PLASTIC FANTASTIC

2/11
a business and technology magazine from sandvik coromant

cArs:

usa:

lAnd of the giAnts nAzcA mystery

malaysia: uk:

virtually perfect

lift-off for Aero contrActor

business tAkes off

Dave Rolley, project engineer, Paul Fabrications.

editorial
KENNETH V SuNDH PRESIDENT SANDVIK COROMANT

Do like the Indians

The Nazca deserT of souTherN Peru hides one of the greatest mysteries of mankind. What look like narrow channels in the dry sand when youre on the ground turn out to be giant animal pictures when viewed from the air. No one knows how and why these lines were drawn, and little is known about the people who made them. Why would I spend an editorial in a company magazine musing on ancient mysteries? Well, as our new R&D manager, Ingrid Reineck, explains in the interview next to the Nazca Lines story on page 23, its all about thinking outside the existing framework.

Metalworking world is a business and technology magazine from AB Sandvik Coromant, 811 81 Sandviken, Sweden. Phone: +46 (26) 26 60 00. Metalworking World is published three times a year in American and British English, Czech, Chinese, Danish, Dutch, Finnish, French, German, Hungarian, Italian, Japanese, Korean, Polish, Portuguese, Russian, Spanish, Swedish and Thai. The magazine is free to customers of Sandvik Coromant worldwide. Published by Spoon Publishing in Stockholm, Sweden. ISSN 1652-5825. editor-in-chief and responsible under Swedish publishing law: Yvonne Strandberg. account executive: Christina Hoffmann. editorial manager: Johan Andersson. art director: Emily Ranneby. technical editor: Christer Richt. Sub editors: Valerie Mindel, Geoff Mortimore. Coordinator: Beate Tjernstrm. Language coordination: Sergio Tenconi. Layout, language editions: Eva Bengtson. Prepress: Markus Dahlstedt. Cover photo: Samir Soudah. Please note that unsolicited manuscripts are not accepted. Material in this publication may only be reproduced with permission. Requests for permission should be sent to the editorial manager, Metalworking World. Editorial material and opinions expressed in Metalworking World do not necessarily reflect the views of Sandvik Coromant or the publisher. Correspondence and enquiries regarding the magazine are welcome. Contact: Metalworking World, Spoon Publishing AB,Kungstensgatan 21B, 113 57 Stockholm, Sweden. Phone: +46 (8) 442 96 20. e-mail: mww@spoon.se. Distribution enquiries: Beate Tjernstrm, Sandvik Coromant. Phone: +46 (26) 26 67 35. e-mail: mww.coromant@sandvik.com Printed in Sweden at Sandvikens Tryckeri. Printed on MultiArt Matt 115 gram and MultiArt Gloss 200 gram from Papyrus AB, certified according to ISO 14001 and registered with EMAS. Coromant Capto, CoroMill, CoroCut, CoroPlex, CoroTurn, CoroThread, CoroDrill, CoroBore, CoroGrip, AutoTAS, GC and iLock are all registered trademarks of Sandvik Coromant.

Its all about thinking outside the existing framework.

There is probably an outside-the-box thought process behind the Nazca Lines, and it is this way of thinking that drives your company, ours and in fact the whole industry forward. Sandvik Coromant invests more than twice the industry average in research and development every year. This is something I am proud of, because I can see the results every day in the solutions we create in partnership with some of the best manufacturers there are within the worlds most demanding industries. Composites are just one example. Already used to a great extent within the aerospace and power generation industries, these lightweight materials are now entering the private car industry, which places even higher demands

on assembly-line efficiency. Read more on page 7. R&D is also at the heart of virtual machining, where now a great deal of the job can be done long before work begins on the factory floor. Sandvik Coromant is always interested in developing methods to improve efficiency and help protect our environment. Our feature on page 14 looks at how the UKs Paul Fabrications takes such issues on board. During the coming year, you will find many of our new innovations and solutions at trade shows around the world. As always, trade shows are a perfect way to meet and discuss challenges and what we can do together to improve the business. As an example, we are already planning for EMO Hannover, the worlds biggest trade show within the industry, which takes place in September. I hope to meet you there! In the meantime, I wish you pleasant reading!

Kenneth V SunDh PReSiDent SanDViK CoRomant

Get your free copy of metalworking World. email your address to mww.coromant@sandvik.com.
Metalworking World is issued for informational purposes. The information provided is of a general nature and should not be treated as advice or be relied upon for making decisions or for use in a specific matter. Any use of the information provided is at the users sole risk, and Sandvik Coromant shall not be liable for any direct, incidental, consequential or indirect damage arising out of the use of the information made available in Metalworking World.

metalworking world

content
METALwORKING wORLD #2 2011

Composites lighten the load for future cars.

