Sandvik-coromant Silent tools - application guide User Manual

APPLICATION GUIDEApplication guide – Silent ToolsSilent ToolsHead office: AB Sandvik Coromant SE-811 81 Sandviken, Swedenwww.sandvik.coromant.com E-m

8 mkfπ21=1. IntroductionIn summary:1. Reduce cutting forces by choosing the right cutting tool and insert2. Minimize deection by increasing the sta

APPLICATION GUIDEApplication guide – Silent ToolsSilent ToolsHead office: AB Sandvik Coromant SE-811 81 Sandviken, Swedenwww.sandvik.coromant.com E-m

91. IntroductionTypical componentsThere is a big potential for increased productivity using Silent Tools in all type of industrial segments. For compo

101. IntroductionOil & GasTypical components: Pump houses, threading components, body spools etc.AutomotiveTypical components: Cylinder blocks, st

111. IntroductionEconomics, ROI calculatorA Silent Tool investment almost always has a short pay-back time, thanks to increased productivity and less

122. Milling2. MillingMain considerationsWorking with rotating tools differ from turning, where you have a boring bar in a rigid tool post, but most o

132. MillingReduce vibrationWorkpiece set up and machine stability are two important things to consider carefully to minimize vibration.Workpiece – Af

143 × BD 4 × BD 5 × BD 6 × BD 7 × BD 8 × BD( )2. MillingAll Silent Tools dampened adaptors are designed for different over-hangs, and with differen

15CoroMill 390/ CoroMill 490CoroMill 345 CoroMill 210CoroMill 200/ CoroMill 3002. MillingFactors that inuence vibrationThere are four basic factors t

162. MillingCutter diameter relative to radial depth of cutA smaller tool diameter will reduce the power and torque require-ments as well as the deec

172. MillingCutter pitchWhen multiple inserts are in contact with the material, the risk of vibration increases. As long as you are working with cutti

More informationUseful information and application techniques can be found in our catalogues, handbooks, application guides and on the Sandvik Coroma

18Nya bilder från Borgs!2. MillingProgramming guidelinesA general rule for face milling is to keep the milling cutter constantly in cut, instead of r

192. MillingMilling directionDown-milling is the rst choice for most milling operations. In some cases, when the machine has insufcient power or the

202. MillingPosition and diameterIn general face milling, the cutter diameter should be 20-50% larger than the cutting width and the cutter should be

212. MillingProduct overviewThere is a wide range of Silent Tools milling adaptors available off the shelf, with HSK or modular Coromant Capto couplin

225 × BD 6 × BD 7 × BD 8 × BD3.000 802.500 632.000 501.500 40403225202. Milling• Dampened solutions from 20–40 mm (0.787-1.575 inc

232. MillingCoroMill® 390D – application areaCoroMill 390D is a real productivity booster for long and slender tools and works well in both vertical a

242. MillingThe program consists of Coromant Capto sizes C6, C5 and cylindrical shanks in diameter 20, 25, 32 and 40 mm (0.787, 0.984, 1.260 and 1.5

252. MillingShort and long basic holdersWith a combination of arbor mounting on the adaptors and basic holders with different lengths, solutions for m

263xBD 4xBD5xBD 6xBD 7xBD 8xBD9xBD3xBD 4xBD5xBD 6xBD 7xBD 8xBD9xBD2. MillingDampened adaptors for face mills and square shoulder face mills• Cx-391.05

272. MillingApplying Silent Tools to a shoulder milling operation in a valve housing resulted in increased metal removal and improved surface nish. E

Content1 Introduction 2Introduction, Silent tools, guide info 2Review of fundamentals 4 Working area specication 6Typical components/segment 9Economi

282. MillingOperation Circular interpolationWorkpiece material CMC 09.1Machine cost Euro 195Machined volume Q=182 cm3/min (11.11 inch3/min)ZEFF 6Assem

292. MillingThe valve housing has a total length of 850 mm (33.46 inch) and a production volume of 300 units per year. In January 2012 the valve housi

302. MillingThe pocket measures 457 x 457 x 406 mm (18 x 18 x 16 inch). The pocket has 25.4 mm (1.0 inch) radii in the corners, which required a 50 mm

312. MillingTips and hints, summaryInsert grades and geometriesChoose a small edge rounding (ER). Go from thick coating to a thin one. If necessary, u

322. MillingAchieve maximum QChoose ae between 60%–80% as a starting value if possible. Reduce the number of inserts to maximize Q. This is particular

333. Turning3. TurningMain considerationsClamping stability and correct centre height are two important factors in order to achieve the right dimensi

3410 xBD4xBDBD3. TurningBoring bars – general• Surface nish of ~1 µm is required to ensure sufcient clamping contact• Recommended clamping length is

353. TurningClamping of Silent Tools barsDue to the design of the turret in a CNC lathe or the exibility of a multi-task machine, the rigidity is usu

363. TurningFlat bed lathesCompared to turret lathes, a at-bed lathe with a tool post is often more rigid and stable and can hold larger and longer b

373. TurningFor best performance of the boring bar, the contact, design, and dimensional tolerance between tool and tool holder are important factors.

