metalworking world 3-2013

8/12/2019 Metalworking World 3-2013

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PROFILETerminator saves climate TECHDeep pocket millingBRAZILNo more breakdownsTECHPushing productivityINSPIRATIONToy story

GEAR MILLINGShifting upTECHAerospace precision

How Manoir Industries was able to offer end-to-end

solutions instead of rough parts.

Power ofpassion

3/A BUSINESS AND TECHNOLOGY MAGAZINE FROM SANDVIK COROMANT

ENERGY:

Facing fusion


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2 METALWORKING WORLD

KLAS FORSSTRM PRESIDENT SANDVIK COROMANT

EDITORIAL

WHEN IT COMES TOknow-how, our pursuit ofexcellence has placed Sandvik Coromant at theforefront of the metalworking industry. We havea particular focus on three areas: innovation,education and competence.

We serve companies from around the globe,and the knowledge we gain from analyzingcustomers processes means that we can re-commend new ways of operating to increaseefciency and protability. This often takes

place through a collaborative relationship. See,for example, the article on Cummins in Brazil(on page 12). The engine maker describes the

partnership as two hands working together.We call it our Productivity ImprovementProgram (PIP). No matter what it is called, the

bottom line is that Cummins was able to realizelarge cost savings. And we added to our compe-tence in the process.

PIP is part of our service offering. The services

represent the competence we have beyond theactual tooling solutions. Our offering coversareas from engineering, where we support themachine investment process, and education,

where 30,000 people attend our various lear-ning programmes annually, to sustainability,where we offer solutions for reconditioningand recycling carbide inserts. The services

also include smart logistic solutions for stockanalysis and reduction programmes, freeingnet working capital.

On page 31 we explain how ManoirIndustries in France benetted from such a

support programme. The companys industrial

methods manager, Gilles Beaujour, describes hisexperience: Sandvik Coromant wasnt just thereto sell me a product, but also to help me developthe most efcient process. This way of working

is what makes us the competence leader.Finally, let me thank you for sharing your

challenges with us. The knowledge and expe-rience we gain is what leads us to create the

best services and make the best tools.

Pleasant reading!

KLAS FORSSTRM

PRESIDENT SANDVIK COROMANT

Metalworking Worldis issued forinformational purposes. The informat

provided is of a general nature andshould not be treated as advice or berelied upon for making decisions or fuse in a specific matter. Any use of thinformation provided is at the users risk, and Sandvik Coromant shall notliable for any direct, incidental,consequential or indirect damage ariout of the use of the information madavailable in Metalworking World.

Get your free copy of Metalwo

World.Email your address to

[email protected]

Metalworking Worldis a business and technology magazinfrom AB Sandvik Coromant,811 81 Sandviken, Sweden.Phone: +46 (26) 26 60 00.Metalworking World is published thretimes a year in American and BritishEnglish, Czech, Chinese, Danish, DutcFinnish, French, German, Hungarian,Italian, Japanese, Korean, Polish,Portuguese, Russian, Spanish, Swediand Thai. The magazine is free tocustomers of Sandvik Coromantworldwide. Published by SpoonPublishing in Stockholm, Sweden.ISSN 1652-5825.

Publisher responsible under Swedpublishing law:Jessica Alm.Editor-in-chief: Mats Sderstrm.Account executive:Christina HoffmEditor:Henrik Emilson. Art director:Emily Ranneby. Art director assistanAnna Boman.Technical editors:Brje Ahnln, Martin Brunnander.Sueditor: Valerie Mindel. Coordinator:Lianne Mills. Language coordinatioSergio Tenconi. Layout, languageeditions:Louise Holpp.Prepress:Markus Dahlstedt. Cover photo: AudBardou. Please note that unsolicitedmanuscripts are not accepted. Materthis publication may only be reproducwith permission. Requests for permisshould be sent to the editorial managMetalworking World.Editorial materiaand opinions expressed in MetalworkWorlddo not necessarily reflect the vof Sandvik Coromant or the publisher

Correspondence and enquiriesregarding the magazine are welcomeContact: Metalworking World,SpooPublishing AB, Rosenlundsgatan 40,118 53 Stockholm, Sweden.Phone:+46 (8) 442 96 20.Email: [email protected] enquiries:CatarinaAndersson, Sandvik Coromant.Phone:+46 (26) 26 62 63. Email:[email protected] in Sweden at SandvikensTryckeri. Printed on MultiArt Matt 11gram and MultiArt Gloss 200 gram frPapyrus AB, certified according to IS14001 and registered with EMAS.Coromant Capto, CoroMill, CoroCut,CoroPlex, CoroTurn, CoroThread,CoroDrill, CoroBore, CoroGrip, AutoTGC, Silent Tools and iLock are allregistered trademarks of SandvikCoromant.

Taking the lead

with competence


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METALWORKING WORLD

10A patented newtechnique puts VoithTurbo on the map.

CONTENT

The promise of a newsuper insert grade.

Untouchableedge

12BrazilProcessimprovemand big csavings.

The new P25 grade providesa new, higher potential incutting speeds and a longer,more predictable tool lifewith high reliability.

The end ofthe line

Long-reachclearance

Powerhouseof engineering

The best way to improvethe parting off processwith increased materialuse and process security.

Optimizingparting off

10

Operational flexibility,security and standard-ization possibilities withmodular tools.

How the aerospace industrmeets the holemakingrequirements of a complexmanufacturing environmen

6Profile

Deusfine-tuned

recycledmotorbikes.

Quicktime:News from around the world

Profile:Deus smart recycling

Profile:Dame Ellen MacArthur

4

6

7

Energy:Intelligent wind turbines

Brick by brickHow Lego got a grip on innovation

Shifting GearsSandvik Coromant vice president onthe shift in gear milling technology

8

18

24

31France

From rough parts tofinished solutions.

26 38

28InnovationFacing the challenof fusion energy.

22

TECHNOLOGY

9


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QUICKTIME


TEXT: HENRIK EMILSON PHOTO: GETTY IMAGES

Get the LED outCLIMATE CONTROL.ArnoldSchwarzenegger has been success-ful in many fields, from bodybuildingto film acting and politics. Now the

former Mr Universe/Terminator/Governor of California is taking ona challenge that might be his big-gest to date the climate. In 2010,together with other global leaders,he founded the non-profit organiza-tion R20 Regions of Climate Actionin cooperation with the UnitedNations. R20 is led by regionalgovernments that work to promoteand implement projects designedto produce local economic andenvironmental benefits in the formof reduced energy consumption andgreenhouse gas emissions. R20s

latest action is a joint venture withPhilips to promote regional andmunicipal LED lightning as a tech-nology that can to help slash thesubstantial carbon footprint ofless-efficient conventional lightsources.