30

Business is big for electric mining shovel maker Bucyrus

Coromill 170 puts precision in focus

metalworking news.... 4 csr in the market ........ 6 a light drive .................. 7 malaysia flies high .....24 virtual machining big is beautiful ...........30 in the real world ........ 14 outlook .......................36 Whats behind the nazca lines? .......20 total solution .............38
Technology
cvd coating wears it well
The demand for better performance and wear resistance has led to the development of high-quality CVD coatings.

20

What do the nazca Lines mean?

a steady hand
How new cutting tools will improve the precision and reliability of the hole-making process using portable machines.

tool library sets standard

A common model for describing cutting tool information will increase effectiveness and improve productivity.

the heat is on for ceramics

How ceramics are proving to be a popular and effective alternative to cemented carbides in HRSA machining.

12

19

28

35
metalworking world

news
WhaTs in iT for me? FIve queSTIoNS AbouT The New CuTTINg TooL STANDArD

What does the Iso13399 mean for a metalcutting company? It provides quick and secure access to cutting tool information directly from the tool supplier.

contribute to a better utilization of your manufacturing resources. So ultimately, the standard saves you time and provides an extra guarantee of quality. are there any aspects that will have a certain impact on the industry? Having the information in a neutral standardized format opens up new opportunities in the cooperation between the tool supplier and the manufacturer in the human-tohuman, human-to-machine and machineto-machine interaction. so what do I do now? we realize that our customers dont want to create this ISO13399 import interface themselves. Our approach is to integrate the Tool Library Services [TLS] [see page 28] with common platforms our customers are already using, such as CAM software. Thus you dont need to do anything right now. wait for TLS, and the tool data import function will come to you! n

do I have to change my way of working? Not really. The standard provides cutting tool information in a neutral format that is independent of any particular system or company nomenclature. Once you have an ISO13399 compliant system, you will no longer have to manually interpret data from paper catalogues and key it into your system. What are the general benefits? Increasingly, advanced functionality in modern manufacturing systems relies on access to relevant information about the manufacturing resources. with the standard, the data-gathering process will be more efficient and of better quality. That will

2 3

4 5

martin Brunnander is senior manager for technical marketing at Sandvik Coromant. Read more about the new iSo standard on page 28.

The art of machining

Modern methods on historic premises
Milling. under the banner Great art can be experienced in many ways and in many places Sandvik Coromant Denmark joined forces with the curators of DieselHouse, a museum in Copenhagen built around a giant HC rsted diesel engine. For 30 years, the engine was the largest of its kind in the world. The combined customer event and seminar proved to be very popular, with the engine providing a perfect backdrop. This was one of a series of events that Sandvik Coromant has presented around the world under the heading The Modern Art of Milling. The events have featured lectures on milling and machining as well as practical demonstrations of useful client solutions. n

green light for new event

Machining. Green Light Machining is another manufacturer-focused event aimed at improving machine utilization and efficiency. The first event will be held in Sandviken, Sweden, in mid-August. The concept will then be rolled out globally at selected machine tool partners premises. For more information, check out www.sandvik.coromant.com or contact your local Sandvik Coromant representative. n

the hC rsted diesel engine was the largest of its kind in the world for 30 years.

metalworking world

uK has wind in its sails

energy. The worlds largest offshore wind facility, Thanet wind farm, has been officially opened off the east coast of England. Swedish electricity supplier Vattenfall says the 100-turbine wind farm, situated some 12 kilometres off the coast of Kent, is expected to generate enough electricity to power 200,000 homes. The 115-metre-high turbines are spread over more than 35 square kilometres. The wind farm cost some 914 million euros and took two years to complete. There are more than 250 wind farms and nearly 3,000 turbines in the united Kingdom. Still, renewable sources of energy account for less than 3 percent of all electricity produced. Vattenfall also owns the 30-turbine Kentish Flats wind farm, off Herne Bay, opened five years ago, one of the first such projects in the uK. n

mel stoUtsenBerger

a major breakthrough for solar power in the California desert.