21. Introduction1. Introduction1. IntroductionSilent Tools has long been the trademark for tool holders, designed to minimize vibration with a dampeni

383. TurningCentre height setting toolFor all cylindrical CoroTurn SL bars, there is a quick and simple method to accurately ensure correct centre hei

393. TurningPressure and directionFor best tool life and process security, use coolant directed to the cutting zone. For tools equipped with SL quick

403. TurningAdvanced cooling technologyThe Sandvik Coromant advanced cooling technology is a unique concept that optimizes the use of coolant in all w

413. TurningFactors that inuence vibrationTo minimize vibration tendencies:• Use a large entering angle and positive rake angle• Use big nose radii a

423. TurningBe aware that re-directing forces can reduce deection:• Entering angle as close to 90° as possible (lead angle 0°) will maximize the port

433. TurningForce direction: mainly axial Force direction: both axial and radialFt = tangential forces and Fr = radial forcesNegative rake angle incre

443. TurningInsert point angleSelect an insert shape relative to the entering angle and accessibility requirements of the tool. One rule of thumb is

453. TurningPositive geometriesPositive geometries and positive rake angles generate less cutting forces and less deection of the tool. Therefore, ch

463. TurningEdge roundingA small edge rounding (ER) gives lower cutting forces in all directions. This means easier cutting action and less deection

473. TurningCutting dataExcessive insert wear, such as ank wear must be avoided, as it changes the clearance between the tool and the component wall,

483. TurningDepth of cut, AP, and feed, fnThe combination of AP and fn is important to achieve the best possible chip areas. Two rules of thumb:• Pro

493. TurningCase one: Turning mud screwsAn oil & gas company machining mud screws invited Sandvik Coromant to the workshop to test Silent Tools a

503. TurningApplication examplesCase two: Turning internal holeInternal turning is sensitive to vibration. Tool choice is restricted by the component’

513. TurningOperation General internal machining, light roughingComponent Process angeWorkpiece material CMC 01.1, P1.1.Z.AN, Low alloy steel Machine

523. TurningCase three: Bearing case, angedThe customer struggled with vibration and asked Sandvik Coromant for a productive solution. By implementin

533. TurningCase four: SpindleThe spindle production involves mainly internal processing and the existing process included two operations – turning fr

543. TurningProduct overviewSelection of boring bar has a big impact on production economy. The Sandvik Coromant tool program is comprehensive and cov

55%'%'%'%'%'%'%'%'%'%'%'%'%'%'

56CoroTurn® SL3. TurningA combination of cutting heads and Silent Tools dampened boring bars gives great exibility, with cutting heads for different

57CoroTurn® SL3. Turning

4Coromant Capto®ISO/CATBIG PLUS MAS BTHSK CAT-V3,532,521,510,50-0,5-1-1,5-20 0,02 0,04 0,06 0,08 0,1 0,12 0,14 0,16 0,18 0,2 0,22 0,24 0,261. Introduc

584 x BD 3 x BD 3 x BD6 x BD 5 x BD 5 x BD10 x BD 5 x BD* 5 x BD*14 x BD 7 x BD 7 x BD3. TurningBar typesInternal turning is very sensitive to vibrati

593. TurningSelect boring bar material to suit the appropriate length to diameter ratio. A carbide bar has a higher static stiffness than a steel bar,

603. TurningTips and hints, summaryReduce the risk of vibration by choosing the largest possible bar diameter with the smallest possible overhang. Use

613. TurningTwo lines on the bar indicate minimum and maximum overhang. Make sure that the overhang is within that range. Outside this range, there is

623. TurningChip evacuationFor best chip evacuation, use a tool holder with integrated coolant and an insert geometry that gives short and spiral form

63∆AP3-5º0,5 x ∆AP3. TurningInternal threadingTo reduce the risk of vibration, use the following tips:• Use modied ank feed• Infeed per pass should

643. TurningInternal grooving and prolingReduce the risk of vibration by applying the following tips:• Set-up should have the shortest possible overh

653. TurningTreatmentFor best performance, clean all parts and lubricate with oil at least once a year. Lubricant should also be applied to the screws

663. TurningSummary: How to avoid vibrationIncrease static stiffness• Check the clamping and set-up• Use Coromant Capto or split holder• Minimum tool

67BDVcLB/BD-PR-WMVcLB/BD4 5 64. Boring4. BoringMain considerationsThe Silent Tools boring tools reach a maximum of six times the bore diameter into yo