Cities, states and provincesare where the real action is whenit comes to energy-efficient proj-ects, Schwarzenegger says. Welook forward to having Philips joinour building and street-lightingefficiency campaign and help tomake everyone an action hero inbuilding sustainable communitiesand fighting climate change.n

THE BAY LIGHPROJE

The worlds largest light sculpture, 1.8 m

wide and 500 feet hcreates a dazz

display across the Francisco Bay Bridg

California with 25,twinkling white LED lig


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METALWORKING WORLD

QUICKTIME

THE NUMBER:

NOODLE FORK

The cumulative global capacitygrowth of wind power

in 2012, led by China andthe United States.

19PERCENT

NEW MATERIALS.Imagine that your recycledcardboard turns up in the street the followingweek as a bike, a wheelchair or a baby stroller.Through the work of Israeli company CardboardTechnologies, this may well be possible. Thecompany manufactures vehicles made of recycled

cardboard strengthened with old car-tyre rubberand organic raw materials but no metal. Thematerial is both waterproof and fireproof and islighter and stronger than metal alloys and carbonfibre. An added bonus: Raw material costs areextremely low.n

In Western cui-sine, noodles aregenerally short

and eaten with afork; in Easterncuisine, noodlesare usually longand eaten withchopsticks. Thenoodle fork is aninnovation that

allows any type ofnoodle to be eaten

with ease andstyle. In 2012 itwon a red dot

from the Red DotDesign Award, aninternational prod-uct design prize,

presented inSingapore.

AEROSPACE

Bright designminds are work-

ing on the prob-lems of space and

other issues inaeroplane cabin

seats in economyclass. Design

student AlirezaYaghoubi enteredthe James Dyson

Foundation designcompetition withhis concept Air-Go, which uses

thinner chairs andtrays to create

more space aswell as videoscreens that

drop from theceiling for eachindividual seat

independentof movements

of the rowin front.

Researchers at Ohio State Universthe United States have been explo

germanium, a material that ordinartakes the form of multi-layered cryAs with graphene, germanium has created in single-atom-thick sheetscalled germanane, that conduct etrons 10 times faster than silicon five times faster than conventionagermanium.

THE WORD:

GERMANANE

In 2012, wind turbines with a totapotential of 45 gigawatts were

constructed worldwide, bringingglobal capacity to 282 GW 3 percent of global electricity de-mand, reports the World Wind EnAssociation (WWEA) in Bonn,Germany.

DID YOU KNOW?

ENERGY BOOM

Dubbed the Alfa,the 28-poundprototype is a

single-speed bicyclewith spokes, rims

and frame all madefrom cardboard thatcan safely support a

rider nearly 20 timesits weight.

METALWORKS.Can metal be comfortable? Itcan if you do what designer Peter Novague didand folded a single sheet of aluminium origami-styleinto a chair. Edge chairs are not only aestheticallypleasing, with their coatings of bright colours, butthey are also easy to stack, and because theyremade of aluminium they can be used both indoorsand out. Cushions for the chairs are available foradded comfort.n

Softmetal

PRESS IMAGES


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Heavy Metal

Thunder

Clever recycling andbranding

ENTREPRENEURS.This is exactlyhow we want it to be a hangout forthe new biker generation, says StefanWigan, Deus Ex Machina brand andspecial projects manager, gesturing tothe hipster bikers crowding the trendyoutlet on Venice Boulevard in theLos Angeles suburb of Venice Beach.Deus Ex Machina is an Australian-based company that wildly mixessurfboards, clothes, coffee and hotlysought-after custom-built motorbikes.

The company originated in Sydneyand has grown into a company withhangouts in Bali, Italy (Milan) and theUnited States. Behind the VeniceBeach location is a garage whereDeus mechanic Michael Woolawayorders in cast-off motorbike partsand sometimes entire motorbikes sohe can disassemble them into theircomponent parts and then rebuildthem into Deus motorbikes.

Its a Deus concept through andthrough, taking inspiration from theshapes of the past and building theminto tools with a modern-day, practicalpurpose, says Woolaway.

It takes up to two months for Deus tobuild a motorbike. The bikes typicallyhave their roots in the 1950 Britishcaf racer culture, but everything fromengine to steering uses the latesttechnology pared down and scaledback to make the small monsters ofhorsepower.n

QUICKTIME


TEXT: MARCUS JOONS PHOTO: DANIEL MNSSON

Founded in Australia in 2006,Deus Ex Machina has based itssuccess on hand-built custommotorcycles that combinestripped-away simplicity withmodern components andperformance.


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METALWORKING WORLD

Going round

in circles

Dame Ellen MacArthurSUSTAINABILITY.After a record-breaking stint as a professional sailor,including solo trips around the world,Englands Dame Ellen MacArthur in2010 launched the Ellen MacArthurFoundation, a charity that works withbusiness for a transition into a circu-lar economy (the generic term for anindustrial system that is restorative innature). The charitys latest endeav-our is to bring together a worldwidenetwork of 100 leading companies tofacilitate development and commit-ment to a circular economy.

The circular economy representsa clear and proven opportunity forbusinesses around the world, saysMacArthur. Our new initiative bringscohesion and focus to this opportunityand allows businesses to share expe-riences, learn from best practice andwork together to achieve real businessbenefits. In total we anticipate that thishas a value of more than 10 billion[US] dollars, encouraging innovation,investment and job creation.

The aim of a circular economy isto rebuild capital, whether financial,manufactured, human, social or

natural, to ensure enhanced flowsof goods and services.n

TEXT: HENRIK EMILSON PHOTO: PHILIPPE CARON/CORBIS IMAGE

Record-breaking sailor DameEllen MacArthur sets the sails foran improved industrial system.

QUICKTIME

METALWORKING WORLD


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QUICKTIMEQUICKTIMETEXT: HENRIK EMILSON ILLUSTRATION: KHUAN + KTRON

110or 139-metresteel tower

120metre rotor

diameter

15percent increase inenergy production

106dB(A) standard

sound power level

new wind turbine from General Electric is not only huges rotor is as big as the London Eye Ferris wheel) but its alsoe first intelligent wind turbine that uses a Web-based net-ork to help manage the intermittency of wind, thus providingmooth, predictable power to the grid regardless of how windyis. As with anti-lock brakes in a car, the turbines in the wind

ark work together in unison instead of as separate entities.one turbine stops, the others pitch in so the total output re-ains constant. A new type of sodium battery stores excess

ower and releases it when the wind slows down.n


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METALWORKING WORLD

TECHNOLOGTEXT: CHRISTER RICHT PHOTO: ADRIAN BU

In steel turning, a P25 grade is seen as a frst

choice for much of the machining. Its an all-

round safe insert that can also be an optimizer

even a problem solver. The existing P25

grade, GC4225, introduced a few years ago,

is a leader in this area, so why a new gradenow? What can it contribute?

Our target for a new grade for the ISO P25turning area has been even higher levels of

process security and cutting data recommen-dations. The variation in material, components,

operations, conditions and limitations in thisarea is unequalled throughout machining. Assuch, the ISO P25 turning area is the mostdifcult to solve with one insert.