green light for solar plant

solar power. Plans for the worlds largest solar power plant, the Blythe Solar Power Project, have been given the go-ahead by the California Energy Commission. Once in operation, the project, situated in the Mojave desert, will have a 1,000 megawatt capacity, which is equal to the turbine output of a nuclear power plant or a big modern coal-fired plant. Final approvals came in December, and initial work on the project has begun. The site is being developed by Solar Millennium LLC, and the first two plants are slated to be connected to the grid in 2013 and 2014. Former California governor Arnold Schwarzenegger applauded the commissions decision to approve the construction of the Blythe project, saying, Projects like this are the future of the California economy. n

new wind farm will boost uK capacity

tore Johannesen

new cutter for gear milling

cutting. Sandvik Coromant has introduced a new CoroMill 170 precision cutter. In combination with insert grades GC1030 and GC4240, the CoroMill 170 can minimize gear machining times and the need for subsequent operations. Designed for one of the toughest existing metalcutting applications, the CoroMill 170 is most effective on applications demanding precision and reliability in roughing operations, such as slewing rings for windmills, cranes and other heavy equipment, as well as external and internal gears. Two insert geometries are offered for medium and heavy machining. The programme is an ideal solution for windmill gear production, including internal and external gears. n

your tube
You can learn about everything from windmills to careers on the Sandvik Coromant Youtube channel. Go to www.youtube.com/sandvikcoromant.

You must have the ability to create a network extending into the markets as well as into the production organization.
INgrId reINeck, research aNd develoPmeNT maNager aT saNdvIk coromaNT. >>> read more oN Page 23.

royal seal of approval

Chris JaCkson

visit. In England, Her Majesty the Queen and her husband the Duke of Edinburgh paid a visit to Sheffield late last year to launch building work on a new nuclear research facility.

As sponsors of the Nuclear Advanced Manufacturing Research Centre, representatives from Sandvik Coromant were invited to the ceremony on 18 November. n
metalworking world

quick time
TExT: GEOFF MORTIMORE PHOTO: JuSTIN GuARIGLIA

new thinker. Chen Shu-chu energetically pursues her own corporate social responsibility by donating huge sums from her vegetable stall in the taitung Central market in taiwan to charity.

Corporate Social responsibility in the marketplace

if you are looking for the worlds most generous givers, taitung County in taiwan might not be the place you would start. But then Chen Shu-chu, 60, is no ordinary woman. as a child, she dropped out of school to help feed her sevenmember family after her mother died, working in a vegetable stall at the taitung Central market. She continues selling vegetables at the market to this day. Corporate social responsibility is playing an increasing role in many large organizations, but Shu-chu proves that the size of your business is not the issue. Despite her modest means and income, she has managed to donate nearly 10 million taiwan dollars (uSD 320,000) to various causes, including tWD 32,000 for a childrens fund, tWD 144,000 to help build a library at a school she attended and another tWD 32,000 to the local orphanage, where she also financially supports three children. Consequently, she earned a place in the heroes category of Times 100 for 2010 and also one of Forbes Asias 48 heroes of Philanthropy. She now plans to establish a fund to help the poor with education, food and health care. n

full of beans

metalworking world

TExT: TOMAS LuNDIN

CARS ON THE SCALES

carbon fibre-based composite materials are expected to play a key role in the search for lighter cars, despite huge challenges in production line manufacturing.

iChiro, lisegagne

metalworking world

Tighter environmental demands and nnn the ever-growing car use in developing cities have forced the automobile industry to think in new ways. In focus are lightweight new body shapes and battery lifetimes, in the form of either hybrid or purely electric cars. By 2014 at the latest, almost all car manufacturers will offer hybrid cars, and that is just the beginning. Ferdinand Dudenhffer, professor and head of the Center for Automotive Research at Duisburg-Essen University in Germany, talks of a change in technology. By 2025 the share of new cars running on fuel alone will have dropped to 35 percent globally, he says. Another forecast states that within 10 years, some 24 million hybrid or electric cars will be sold annually. This figure, says Dudenhffer, is conservative. All automakers will be wrestling with the same problem, though weight. When a battery is installed, the weight of a purely electric car increases by some 250 kilograms, while for a plug-in hybrid its around 200 kilograms. Volvo Cars is working on a possible solution. Together with researchers at Imperial College Londons Department of Aeronautics, engineers in Gothenburg, Sweden, have come up with a composite material made from a mixture of carbon fibre and polymer that is capable of charging and storing energy. The idea is that Volvo cars of the future will have a body that, in effect, acts as an electrochemical battery. But how far away is such a solution?

Ferdinand Dudenhffer, professor, university Duisburg-essen

Per-ivar Sellergren, development engineer, Volvo Cars

Per-Ivar Sellergren, development engineer at the Volvo Cars Materials Center, is optimistic. If everything goes according to plan, we will have a prototype in the form of a car boot by the end of 2012, he says. Cost is an issue, but Sellergren says that even though it is still considerably more expensive than steel and aluminium, the future still lies in composites for electric and hybrid cars. According to Volvos calculations, the cost of a bonnet made of the new battery material could be equal to that of an original bonnet plus a lithium-ion battery. As manufacturers, we could add on an extra amount for the carbon fibre bonnet, because we are, in effect, getting a battery for nothing, he says. According to Ulf Carlund, Volvo Cars composite expert, until now production methods have been too slow, and earlier investments in traditional auto plants have needed to be ex-

