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.
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.