With GC4325 now being introduced, weare moving on to our seventh generation incoated P25 grades to cover this large and

diversied area with even better optimizationpotentials. It is light years from the rst gene-

ration and has produced the best grade-testresults we have experienced in more than10 years. Just think of the implications forthe machine shops involved in this type ofmachining.

As the market leader in cutting tools, weare committed to providing our customerswith continuous improvement in their manu-facturing. We know that the growing P25steel-turning area makes more and different

demands on the cutting edge. In regard to thegrade development, the all-important coatingadhesion has been improved to combat anyopenings for tool wear. The insert substrate

has to stand up to high temperatures,with no structuralchanges taking

place. The coating and substrate

have been developed together ona scale that was previously not

possible. We have cutting datarecommendations higher than ever

before for this area, but we havekept process security, with

predictable tool life, in

focus as the main advan-tage of the new grade.

Reaching this level of

capability represents

more than advances in

coating and substrate

How did a new super insert grade GC4325 come about, and what does this new-

generation grade promise for the large steel-turning area? Metalworking Worldcontributor Christer Richt asked Mia Plsson, a senior product manager at

Sandvik Coromant, what has been going on and what has been achieved.

structure. We are talking about a step in

proportion to the very frst coated grade.

What other innovations lie behind the

development of GC4325?

There is a lot behind the achievement. Wevhad to take a hard look at all the factors.Practically all the manufacturing and pro-cesses to make the grade have been the res

of innovations.If I had to mention just one, it would

the new crystal structure of the coatiwhich is responsible for the incredibnew level of resistance to wear. n

A new, untouchablecutting edge

Want to know more?www.sandvik.coromant.comgc4325.


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TECHNOLOGYTEXT: CHRISTER RICHT IMAGE: BORGS

AN INSERT CUTTING edge that cuts metal effectively,

leaving a satisfactory nish, does so for as long as ithas an intact edge line. When the line is broken, sometimes

prematurely, it is mostly through the development of thewrong type of wear. This results in a rapid breakdown,

producing unacceptable parts and compromising security.It is the end of the line for the cutting edge.

Predictability has become increasingly important inmodern machining, especially with limited supervision,and there are a number of threats to the edge line remain-ing intact long enough in steel turning. One challenge isthe large ISO P25 application area, which includes severalvery different materials, from ductile low-carbon steels tohard high-alloy steels, bar material to forgings, castings to

pre-machined parts.

For this reason, when it comes to cutting speed levels insteel turning, the manufacturing industry average is about70 percent of recommended values. Factors such asmachine capability, workpiece diameters, operatorcompetence and risk aversion come into the picture. The

advances with a new P25 grade, GC4325, will actuallyhelp users resist holding back on cutting-data levels. The

grade provides extremely high process security

through its ability to retain an intact edge line.Representative of advances brought about by

this new grade is the turning of a particularlydemanding type of alloyed steel used mainlyfor bearings and associated applications.Improvements here have been far aboveexpectations of what the grade might

provide. These steels challenge the

cutting edge, with abrasive hardcarbides as inclusions in the steel,and tend to generate rapid craterwear and, sometimes, risky weardevelopment.

THE INSERT SUBSTRATE andcoating of GC4325 have beendeveloped to better stand up tohigh temperatures, therebyreducing the effect that causesexcessive wear. As a bonus, thegrade is highly capable of

The end of

CHALLENGE: How to further

increase output and add security in

steel turning with one indexable-

insert grade in an area where thematerial, conditions and operations

vary widely.

SOLUTION: The new-generation coated

cemented-carbide grade developed for the

large and varied ISO P25 application area.

This innovation in tool material provides anew, higher potential in cutting speeds and

a longer, more predictable tool life with very

high reliability over an extended area.


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METALWORKING WORLD

the line

SUMMARY

An average productivity increase of 30 percent from todaysexisting levels is now available with a new P25 steel-turning gradGC4325. The increase is due to the grade's capacity for highercutting data, longer tool life and higher security. It representsa new generation of performance with coated cemented-carbideindexable inserts and provides a new potential to be tappedthroughout a large and diversified application area.

maintaining the insert edge line at temperatures

more suited for an ideal uid ow zone whengenerating chips.

This translates to capability for

higher cutting speeds with the edgesecurity for more predictable,

longer tool life as increasinglyneeded for unmanned

machining throughout theP25 area. n

Controlling continuous, naturalwear and eliminating discontinuous,often uncontrollable wear is a key tosuccess for steel turning in the ISOP25 application area. The imageabove shows a cutting edge typicalof the best existing insert grades.Premature wear has terminated thetools life.

The image below shows a GC4325cutting edge at the same stage ofthe same operation. The edge lineis good, and the tool is still viable.

Pushing productivityProductivity throughout the large and varied ISO P25 steel-turning area isto some extent an individual measure, depending on type of production.But generally it is a combination of machining efficiency, often measuredin metal removal rate, and machine-tool utilization, in pieces machinedper hour. For the cutting edge, this comes down to levels of cutting dataand tool life. Cutting speeds of 400 m/min are normal for GC4325,

depending on the application.

Piecesmachinedper hour

Metalremovalrate

Cutting speed


12/40

So Paulo, Brazil.In So Paulo, a partnership or working withtwo hands, as the Brazilians say has meant process improvementsand big cost savings for engine block manufacturer Cummins.

TEXT: VINCENT BEVINS PHOTO: LALO DE ALMEIDA

Working with

two hands


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Cummins engine factory, Guarulhos,Brazil. The combined SandvikCoromant and Cummins teamworked together to develop anoptimized process.


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]

2]


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METALWORKING WORLD

nnnAt Cummins plant in So Paulo, Brazil, a problemwith the Operation 120 boring process on the Block C line

was getting worse. Breakdowns in an old machine thatbored into the blocks of truck diesel engines were costingas much as 80,000 reais (more than EUR 30,000) a year indowntime, and repairs in 2011 were projected to cost someBRL 30,000 (EUR 12,000).

The Cummins operation in So Paulo maintains a team of

specialists and suppliers embedded at the plant. Still, theplant management didnt think it had the technical means tofully deal with the problem. It turned to Sandvik Coromantwith a stopgap solution: to buy an extra replacement partfor the old machine that kept breaking down.

But Sandvik Coromant came back with a different idea,one that would completely eliminate Operation 120, takingadvantage of new tools and some logistical reorganizations

to move the other operations on the old machine to newer,more exible machines. Perhaps most crucially, the new

layout would provide operators with a much safer workingenvironment.

Cummins ofcials were convinced when they saw a

presentation by Antonio Granzoto, a technical salesman atSandvik Coromant. Wed seen people try to come up withsolutions to that before and it hadnt worked, says EmersonCarlos dos Santos, a manufacturing engineer at Cummins.But when we saw his presentation we thought, Man, wehave to try that. It could really work.

WHAT RESULTED WAS typical of the partnership betweenCummins and Sandvik Coromant, which has maintained a

presence within the plant since 2005. Together the companiesformed an 11-person implementation team, with eight fromCummins and three from Sandvik, to work on recoordinatingthe entire machining line.