ploited. Partly, it is also due to the fact that traditional steel automakers have found it difficult to think and work with composites. However, there is a strong will to change, and the public will see more and more polymer materials on the inside and outside of new cars, according to Volvo experts. Audi, by virtue of the aluminium car A2, is a forerunner in lightweight car manufacturing. In the companys lightweight centre in Neckarsulm, in southern Germany, Audi engineers build on the carbon fibre techniques already used by subsidiary Lamborghini as well as on composite technology/expertise developed by parent company Volkswagens luxury Bugatti model. In the Audi R8 Spyder sports car, which costs more than 120,000 euros and is only made at a rate of about 1520 per day, Audi uses carbon fibre-strengthened polymer in both the sides and the top of the roof box. One prerequisite that would make it more cost-effective in cheaper mass-produced cars is that a number of aluminium components
Bill PUgliano

24

UlriCh Zillmann

million hybrid or electric cars will be sold annually by 2025.

assembly line production poses a major challenge for future cars.

35 %

of new cars will run on fuel only by the year 2025, according to estimates.

iChiro

could be replaced by a single carbon fibre component. Instead of five or six different tools, maybe you would only need a single tool, says Karl Durst, a development engineer at Audis Leichtbauzentrum. Here, among other projects, fibres are packed into a composite material to increase the weight advantage in comparison with aluminium, from around 1718 percent to about 25 percent. The project hinges on a material that has the same drag and press weight burden capability as aluminium. Despite this, there are still several major and minor problems to solve, says Durst, not least the corrosion in the joints between composites and other materials. There is also a noise factor. For every kilogram that the car becomes lighter, the noise level increases,

metalworking world

aUdi mediaserviCes

carbon fibre
Composites that are used in the aerospace and car industries are mostly made of epoxy or vinylester that are reinforced with carbon fibre. the advantages of these composites are their low weight and mechanical properties such as high tautness. Carbon fibres split easily, but they can also be formed to absorb high amounts of energy. this is necessary in racing cars, which are in danger of head-on collisions at high speeds. Less-advanced fibre-reinforced plastics have long been used in the car industry. in the former east Germany, more than 3 million trabants were made from duroplastic, consisting of Soviet union cotton and phenolic resin from chemical factories. n

the audi R8 Spyder sports car uses carbon fibre-strengthened polymer in both the sides and the top of the roof box.

requiring insulation, which in turn adds more weight. Another challenge will be the materials familiarity among car mechanics handling it. It should be possible to fix the car and replace composite car parts in even the smallest Audi workshop anywhere in the world, says Durst.
The maNufacTurINg Process

needs to be improved. Lars Herbeck, who is manager of German machine manufacturer Voiths subsidiary Voith Composites, foresees a large need in several areas. One is with the optimized flow processes for materials, and another is a paced production of more than 100,000 components a year, as well as a much faster pace in the cycle. Compared with aluminium components, which can be made

every second, it can take from 20 minutes to an hour for larger composite parts. This works in the aerospace industry but not in the auto industrys large-scale assembly line production, which turns out more than 55 million cars a year globally. Oliver Geiger, who is a researcher in the composite materials department at research institute Fraunhofer-Institut fr Chemische Technologie in Pfinztal, Germany, is looking at ways to get large companies to work together in various sectors. Audis Durst talks of the need for a leap forward in the technology, rather than relying on a slower evolutionary development. Daimler too, which has used carbon fibre in its racing car, the SLR McLaren, since 2004, is also concentrating heavily on developing

the technology. In April 2010, it started a cooperation with Japanese chemicals company Toray, the worlds leading manufacturer of carbon fibre. The aim is that within three years the company will be developing components made of carbon fibre for models with an average manufacturing volume of 20,000 to 40,000 cars a year. Meanwhile archrival BMW is being considerably braver. Together with German partner SGL Carbon, BMW is investing 100 million US dollars in a composite factory in Moses Lake, Washington, in the United States. According to BMW Head of Finance Friedrich Eichiner, the factory will make large volumes at competitive prices for the first time. The aim is to reduce the price of materials to less than half of the current price of carbon fibre,
metalworking world

randy Faris

technicAl insight

Plenty of uncertainty
Composites in the aerospace industry are already a growth market. Sandvik Coromant has many tool solutions on offer in this area, including PCD (polycrystalline diamond) and carbide drills. In the auto industry, however, there is still plenty of uncertainty over what kind of need there will actually be for composites. Carbon fibre technology is certainly already established in Formula One racing cars and expensive luxury and sports cars. But these are cars that are made more or less manually in very small numbers. when it comes to mass production we are still at the research and development stage, says Francis Richt, who works with composite development at Sandvik Coromant. But we are counting on this new material soon being used to reduce the weight of electric and hybrid cars. Richt adds that the appliances in the aerospace industry are more complex than in vehicles, with a greater necessity for quality and with simultaneous processing of composites and other materials such as titanium. we know that cars have a more homogenous structure than planes, which, for example, reduces the need to drill thousands of holes and Francis Richt, mill large areas, says Richt. On the other hand, Sandvik Coromant there is a need to be prepared to open up other holes and cavities. Nevertheless, we see other demands in automotive compared to the very advanced aerospace industry. There are tools existing today that can be used in the car industry. For example some Sandvik Coromant CoroDrill drillshave a diamond surface, which improves the hole quality and performance of the users machines. n

