 30%, manual tool polishing was totally eliminated, and other manual machining was reduced considerably.

 

How did they do it?

First, high-speed steel drills were replaced by indexable inserts drills, a simple measure that gave a considerable boost in efficiency. Then, to improve machining efficiency of parts with long overhangs, silent tools replaced traditional tools and a number of templates were developed for future use. 

 

 

 

Kenneth Rooth

 

​Stamping die machining reinvented

Perhaps the largest savings in machining stamping dies can be found in new methods for material removal. Here are a few examples of measures that helped make Kenneth Rooth a hero in cost cutting.

 
Round insert milling cutter instead of a ball nose cutter: lead time savings in 3D roughing

A common rough machining method on 3D surfaces uses a ball nose cutter in a copy milling operation at varying depths of cut. In combination with long overhangs from the spindle nose, this puts excessive stress on the cutting tool and machine spindle.

By switching to a contouring tool path using a round insert cutter, a higher metal removal rate can be achieved by taking advantage of the larger number of effective teeth. A constant axial depth of cut gives a more even and constant load on the spindle, allowing process optimizations to be made. 

 

Faster hole making on die shoes

Holes are traditionally drilled with high speed drills in cast iron die shoes. Since die shoes often contain lots of bolt holes, eyelet holes, etc., the total drilling time is usually long.

By replacing these drills with an indexable drill, such as CoroDrill 880, huge productivity improvements can be achieved, even in dry machining.

 

Efficient hole making with plunge drilling in a trimming steel

Traditionally, these oval hole features are made with a high-speed steel drill and then widened with a milling cutter.

CoroDrill 880 replaces this combination by using an intermittent plunge drilling operation to widen the hole.

This method removes 85% of the material, in much shorter time, leaving the rest for a traditional round milling cutter. 

 

Lifter feature

The standard method for lifter features is to make the hole with a high-speed steel drill, followed up by a solid milling cutter to open up the feature.

Instead, however, Sandvik Coromant chose to drill straight down with an indexable insert drill (CoroDrill 880) and then widen the slot with an indexable plunge cutter (CoroMill 210).

A highly efficient trochoidal milling method was then used to remove quickly as much material as possible, at large cutting depths and at the more narrow part of the slot.

 

Guide bush seats

An efficient and flexible way of machining seats for guide bushes is using the round insert cutter CoroMill 300, the CoroMill 390 long edge cutter, and the CoroBore 825 for finishing.

The CoroMill 300 is used initially for the facing operation, then for opening up the hole in a three axis helical interpolation.

The CoroMill 390 LE machines the seat efficiently, thanks to its large depth of cut capability in combination with a light cutting action.

The finish tolerance is obtained with the precision boring tool CoroBore 825. This process saves both time and inventory.

Typically, drilling tools, in combination with solid cutters, are used for this kind of feature at much lower productivity levels.

 

Machining of surface for safety bolts

Plunge milling with the CoroMill 210 can be an excellent alternative to a long-edge milling cutter when accessibility is sometimes reduced and a long overhang is required. Standard methods use a high-speed steel long-edge cutter.

The plunging method directs the forces in an axial direction, which is favorable from a vibration point of view when machining with long overhangs.

Taking advantage of the Coromant Capto system with its excellent stability and modularity makes it possible to optimize tool assembly.

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CoroMill 300 in roughing of 3D surfaces.

 

 

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CoroDrill 880 in stamping die hole making.

 


 

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Plunge drilling with CoroDrill 880.


 

 

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Trochoidal milling with CoroMill Plura.
   

 

 

 

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CoroMill 390 LE in guide bush machining. 

 

 

 

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CoroMill 210 in plunge milling.
Coromant Capto®

Saves time and money every time you change a turning, drilling, or milling tool.

Market-beating flexibility extra useful in die making. Coromant Capto now acknowledged with ISO standard.

Coromant Capto®

Silent Tools

In a vibration-sensitive application, considerable productivity improvements can be achieved by using Silent Tools.

With Silent Tools, the vibration energy is absorbed into the dampened bar, minimizing vibration, and substantially increasing cutting data.

Silent Tools

CoroChuck™ 930

With the best pull-out security on the market, The CoroChuck 930 is designed to eliminate vibration for excellent stability and accessibility in all milling and drilling operations.

CoroChuck™ 930

 
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