It started off as a smaller team and then was extendedto include programming issues, says Thiago Vasques, a

Cummins manufacturing engineer. It was a big project,with lots of different people involved. The idea was to

bring together as many people as possible. We wereworking with eight exible machines, and we needed

leading operators involved.Rejigging the line involved two major challenges.Firstly, a new technology, Silent Tools, was needed to

replace Operation 120. Secondly, all other operations onthe old machine had to be moved around on the linewithout increasing the total time required. A line can onlygo as fast as the slowest machine.

The original plan developed by Granzoto specied that

no single machine step would take more than 12 minutes.Thus implementation required an entire physical reorgani-zation of the line. But if it succeeded, it could createsavings of BRL 700,000 (EUR 270,000) per year, muchmore than the projects cost.

It worked. Even in its early days, the new system is

saving BRL 180,000 (almost EUR 70,000) a year just inoperating expenses.

IN THE CUMMINS-SANDVIK Coromant partnership, such twohands solutions are developed all the time.

Without a doubt, the Block C project had a hugeimpact, not only on costs but in terms of ergonomics, saysGeraldo Sumitomo, head manufacturing supervisor atCummins. Were very happy with the partnership withSandvik Coromant. We get top-notch technology in termsof tools and processes. We have eight new tools in thetesting phase just this year alone.

These kinds of projects are very common, Sumitomo

says. They may come from one side or the other, but all

the improvements and development work are done withtwo hands.

Emerson Carlos dos Santos says the best ideas cometogether around the coffee machine. We are alwaysneeding to reduce costs, he says. Thiago [Vasques]

thinks about the tools, and we talk with the Cummins teamevery day.

They also meet every Friday to come up with ways to

Metalwork for theautomotive sector

a place of honour iBrazil, one of theworlds fastest-growing automotivmarkets. But in achallenging economclimate, cutting cois critical.

The Cummins factoprecision-drills rawblocks and heads tcreate diesel truckengines for customsuch as Ford and M

The factory has anannual turnover ofabout 12 million eu

Cummins exports 1to 20 percent of itsproduction, mostlythe United States. company is planninbuild another majoplant in Brazil.

Marcos Morine, roundols specialist fromndvik Coromant, atmmins' machining line.

Luiz Adam Vavallo,ols pre-setter fromndvik Coromant.


16/40


The Quality InDepartment the final deta

machined engibefore send

m

TECHNICAL INSIGHTCUMMINS: SO PAULO, BRAZIL

OPERATION 120was an engine blockboring process performed on 1,200units per month at the Cummins plant.Repeated stoppages were a problem,and there were safety issues. Instead ofsimply providing an extra boring for theixed-function machine, Sandvik Coro-

mant created a new solution through itsProductivity Improvement Program,spreading its function across othermachines.

The key was a new tool, Silent Tools,which is strong enough to preciselyperform the 120 mm bore on a flexiblemachine rather than a supported single-unction machine. The antivibration Silent

Tools bar allows long-length machiningand makes it possible for the tool to workn a CNC machine with automatic toolchanges, rather than in a dedicatedmachine as before.

Crucially, the time required for thebearing camshaft rough operation wascut from six minutes to two minutes.

The entire production line was reas-sembled, and seven other processeswere migrated to the Heller and GROBmachines. The new process and tooleduced costs while increasing efficiency

and saving production time.


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METALWORKING WORLD

[2]

improve the relationship, with the aim of having a majornew project every six months.

Theres always an opportunity to improve something,

says Granzoto.

IN RECENT YEARS, the overwhelming focus has been onreducing costs rather than expanding or reorganizing

production, reecting trends in Brazilian metal manufac-turing. The country has a huge internal market as well as

markets in neighbouring countries such as Argentina, butthe success of Brazils economy has led to a relative loss ofcompetitiveness in much of the manufacturing industry,due to the rising value of Brazils currency since thenancial crisis hit the United States and Europe. Produc-tion on Block C has dropped 20 percent in 2013 from theyear before.

Cutting costs is essential, as is having people who

intimately know the specics of the metalworkingprocesses.

Sandvik Coromant will be there if we need a new toolor new strategy, says dos Santos. They know us, and

they know our factory.n

[1] Via Dutra, a majorhighway connecting the

city of So Paulo to Rio deJaneiro, can be seen from

the Cummins plant.

[2] Leidson Nunes, toolspre-setter from SandvikCoromant, prepares the

Silent Tools bar.

[3] Round tools thathave been reground

and prepared.

[1]

[3]


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19/40


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The new innovation guidance system keeps innovation

focused. In the past, LEGO managers were pulling leversthat werent connected to anything.

What you need is control, says Robertson. That does

constrain the designers more, but some designers are happierwith the new way of doing things because instead ofcreating something that will never see the light of day, their

products now make it to the market nine times out of 10.Innovation is not the same thing as creativity, he adds.There are a lot of different roles inside a company that

all matter for innovation, he says. OK, maybe youre not

the creative type, but maybe youre really good at nding

companies that do cool things and bringing their ideas intoyour company, or managing a creative team, or workingwith outside partners. Bringing lots of ideas together andconnecting them systematically is really valuable, andthats the secret to protable innovation.

Creativity is a part of that, but not an especially big part,

Robertson says. I think creativity is overrated, he says.I think creative ideas are a natural by-product of a good

process, and they happen frequently if you do the rightthing.

LEGOs new system has been in place for almost adecade, and it seems to work.

Five years of 24 percent annual sales growth and40 percent annual prot growth is impressive, says

Robertson. Everyone uses Apple as an example of a greatinnovation-driven company, but LEGO belongs in thatconversation too. Their recent results are even better than

Apples. n

David Robertson,professor at the Wharton

School, University ofPennsylvania.


What can manufacturers learn from the LEGO story?:[1]Innovation is not always profitable. Understand how to balance creativity and efficiency. [2]Review your approach and offering on a regular basis,and change anything that is not working. [3]Adaptability is key to long-term success. Be alert to new possibilities for diversification. [4]Keep playingand have fun!

and the rst half of 2004, they were in trouble. Almost all

their innovations between 1999 and 2002 were unprotable.

Also, Roberstson adds, LEGO is a xed-cost business.

When they sell above a certain level, prots accumulate

quickly. If they sell below that level, the losses accumulate.But a main reason that LEGO almost went out of

business was that it succeeded in its attempts to boostcreativity, says Robertson. A lot of things were happeningeverywhere in the company, and LEGO encouraged peopleto come up with new ideas, he says. It wasnt protable,

and they lost control. Now they have a new system in place,

and while they can be just as creative now, if youre a LEGOdesigner, your job is not just to create a cool toy your jobis to come up with a cool Ninjago toy or a police station.

They are much more focused now, he says, and

therefore protable.