10

Composites are already being used in Formula one racing cars. the challenge is to bring the technique into the mass production of private cars.

metalworking world

soUrCe: volvo Cars

how to turn a car body into a battery

Volvo Cars solution for lighter electric cars is simple: Instead of installing heavy batteries, the company hopes to be able to turn the whole car body into a battery. That can save up to 250 kilograms of weight, and every kilogram is crucial when it comes to making electric cars work for real. In the centre of this new technique is the use of new composite materials. This is how the solution works:

the latest nanomaterials made of extremely thin and strong carbon fibre replace the cars steel body panels and can be used in the cars roof, doors, bonnet and floor. these panels also double up as the cars battery.

expected range is 130 kilometres when the doors, roof and bonnet are replaced.

15 %
the cars weight can be reduced by 15 percent. there is potential for cutting weight still further.

Plenty of uncertainty130 km
electrons (-) Carbon fibre ions (+) Fibreglass Carbon fibre
the body panels are discharged as the cars electric motor is used.

the material can be recharged by: 1) harnessing the energy generated when the car brakes 2) Plugging into the mains electricity grid.

which is used today in racing cars at a cost of USD 22 to 55 a kilogram.

The carboN fIbre

will be made on two lines, with an annual capacity of some 1,500 tonnes, and will be used to make the new BMW electric car, the Megacity Vehicle, a four-seat hatchback with a 35 kWh lithium battery, capable of travelling more than 100 kilometres on a charge. A sports car variation, with a small additional diesel engine and two electric engines should be capable of reaching a top speed of more than 200 kilometres an hour. Megacity is expected to roll off the production line in 20132014 in Leipzig, where BMW has invested more than EUR 400

million. According to BMW, it will be the worlds first production-line car with an entire passenger cell made of light carbon-fibre composite on an aluminium chassis. The first sketches that BMW has released reveal a car that looks straight out of a science fiction movie, with a battery like a flat mattress under the whole coupe, over-dimensioned wheels and a dynamic, almost aggressive image. It remains to be seen what the effect will be on the factory floor of an industry already under pressure. Its a gamble, says a lightweight specialist at one of BMWs competitors. Manager Norbert Reithofer is also fully aware of the risks. At a auto conference in Nuremberg in October 2010 he said:

Its possible we wont make any money during the first production cycle with this technology, but then it will be subsidized by traditional techniques. n

ttle John ra

metalworking world

11

technology
TExT: ELAINE MCCLARENCE

challenge: To improve cutting tool performance by developing better wearresistant coatings.

soluTion: New, high-quality coatings that result in much less wear.

CvD lays down the gauntlet

is the key technology for creating high-quality coatings that enhance cutting tool performance. The evolution of tool coatings and processes has dramatically increased tool productivity, and CVD has been one of the major contributors to its growth. The Sandvik Coromant history in CVD goes back to 1969, when its first coated insert grade was introduced. GC125 had a single titanium carbide coating a few microns thick and resulted in increased cutting speeds and tool life. CVD is an extremely versatile technology that is used to create thin or thick coatings of everything from hard wear-resistant coatings such as titanium carbonitride, aluminium oxide and diamond to semiconductor products. It is a complementary technique to another widely used tool coating technology physical vapour deposition (PVD). For tool inserts, CVD enables thick coatings (525 m) of aluminium oxide (Al2O3), titanium carbide (TiC), titanium carbonitride (TiCN) and titanium nitride (TiN) that offer extremely high wear resistance and make it suitable for conditions where abrasive wear is substantial. By contrast, the thinner coatings produced by PVD processes
chemIcal vaPour dePosITIoN (cvd)

possess high compressive stresses and are therefore much more suitable for cutting applications where toughness requirements are important. CVD technology is constantly evolving and growing in sophistication. One of the reasons for the growth of CVD is that it allows engineers to optimize each coating layer, and it still remains the only coating process capable of depositing high-quality crystalline -Al2O3 layers. The most recent coated cemented carbide inserts have coatings with up to 10 individual layers, each having its own function. In multilayered coated grades a thin TiN outer layer is used for wear detection; below this is often an Al2O3 layer to provide chemical and wear resistance. This layer is formed on top of a stack of tough carbonitride and nitride layers that give high flank wear resistance. The insert substrate comprises a base of hard carbides and a cobalt binder phase, and in a zone near the coating the substrate has been depleted on some hard carbide substituents in order to offer improved edge fracture resistance.

inserts can have a number of different CVD coatings, each having its own function.