51. IntroductionThe dampening system consists of a heavy mass, supported on rubber spring elements. Rubber springsDampening system inside tool body•

684. BoringInsert shape and entering angle/lead angleUse entering angle 90° (0°) for roughing and 92°(-2°) for nishing. Less force in the radial dire

694. BoringForce direction mainly axial Force direction both axial and radialNose radius in relation to depth of cutThe radial forces that push the in

704. BoringRough boringChoose a roughing geometry unless a small depth of cut is needed. For smaller cutting depths, use a medium geometry. Recommende

714. BoringSingle-edge boringProductive boringStep boringProductive boringInvolves two cutting edges and is employed for roughing operations of holes,

724. BoringFinish boring The nish boring tools are single-edge tools with radial micrometer adjustment on the cutting unit head. Finishing is used wh

734. BoringVibration inuence factorsTo reduce vibrations, choose a light cutting insert with a positive cutting geometry and small nose radius. T-sty

746 × DC12.401 3155.906 1506.575 167.906 235.906 1501.000 254. BoringProduct overviewSandvik Coromant offers dampened boring tools for

754. BoringBoring range 25-150 mm (0.984–5.906 inch)Boring depth 6 x DC (23.6–27.6 inch)Hole tolerance IT9Cutting uid InternalInsert size/types:

764. BoringCoroBore® 825/826 – nish boring toolsDampened CoroBore 825 and CoroBore 826 are designed for nishing operations with excellent surface 

77 4. BoringHow to use CoroBore® 825Example of setting: In this example the blue line on the scale disc is a reference since it is aligned to a li

61. IntroductionChoose the right toolChoosing the correct tool is important to achieve best possible pro-ductivity and results. There is always an opt

784. BoringApplication examplesCase one: Lug holes, landing gearMachining of an aerospace part, with a length of 2.1 m (7 ft) and width of 0.91 m (3 f

794. BoringOperation FinishingWorkpiece material 300M, high alloy steelMachine cost EUR/hour € 75Dampened adaptors usage 6%Machined volume/pc cm3 (inc

804. BoringCase two: Boom bracketA customer producing boom brackets used a tailored boring bar with positive inserts for his application. He experienc

81VcLB/BD-PR-WMVcLB/BD4 5 6Fc [N]Fc [N]FpFpfnfn4. BoringTips and hints, summary• Choose the largest possible tool diameter with the shortest pos-sible

824. BoringTool assembly and maintenanceWhen using dampened tools in assemblies, care should be taken to hold the tool bodies correctly to make sure t

835. Engineered Solutions5. Engineered solutionsOfferThe standard off-the-shelf boring bar offer represents a good platform for optimized solutions an

845. Engineered SolutionsSilent Tools – engineered solutions Turning-, milling- and boring adapters can be engineered with most of the common back- an

855. Engineered SolutionsSpecial solutions for multi-task machine toolsAs multi-task machines are equipped with all the necessary tooling when perfor

865. Engineered SolutionsApplication exampleOperation Face millingComponent Upper body steering unitWorkpiece material CMC 09.1, K3.2.C.UT, Nodular ca

87vf = fz × n × ZEFFn = vc × 1000π × DCapfz = vfn × ZEFFMc = Pc × 30 × 103π × nPc = ae × AP × vf × kc60 × 106vc = π × DCap × n1000fn = vf n

7BDFLU1. IntroductionReduce the cutting forcesStart out by choosing the best available cutting solution. Then, choose the largest possible diameter an

886. Formulas and DenitionsaeAPDCapDmfzfnnvcvfZEFFhexhmkcPcMcQKAPRPSIRBDDCLUmmmmmmmmmmmm/rrpmm/minmm/minpcsmmmmN/mm2kWNmcm3/mindegreemmmmmmWorking en

89vc = π × Dm × n1000Tc = lmfn × nQ = vc × AP × fnn = vc × 1000π × Dmvc = π × Dm × n12Tc = lmfn × nQ = vc × AP × fn × 12n = vc × 12π × DmPc

906. Formulas and DenitionsDmfnAPvcnPcQhmhexTclmkcKAPRPSIRBDDCLUmmmm/rmmm/minrpmkWcm3/minmmmmminmmN/mm2degreemmmmmmMachined diameterFeed per revoluti

91Ft = kc 0,4 x0,4fn((0,29 x fn x AP0,4fn x sin KAPR((mc x fn x APFt = kc 0,4 x6. Formulas and DenitionsTurning – METRICTangential force

926. Formulas and Denitions3-pass methodMethod for achieving high accuracy in internal turning with slender boring bars where the deection of the ba

93vc = π × Dm × n1000Tc = lmfn × nQ = vc × AP × fnn = vc × 1000π × Dmvc = π × Dm × n12Tc = lmfn × nQ = vc × AP × fn × 12n = vc × 12π × DmVf

94Notes

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