ON ITS WAYback to protability, LEGO has also gone back

to its core: the brick. LEGO is good at telling storiesthrough the bricks and nding interesting drama in the

constructions you build, says Robertson.The crisis taught LEGO some humility. In the past, the

company would have big internal shows of new ideas, andthen management would decide yea or nay. Now they createsketches of a scene in a story, like ninjas battling, and they

listen to the children talk about them, says Robertson. Ifthe kids come up with a lot of stories, LEGO knows the toyhas potential. As they like to say inside the company, There

are only two groups of honest people: kids and drunks.The managers job is to ask what the kids say. What do the

German kids say? What did we learn? The process is much

different.


21/40

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22/40


TECHNOLOGYTEXT: ELAINE MCCLARENCE IMAGE: BORGS

FOR VOLUME BAR fed parts manufacturing, producers are

continually seeking solutions that offer more efcientmaterial usage to control overall costs and support increased

bar feed capacity. Ensuring process security through a pre-dictable and consistent tool life is also important to ensurereproducible parts quality, particularly for parting off.

Sandvik Coromant has introduced a range of solutionscovering parting and SL blades, adaptors, shank and Swisstools and a new generation of inserts for parting off thatmeets these aspirations. CoroCut QD builds on the well-

proven Q-Cut and CoroCut ranges, and in doing so expandsthe options for these processes with a exible, simple-to-use

and easy-to-select tooling range.The focus has been on improvement in key aspects such as

new tool material and a tooling design calculated by FEM

for greater process stability. Tool attachment is achieved viaa smart yet simple user-friendly clamping mechanism. The

tool tip seat is tilted 20 degrees and incorporates a back stop towithstand high cutting forces. For insert widths 2 millimetresand wider, the insert interface has a rail to increase stability.

In developing CoroCut QD, attention has been paid tothe development of new and upgraded parting geometries.When parting off a component, minimized cutting forces

and efcient material removal are important.

An insert should be as narrow as possible andhave a geometry that makes the chip narrowerthan the groove to provide a parting off opera-tion with good chip control and surface nish.

Within CoroCut QD are inserts with ve

parting geometries and one turning geometryas well as options for do-it-yourself grindingand tailor-made options for a broad range ofmaterial types. The PVD insert coating offers

better adhesion, improved edge-line qualities andbetter ER tolerance.

As high-pressure coolant, HPC, is commonlyavailable on most modern lathes, CoroCut QD has beendesigned with a through coolant option available on all

tools with insert widths of 2 millimetres and more. Thisfeature has been designed to be as easy to use as possiblethrough plug-and-play connections, and inserts are designedto meet the requirements of HPC.

CoroCut QD addresses the issue of higher material costsby offering tools with reduced parting widths; it addressesthe trend towards the greater use of high-alloy materials andincreased bar feed capacity with the use of HPC. n

Optimized

concepts forparting off

CHALLENGE: How to improve

parting off processes?

SOLUTION: Adopt optimized

solutions that increase material

use and process security.


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METALWORKING WORLD

SUMMARYThe manufacture of volume productsfrom bar requires parting off processes

that contribute to lowering costs andmaximizing material use. CoroCut QDis the latest solution from SandvikCoromant that builds on the companyslong experience with secure and pro-ductive bar fed machining. The result isa simple-to-use and easy-to-select range.

ENDRESS & HAUSER,a leading manu-facturer of industrial measurement

and automation equipment, producescomponents from bars of up to 60 milli-metres in diameter. Depending on thecomponent, processing time takes twoto 10 minutes, with parting off beingone of the last operations. Because ofthe high cost of each component, thecompany turned to Sandvik Coromantfor help in developing a more secureprocess. With component materialsranging in Hastelloy or stainless steel,the aim was to use only one insert gradeand geometry for all parting off operations.

Endress & Hauser tested CorocutQD, which resulted not only in highersecurity in the process with improved

surface finish but greater tool life.Typical results were six times greater

tool life for stainless steel and three tofive times greater for Hastelloy. Anotherbenefit of adopting the new toolingsolution was the cost savings. Thematerial savings through the use ofsmaller insert widths meant reducedcosts, and the selection of one gradeand geometry resulted in reducedinventory, which also contributed tocost savings.

CASE STUDY:

When parting off a component, minimized cutting forces andefficient material removal are important.


24/40


We are doing thingsthat were consideredimpossible just ashort while ago, saysLars Bursche, vicepresident SandvikCoromant.

nnnQuality is the paramount issue in gearmilling. For this reason, the industry has beenslow to adopt new technologies, preferring to

wait until they are fully proven. But innovationssuch as indexable insert technology, hobsand new disc cutter concepts are enabling

productivity gains that should be too great toignore.

The technology shift is about revolution

rather than evolution, says Lars Bursche, vicepresident Sandvik Coromant. He believes thatthe industry is at an important crossroads andthat how manufacturers respond to the newtechnology will shape the future competitivelandscape.

Q: Is this really a revolution?

A:Certainly! When you offer tools andmethods that reduce cycle times by 50 to 90

percent compared with existing solutions, itcant really be called anything else. A shiftlike this is scary for some manufacturers.But they have to ask themselves a question:Can we afford not to take this technologyon board?

New cutting technologies are about to transform the world

of gear milling, enabling higher accuracy and reductionsin production time. Time savings of up to 90 percent take

competitiveness to a whole new level.

TEXT: PAUL REDSTONE

PERMORTEN

ABRAHAMSEN

Q: What are the risks?

A:Very few. The tools of thetechnology shift are an investment

that will last for three to ve years.Normally we are talking about a payback tiof less than three months. Gear manufacturtoday do not just buy one HSS [high-speed st

hob. Typically they buy 10 of the same-size

hob to cope with the logistics of de-coatingregrinding and re-coating so as to keep theow of production on track.

Q: What breakthroughs has Sandvik

Coromant made in gear milling and

hobbing?

A:Within gear milling we are pushing thelimits of what is possible in cutting tool

technology. We are doing things that wereconsidered impossible just a short while agwhich makes our full prole hob, CoroMill1

unique. Our new disc cutter concepts havepaved the way for greatly improved productivity and tool life.

We have also taken great strides when itcomes to nishing cutters, thanks to our

development work with advanced design an

An upward shiftingear milling


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METALWORKING WORLD

metrology software. Now we can predict thequality of the cutter even before producing it.

For hobbing, we can tailor-make insertsaccording to the process demands and thedesired result with or without protuberance.Our new concepts often result in more suit-able surfaces and allowances for grindingcompared with HSS hobs. When it comes to

pre-hardened gear wheels, our conceptsgreatly outperform HSS. Gear wheels with52 HRC can be machined, which is only

possible with cemented carbide solutions.

Q: Does modern tooling demandmodern machines?

A:No. We see good results in gear hobbingwith our new concepts on 50-year-oldmachinery with time reductions of morethan 50 percent. But if you put the new toolson a new hobbing machine for example,with integrated Coromant Capto tool-holding

you will experience magic!

Q: Can small as well as large

manufacturers benet?