12

metalworking world

cVd grAdes AVAilAble

s05f CVD coated carbide for high-speed finishing in HRSA or long cuts at lower speeds. gc3215 CVD coated carbide for demanding

interrupted cutting conditions. Suitable for all cast irons.

gc3210 Thick-coating CVD coated carbide for nodular cast iron high-speed turning applications. gc4235 with a low-stress MTCVD TiCN coating for steel turning and stainless steel applications. gc4215 MTCVD TiCN coated grade with

dressed for success

Resultant wear in a cutting test in ball bearing steel. A standard coating is compared with a recently improved coating. The much-thinner white area on the cutting insert to the right indicates less wear.
Crater wear

a thicker low-stress aluminium layer for maximum protection.

gc2025 CVD coated carbide for semi-finishing to roughing. gc3205 Thick-coating CVD coated carbide for grey cast iron high-speed turning applications.

StanDaRD CoatinG Crater wear of a standard tiCn/ai2o3-coating.

imPRoVeD CoatinG Crater wear of a recently improved tiCn/ai2o3-coating.

gc4225 CVD coated carbide with a broad application area.

One of the first grades from Sandvik Coromant that used sophisticated CVD technology was the grade GC3020 aimed for cast iron milling. It was introduced in 1994 and incorporated a moderate temperature CVD (MTCVD) titanium carbonitride (TiCN) inner layer with a unique, patented aluminium oxide (Al2O3) on top, which resulted in excellent wear resistance and coating adhesion. Todays state-of-the-art technology is as an example represented by the GC2025 grade, which is used for stainless steel cutting.
IN realITy, CVD relates to a range of processes that involve depositing a solid material from a gaseous phase. The essence of a CVD system, in its simplest form, consists of a heated reactor chamber (where

the inserts to be coated are placed on trays), a gas delivery system and a vacuum pump system. The pump is used to allow low reactor pressure and for removal of excess and by-product gaseous species. Precursor gases, such as aluminium chloride, carbon monoxide, carbon dioxide, hydrogen, nitrogen and titanium tetrachloride, are introduced at preheated temperatures into the reaction chamber. As they pass over the heated surface of the inserts they react and form the solid coating. Process parameters such as gas flows, pressure and reactor temperature are critical. For deposition of Al2O3 temperatures of around 1 000 degrees C are used, while for TiCN the process works best at temperatures in the 800 to 950 degrees C range. A CVD process can take up to 24 hours. n

gc2015 CVD coated carbide for finishing and roughing of stainless steels and chemical protection.

summary
CVD is likely to remain important in the future. Such has been its impact on tooling performance that today more than 80 percent of insert grades employ coatings technology, and CVD is involved in almost 70 percent of the coated grades currently offered by Sandvik Coromant. n

metalworking world

13

TExT: GEOFF MORTIMORE PHOTO: SAMIR SOuDAH

virtual Machining takes off

Derbyshire, uk. handily located close to an airport in englands industrial and geographic heartland, a specialist component manufacturer is discovering that the skys the limit in the field of virtual machining.

14

metalworking world

With passenger numbers expected to boom, demand from the aerospace industry will continue to grow.

Components for the exhaust part of aeroplane engines are machined first in a virtual environment.

metalworking world

15

natalie Flemming

noise can be a major issue on the factory floor.

nnn While planes fly noisily overhead, on the factory floor at Paul Fabrications in Castle Donington, Derbyshire, in Englands eastern Midlands, work continues apace to keep up with growing demand from the aerospace sector. Having successfully weathered the worst of the recession, this high-tech precision manufacturer of bespoke components, complex fabrications and high-value assemblies was enjoying a fruitful year in 2010. However, one particular job forming and shaping a component in a Rolls-Royce aeroplane engine was proving to be problematic. With deliveries falling behind and problems on the factory floor, computer software brought the project back on track. Paul Fabrications was already using CAD/CAM technology, but as it struggled to find a solution for a job on a titanium engine access plate, project engineer Dave Rolley turned to Sandvik Coromant area sales engineer Paul OBrien for help. 16
metalworking world

Dave Rolley, project engineer, Paul Fabrications.