A:Yes! Large-volume producers shouldalways go for the new hobbing concepts, suchas CoroMill 176 and 177. The medium-volume

producer can also gain advantages using thehob concepts if volumes of gearwheels are inthe region of 1,000 to 1,500 per year. Forsmall-volume producers, the new disc cutterconcept for example, CoroMill 172 is theoptimum choice. Small-volume producers canalso benet from our revolutionary new methods

for milling gears: InvoMilling and uP gear

milling.

Q: What are the applications for

InvoMilling and uP gear milling?

A:InvoMilling is ideal for high componentexibility for example, as needed for small

batches and prototype making. It is alsointended for the growing number of machineshops that do not have a dedicated gear-milling

machine. InvoMilling combines slot- andturn-milling, enabling machining of involugears and splines of any module and helixangle in one setup on one machine. There i

also a new multi-axis machining method fospur and helical gears, where variations ingear shape are generated according to the pof the tool rather than its shape.

The uP-Gear technology boosts productiv

and exibility in machining bevel gears. It is aused on multi-axis machines, with dedicateuser-friendly software and a set of gear-millcutters selected for the application involved

Q: How does indexable insert tooling

compare with HSS when it comes to

precision?

A:When you regrind an HSS hob, you inevtably lose quality. But with modern, cementcarbide, indexable insert hobs, you get a nehob when you change inserts with the samquality as the original. And with a 50 to 90

percent reduction in production time, the

nished gear wheel should be considerablyless expensive.

Q: What gains can be made regarding to

life in combination with lower cutting da

A:We promise at least two or three timeslonger tool life, but in practice we often seeve times. When it comes to cutting data, w

can go as low as 80 m/min in cutting speedTo boost production, the technology offers

potential of 250 m/min, with no oil requiredThe CoroMill 176 indexable insert hob is a

available as a Coromant Capto integrated tofor 4-5 axis machines.

Q: What range of gear components can b

manufactured with the new technology?

A:Modules from M1.5 (invomilling) up toM50 can be machined today, but the only liis the imagination. Our full-prole insert

solutions are currently limited to M10, but are looking to take this further. Developmenever sleeps!n


26/40


TECHNOLOGYTEXT: TURKKA KULMALA IMAGE: BORGS

THE PHILOSOPHY OF modularity in tooling is essentiallythat of consciously narrowing down choices to achieveoperational exibility. A standardized coupling streamlines

tool inventories and enables multifunctionality withoutsacricing rigidity (as reported inMWW2/2010, p. 7).

The Sandvik Coromant Capto and exchangeable

cutting head (EH) represent two layers of modularitybased on the same principle of a pre-loaded taper andange contact to achieve extreme rigidity and strength.

The EH system specically offers a range of solid and

indexable end milling cutters and boring tools for thesame shank in the intermediate diameter range of 1032

millimetres, between the typical ranges of traditionalsolid carbide and indexable-insert tools.

Two distinctly different applications benet from the

compact structure of EH tools: operations requiring longreach, as in large machining centres (MC) in the diameterrange of 1032 millimetres, and those with critical gaugelength requirements, such as in small and medium-sized

MCs and driven tool holders (DTH) in turning centres.

Typical tool interfaces in turning centre turrets include

the Coromant Capto sizes C3 to C5, while small MCstypically have couplings such as BT30 and HSK40/50,

where productivity is the key requirement.Long reach essentially necessitates a slim yet rigid

tool. The EH system provides this by allowing an under-

sized shank compared with the cutter head, which givesthe clearance around the shank required in deep pockets.

MILLING OF DEEPpockets for the aerospace industry is agood example of the machining operations where

modular EH cutters, combined with solid carbide orheavy metal shanks, offer the required reach withoutlimiting process security. As an alternative for the EHsystem, one can of course use specialized engineeredtooling, but this involves additional costs and longerlead times and also makes tool breakages a very costlyscenario.

Flexiblecompactness

CHALLENGE: How to successfully

end mill a 125-millimetre deep pocket

in a demanding aerospace component

with 15-millimetre corner radii?

SOLUTION: Try an EH indexable

cutter with an undersized cylindrical

shank manufactured from heavy

metal material.


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METALWORKING WORLD

SUMMARYModularity offers operational flexibility, security andstandardization possibilities. Modular tools with exchangeable cutter heads provide long reach for deep pockets aswell as short gauge length for cramped turrets. Goodrigidity offers productivity benefits in both cases.

Another key feature in the EH system is its compactness:The entire tool from the spindle to the cutting edge consists

of only two parts, the shank and the cutter head, whicheliminates the need for a separate holder. This is capital-

ized on in applications requiring short gauge length, suchas DTHs in turning centres, where the length of tools is

limited by the swing diameter, i.e., the required clearancearound the rotating turret.

The productivity impact of the short and rigid EH tools

can be quite signicant in these applications: The cutting

depth may be increased by up to 10 times. n

A short gauge length is criticalin small machining centres tocome under the 'critical gaugeline', which has a huge impacton productivity.


28/40


It started withEINSTEINInnovation.ITER, a new research reactor for fusionenergy, is now under construction. The goal: a tenfoldincrease on the energy put in. Expectations are high,but the challenges are numerous.

TEXT: JOHAN RAPP ILLUSTRATION: KHUAN + KTRON

nnnIn Saint-Paul-lez-Durance, northeast of Marseille in southernFrance, construction is under way for the worlds biggest researchreactor designed for fusion energy, ITER. Researchers say it may hold

the key to solving humanitys energy problems for future generations.The goal of fusion is to make the energy of the stars available on

earth, says Francesco Romanelli, head of the European FusionDevelopment Agreement (EFDA).

Fission energy currently used in commercial nuclear reactors is basedon energy that is released as atoms are split. Fusion energy gives offenergy as atoms fuse together.

It is virtually unlimited because it draws on abundant raw materials(deuterium, from water, and lithium, from the earth). Fusion does not

produce greenhouse gases or radioactive waste and is considered muchsafer than ssion since it cannot trigger chain reactions. An accident

would have very limited, local consequences, according to ITER ofcials.

THE ENORMOUS AMOUNTS of energy needed to run the fusion processpresent a huge challenge. Matter is turned into plasma at extremetemperatures.

In 1991, for the rst time, a European test facility (JET) produced a

signicant amount of power (1.7 megawatts) from controlled nuclear

fusion. Subsequent tests provided more power, but so far much moreenergy is put in than is produced. ITER is expected to change this. It

will be built to reach temperatures up to 150 million degrees Celsiusunder high pressure and have the capacity to produce 500 megawattsof output power from 50 megawatts of input power.

Construction of ITER began in 2007. A hundred bulldozers spent

more than a year attening the platform on which the technical

buildings will be constructed. Earlier this year, ITERs futuristic ofc

building was inaugurated.ITER is not ready yet. It is being built step by step. Researchers ha

to solve major problems along the way. One issue is heat exhaust. Th

plasma will be held by magnetism in a huge doughnut structure know

as a tokamak. A diverter made of stainless steel and tungsten at thebottom will come in contact with exhaust at very high temperatures.This works in a research environment where a reactor is operated for

only a few minutes, but not in a facility that continuously generatesgigawatts of power.

Another unknown is which material to use inside the tokamak andother plasma-facing components. Fusion produces high-energyneutrons that bombard and weaken solid materials. Research needs tond materials that can withstand this process.


29/40

Some 80,000kilometres ofniobium-tinsuperconductinstrands will benecessary forITER's toroidalfield magnets.

ITER is fundedand run by theEuropean UnionIndia, Japan, ChRussia, South

Korea and theUnited States.

The tokamakbuilding will rise60 metres abovground and exte13 metres below

The ITERtokamak will

weigh 23,000tonnes three

times as heavyas the EiffelTower.

Temperatures inthe ITER tokamawill reach 150million degreesCelsius 10 timehotter than thecore of the sun.

ITER TOKAMAK


30/40


There are many more questions to answer. Some critics say commercial

use of fusion energy is an unattainable dream.Challenges abound, but the potential benets are too great to go

unexplored, says Michel Claessens, ITERs head of communication.

We are working hard to prove the critics wrong.The year 2020 is the target for the rst plasma tests. Fusion experiments

aimed at the tenfold amplication of the power injected will begin seven

years later, according to the ITER timeline.

Plans are for ITER to be succeeded by a prototype commercial reactor,

DEMO, in the 2030s. It would be the rst to deliver fusion electricity to

the grid. According to the EFDA roadmap, the hope is that fusion willbe a viable commercial energy source by 2050.

This is almost 150 years after Albert Einstein provided the rst clueson how stars get their energy with his famousE=mcequation, which

predicts that a small amount of mass (m)can yield a very large amountof energy (E). After that, researchers began unlocking the secrets offusion.

If you are curious about how a fusion reactor works, check out thethe sun. It generates energy by nuclear fusion of hydrogen nuclei intohelium. At its core, the sun fuses 620 million tonnes of hydrogen each

second.n

Sandvik Coromant invests heavilyin R&D to help power generationcompanies with new solutions.We asked Per Forssell, businesssegment manager, energy, aboutcurrent and future needs.

Q: The construction of ITER placehigh demands on materials andtechnology. How does SandvikCoromant participate?

We are on the edge of advancedmetalcutting technology in the powegeneration industry. We offer solutioand applications to customers thatprovide components to ITER.

Q: What characterizes yourcurrent work with power generatcustomers?

We are a prominent player in this secand work with the metalcutting ofcomponents used in coal, gas, watewind and nuclear power. The needsvary, depending on the power genertion system. When the systems arecomplex and shutdowns are costly,high-end components are essential order to avoid problems. We canprovide them.

Q: What is your view on thefuture of power generation?

The climate issue is crucial. It will tatime before we can rely on solutions

such as ITER. At least for the next 20years, we will depend on coal powergeneration. Because coal pollutes, tfocus is on reducing emissions andimproving efficiency in modern systeThis involves new material in turbinethat can handle higher pressures anhigher temperatures a developmenthat places high demands on metal-cutting technologies. Thanks to ourfocus on R&D we are able to meetdifferent needs.

PER FORSSELLbusiness segmentmanager, energy,Sandvik Coromant

INNOVATION

IS THE ANSWER

Fusion of deuteriumwith tritium,creating helium-4,freeing a neutronand releasing 17.59MeV of energy.

Deuterium

Tritium

Helium

Neutron


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METALWORKING WORLD

Ptres, France.Manoir Industries manufactures huge-scale

components such as elbows and pipes for the nuclear power

industry. Thanks to a partnership with Sandvik Coromant, the

company can now supply finished solutions rather than just

rough parts.

More power

to your elbow

TEXT: ANNA MCQUEEN PHOTO: AUDREY BARDOU


32/40


nnnThe image of Normandy as a place of

rolling hills, apple orchards and cows grazingon lush green grass to produce creamy Cam-embert cheese is swiftly forgotten when youenter the Manoir Industries plant in Ptres,near Rouen in northern France. Flames, melt-ing steel, heavy industry and the high-techmachining of critical components for the

nuclear industry bring you crashing back to adifferent kind of reality.

Manoir Industries is the world leader inmoulded primary loops for nuclear powerstations and a specialist in intricate parts madefrom complex metals that require specialqualities to t their applications in the petro-chemical and nuclear industries. With thesecomponents, there is no room for error.

In 2011, the company decided to invest in anew horizontal machining centre, equippingitself with a TOS Varnsdorf WRD130 machine

at a value of 2.3 million euros, to machinevalve bodies and pump components of up to16 tonnes in weight. The investment illustrates

Manoir Industries determination to become akey partner in worldwide power plant con-

struction, and to full its partnership withFrench energy conglomerate Areva, signed in2012, to replace the primary circuits of thecountrys rst-generation nuclear power

plants.Now we can machine the

interiors of primary loops fornuclear applications, saysGilles Beaujour, industrial

methods manager for Manoir Industries.These large elbows and tubes are already

manufactured by us at the foundry in Ptresbut until now we have only been able to supour customers with rough parts. Now we ca

provide an end-to-end solution for existingcustomers and can open the door to new oneseeking a nal machining solution for their

parts. These could include customers in thepiping, energy, valve and pump, and defencindustries.

The machine was ordered in October 201

via French distributer REPMO from Czechmanufacturer TOS Varnsdorf a

delivered in May 2012. Installthe machine was a complextechnical challenge requiring

lbows like this one mayweigh eight tonnes or more

nd are critical componentsor the nuclear industry.

Rough finishing ofsmall componentsin progress. Withthe new machine,Manoir Industriescan now finishcomponents up to

16 tonnes in weight.


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METALWORKING WORLD

34 trucks of concrete, 1,400 cinder blocks,11 tonnes of steel reinforcements and 900tonnes of hardcore material just to make the

base for the site.Once the machine was ordered, Manoir

Industries needed to establish what toolingequipment it was going to use and, moreimportantly, who was going to supply it.

BEAUJOURS FIRST MOVE was to call three ofManoir Industries regular suppliers for theirinput and at the same time launch a study with theR&D centre of the cole Nationale SuprieuredArts et Mtiers (ENSAM) in Cluny. Icommissioned a project to establish the bestcut and cutting material, says Beaujour,himself an alumnus of ENSAM. We had to

optimize this new means of production andvalidate the cutting tools and positions neededto establish the best compromise betweenspeed, chips and wear.

With the Sandvik Coromant Capto system asthe favourite, Beaujour began working withDamien Benoist, a tooling system specialist atSandvik Coromant, based in Orlans, to rene

the details. A primary circuit 90-degree elbowpart has a diameter of 787.4 millimetres and aweight of eight tonnes, says Benoist. Machiningthese parts involves the removal of some 2.5tonnes of metal chips, but the biggest technicalchallenge was designing a system that wouldhave the necessary manoeuvrability inside thesehuge parts to remove between four and 20millimetres all over for the nished piece.