We asked Sandvik Coromant to come in and look at it with us, because it was a large volume job, says Rolley. We were falling behind with deliveries, and it was causing us environmental problems on the factory floor. We wanted to reduce time so we could get deliveries out to the customer, but it was also turning out to be a very noisy operation. There were several challenges, not least the extensive machining involved in cutting and maintaining the bottom of a pocket to within 0.1 millimetres of flatness (the thickness at the pocket base ends up 2mm thick, which is less than half the original material thickness, and covers 90% of the component area) as well as trying to reduce cycle time to free up capacity whilst improving tool life to provide a more cost-effective solution. Due to the concerns Paul Fabrications had over capacity on the machine, Sandvik Coromant could not carry out any trials onsite without further

as a result of the extended usage of virtual machining, the company saved considerable time and money.

Paul Fabrications manufactures high-value assemblies for the aerospace, nuclear and engineering industries.

Bespoke solutions can halve the number of tools required.

aT a glance
Formed more than 70 years ago, Paul Fabrications is a high-tech precision manufacturer of bespoke components, complex fabrications and high-value assemblies in the aerospace, nuclear and engineering industries. Based near the East Midlands airport, near Derby, in the uK, the company maintains business activities not only in the domestic market, but also across Europe, Asia and the united States.

affecting deliveries to the customer. To overcome this problem the drawings and data were taken to the Sandvik Coromant Aerospace Application Center to determine what improvements could be made. Using CG Techs Vericut simulation software to understand the current process, the problems with the machining strategy immediately became apparent. OBrien says, Using the experience and knowledge we have in machining strategies and programming methodologies, we were able to provide a bespoke solution using the MasterCam X4 Cam software. Also, by using our CoroMill 300 and CoroMill 490 concepts with PL geometry in grade GC1030, we were able to halve the number of tools required from four to two.
back aT Paul fabrIcaTIoNs, the results were immediate. The new plans showed we could reduce the previous cycle savings by a further

seven minutes, says Rolley. This may not sound like much, but with more than 2,500 components over a 12-month period, it soon mounts up. emPloyees: 109 The time savings, in conjuncTurNover: 12 million euros tion with a different type of facIlITIes: 5-axis milling machines, 4-axis milling tooling that reduced insert costs, machines, CNC lathes and 6-axis laser machines added up to a total savings of as well as a CAD/CAM system cusTomers: Rolls-Royce, FACC, Meggitt & Pattonair some 30,000 euros over the year. and more. Meanwhile, an additional seven weeks capacity was freed up, along with a reduction in the number of cutting tools and inserts required. A further benefit was also apparent on the workshop floor. Colin Last, the first engineer to work in the factory with the new tooling, says: Working on these components changed dramatically. One of the noisiest jobs in the factory turned into one of the quietest.

metalworking world

17

There are also quality and reliability benefits. When you come to actually machining the job, you are 99 percent sure that it is meeting the tolerances required, says Rolley. If you dont need to develop the job on the machine itself you dont waste valuable manufacturing time or components. It becomes expensive if you scrap components trying out different methods on machines, but with virtual machining you can change strategies, change the method and see the results instantly on the screen without any physical waste.

Flexibility is also a key factor in virtual machining, says OBrien. In the shorter term, he says, we can take a headache away from the customer. In the longer term, although we mainly use this process in aerospace, it can be applied to any sector automotive, nuclear, general engineering and even for designers. For Sandvik Coromant, the more that customers such as Paul Fabrications use this kind of technology, the more it underlines its commitment not only to R&D and new product introductions, but also to the aerospace industry. n

illUstrations: marCelo CCeres, Barney Boogles, danleaP

VirTual benefiTs
The Virtual Machine is purely a software solution that includes almost every function of a real machine, and complements it with additional components. By copying workplace characteristics, it allows the user (in this case Paul Fabrications) to try out complete programs and programming changes to maximize productivity, avoid potential problems during a machining cycle and ensure that machine hours are dedicated to production rather than running trial programs on real machines. It is possible to run the program on the machine or with a CAM system, but in both cases it simulates the exact machining.

non-VirTual meThoD
Machining in the more traditional way can take more time as several attempts are sometimes necessary for the desired result. It can also cause unnecessary waste. unnecessary waste is a problem

Raw material

Several attempts with traditional machining

Lots of expensive material wasted

It can be a time-consuming exercise

VirTual meThoD
time-saving method: five days to train an operator The virtual way can almost guarantee that the job is done correctly with a precise calculation of the time needed and the cost.

Raw material

The job specifications are laid out on a computer

Time, materials and cost are saved

maTerials
The materials have to be heat resistant, strong and light, so much of the work involves titanium, Nimonics, Inconel and other high-value heat-resistant alloys and difficult-to-machine materials. This makes machining them a very expensive process, so waste has to be minimal.