The WRD130 machuses Coromant Capto clam

units, sizes C10, C8 andIt offers a quick-cha

solution that is sreliable and easy to

Tool holders include sevtailor-made Corom

Capto C10 cutting uboth long and short, wright-hand, left-hand

neutral combinati

The machine also uindexable carbide inse

which are recycledManoir Industrie

Sandvik Corom


34/40


35/40

METALWORKING WORLD

No room for error. GilBeaujour and his colleat Manoir Industries aworld leaders in moulprimary loops for nucpower stations.


36/40

36 METALWORKING WORLD36 METALWORKING WORLD

he TOS machine inction. The first elbowo be machined waselivered in October012.


37/40

METALWORKING WORLD

The solution uses the C10-size Coromant

Capto clamping and cutting unit, designedespecially for this application. Damien wasable to take my specications and transform

them into an industrial projection, Beaujourcontinues. Sandvik Coromant wasnt just

there to sell me a product, but also to help medevelop the most efcient process.Benoist came up with the idea to use double-

headed tools to reduce tool-changing times.Double-headed or turbo tools are mainly usedin automotive applications, but this seemedlike an ideal situation for that technology, hesays. At ACES (Advanced Center for Engi-neered Solutions), our task is to respond to thetechnical challenges of a project where standardsolutions are not enough, and to come up withoptimized processes that are both at the cuttingedge of technology and economically viable.

MANOIR INDUSTRIES WAS also very keen thatthe clamping and cutting solution should be asstandard as possible. Quick changes, modu-larity and cross-compatibility are very importantto our long-term money-saving strategy, and weneed to be able to add a range of standardizedtools to the system when our machining businessexpands into other parts, says Beaujour.

The newly installed machine was red up

for the rst time in September 2012.

However, Manoir Industries quickly real-ized it had failed to consider how the parts

being machined would vibrate. Beaujourrecalls: We just assumed that the weight

nine tonnes for an elbow would hold it rm,

but such is the stress of the cut that itbegan to vibrate with the force. Iimmediately launched a study withENSAM to develop a dedicatedmount to secure the parts, but we hadto shackle down the rst piece we

machined with lengths of heavy-dutychain.The team was also slightly appre-

hensive about how the two cutswould meet in the middle. Given thesize of the parts, they are cut fromone end before being rotated 180degrees and then cut from the other. In theend, we were pretty impressed when wediscovered that there was less than 0.1 milli-metre difference between the cuts, saysBeaujour.

The rst elbow to be machined was delivered

at the end of October. Each part requires around

250 hours of machining and uses about two kilo-grams of carbide inserts, which are collectedand recycled by Sandvik Coromant.

Those involved agree that one of the reasons

for the success of the partnership was a sharedpassion. We had a common aim, and weworked together to nd the optimal solution,

says Beaujour. I believe its when thingsreally click on a human level that partnershipstruly work.

THESE ARE exciting times for Manoir Industries.A new investor has come on board with a solidve-year plan to grow the business, and the

company is undertaking a new strategy toreplace and upgrade its equipment. The future

looks very promising, says Beaujour. Pro-ducing nished parts with high added value

on the TOS machine is another step towards

creating the industry of the future. nSophie Maire (left) and Damien Benoistiddle) from Sandvik Coromant, with

anoir Industries Thierry Grille (mid-right)d Gilles Beaujour (right). "We workedgether to find an optimal solution," saysaujour.

Founded in Normandy in 1917Manoir Industries nowhas a worldwide presence.

The group has three keymarkets: petrochemical andnuclear; energy and industryand rail and construction.It employs 1,600 people andhas annual sales of about220 million euros.

In 2013, Manoir Industrieswas acquired by the groupshistoric partner, Chinesemetalworking giant YantaiTaihai.

The company focuses onone-off pieces conceived anddesigned in partnership withclients, so quality andcustomer service are key.

Manoir Industries prides itseon expertise in raw materialsand works with clients startinat the earliest stage possiblein order to develop tailoredsolutions that lead to long-terpartnerships.

Manoir IndustriesGillesBeaujour sees a bright future

ahead for his company.


38/40


TECHNOLOGYTEXT: ELAINE MCCLARENCE ILLUSTRATION: KJELL THORSSON

Powerhouseof engineeringIN THE AEROSPACE industry, theengine section represents the

pinnacle of engineering in termsof complexity and manufactur-ing precision. The industry is

forecast to double its productionover the next 15 years, at thesame time increasing the use ofsophisticated high-strength and

-hardness materials. Machiningto the precise tolerances that arerequired puts additional pres-sures on an already extremelydemanding production environ-ment. Sandvik Coromant hasnew and proven solutions forholemaking in heat-resistantsuper alloys (HRSAs) that

support the uncompromisingrequirements of these keyoperations in aerospace as well asin industries such as oil and gas.

HRSAs are difcult to ma-chine because they generate highcutting forces during machining,leading to high pressure andheat, which in turn can result in

work hardening. In addition, due topoor thermal dissipation, drills arable to withstand high tempera-tures, which means that heat generated during the drilling procesis retained within the workpieceand theres a risk that the heat will

be transferred to the drill, causingpremature drill failure.n


39/40

METALWORKING WORLD

MAXIMUM PRECISIONCoroDrill 846Thin-walled componentsrequire precision-drilled holes.The updated CoroDrill 846offers a safe and secureprocess through controllededge wear with reduced axial

cutting forces.

DEDICATED GEOMETRIESCoroReamer 835Complex and sophisticatedcomponents under extreme stressplace high demands on hole quality.High-performance solid carbide

reamers from the CoroReamer familyare the solution, with dedicatedgeometries for various applicationsand materials.

SECURE THREADINGCoroTap SThe tapping of ISO-S andheat-resistant materials is ahighly abrasive operation threquires cutting forces to bekept to a minimum. CoroTaptools feature an enhancededge design and materialgrade to ensure reduced axiforces and torques.

SECURE TOOLING PERFORMANCECoroChuck 970 and 930These precision hydraulic chucks offersecure tooling performance in tapping and

drilling operations. They can be quicklytightened or released with a dedicatedtorque wrench, improving efficiency throughquick and easy set-ups and changes.

EXCELLENT SURFACE FINISHCoroBore 824XSDesigned for small diameter holes incasings and shafts where tight tolerancesand excellent surface finish are required,these tools have an adjustment scale,making it possible to adjust the diameterto micron tolerances.


40/40

Inveio

An innovation at the atomic level has changed the face

of metal cutting. The finely controlled structure of its

coating guarantees that GC4325 shows longer tool

life and more reliable wear in the widest range of steel

turning applications.

It redefines the performance possibilities of ISO P25

and is everything you ever needed in one single insert.

Redefining ISO P25Superior enduranceOutstanding predictability

Uni-directional crystal orientation

Performance beyondwhat the eye can see

New GC4325 for steel turning

The first insert grade featuring Inveio

metalworking world 3-2013

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