Check out the film clip at www.youtube.com/sandvikcoromant

18
metalworking world

technology
TExT: CHRISTER RICHT

challenge: To improve the hole-making process in composite materials in the aerospace industry using portable machines.

soluTion: New cutting tools that meet the variations and demands experienced in portable applications.

A steady hand for the aero future

tions with handheld tools leaves them prone to instability and even inconsistency. The performance of the equipment being used and the operators experience directly affect the quality of holes and productivity. If hole-making with handheld tools is hampered by grab effect from the drill, and a high thrust force is needed to For aerospace manufacturers working with composites, there penetrate the hole, then levels is plenty of room for improvement when drilling with handheld tools. of quality, efficiency and operator fatigue will be negatively affected. Operators have to applications and composite metal-stacked concentrate more on countering the effects applications that are performed with hand of the portable tool and are more likely to tools. On the composite drill, combinations make mistakes, with scrap as a result. such as the left-hand helix and right-hand Handheld tools are also greatly affected by drill point promote smooth cutting action how well the cutting tool functions. Cutting with minimized or no grab effect. Only a low action, size and direction of cutting forces, level of feed force is needed, and the drill possible cutting data and achievable tool life makes a smoother, non-destructive exit from are cutting tool factors that very much the material. determine the quality and economic outcome. For the metal-stacked version there is a Portable handheld drills need more choice between a drill with or without a pilot toughness, due to the inherent instability of incorporated in it, to reduce differences in the operation. For this reason, an uncoated thrust effect between the materials and to cemented carbide drill and reamer is the best provide high hole accuracy and finish. The solution, as the balance of toughness and hole-size difference between the materials is wear resistance has to be strength-oriented. then minimal, and exit burrs are eliminated. The non-piloted drill has a double margin edge for stability, which further improves The corodrIll 452 standard drill range has performance and results. n been designed to optimize composite
The very NaTure of opera-

A long, sharp cutting edge chamfer makes a clean cut of all fibres.

A unique split-point design gives very close hole roundness as well as minimizing thrust effect. uncoated cemented carbide drill for the best toughness and wear resistance.

More toughness due to the instability of the operations.

coroDrill 452

summary
The development of cutting-tool geometry plays a primary role in achieving the right quality level, tool performance and productivity. Cemented carbide drills and reamers with new, patented designs are the backbone of a new standard range of cutting tools for handheld tools in composite hole-making. n

metalworking world

19

inspiration beyond the metalcutting world

Some believe the giant spider figure is an anamorphic diagram of the constellation orion.

JaCoB halaska

istoCkPhoto.Com/PawelCeBo

Spider.

monkey.

TExT: STEFAN SJDIN, DAVID SHAMY

a plain mystery
Thousands of years ago the Nazca Desert in southern Peru was turned into a canvas for giant drawings. No one knows exactly how or why. Metalworking World investigates.
Nazca, in southern Peru, is one of the driest nnn places in the world. Here the sun shines relentlessly over sand dunes standing hundreds of metres high. Ancient remains of whales lie in the sand with spines 13 metres long. The whales remained under a thin layer of sand when the Pacific Ocean drained away. Our jeep has a built-in shower we use to find what little respite from the heat we can. Sometimes we climb out of the jeep and pick up the odd razor-sharp shark tooth. Sharks used to attack the whales around us; now only their decimetre-long teeth remain. Very little rain has fallen here over the past 10,000 years, but the moment we arrive the heavens open. The locals look anxiously toward the black clouds. On the one hand they welcome a bit of cool rain, but the El Nio phenomenon, which produces wet weather along the coast of Peru, could also trigger an economic catastrophe for the people of Nazca. Bad weather could wipe away the Nazca Lines ancient artefacts whose origin is one of the worlds great mysteries. The lines were created by removing reddish-brown pebbles on the surface to expose the lighter-coloured earth below, and scientists speculate that increased rainfall could wash the lines away. Scientists speculate that heavy rainfall could dump clay and sand over the lines while also increasing the chances of mudslides and flooding. 20
metalworking world

If the lines disappear, the locals principal source of income, tourism, will also disappear. We decide to get a look at the lines before they are gone for good. From a tiny plane flying a couple of hundred metres above the ground, the lines form pictures below us. Look at the kolibri [hummingbird], screams the pilot as he bows the plane down almost into a somersault. Over there you can see a lizard. We can also see a spider, a condor, a whale, a flower and a monkey. Some of the drawings are larger than two football pitches. The lizard, for example, is more than 180 metres long. But thats not all. In addition to three dozen animals and plants, more than 1,300 kilometres of straight lines and 300 geometric shapes stretch out across the landscape in what looks like chaos. The lines were drawn by Indians from the Nazca tribe between 500 BC and 500 AD, but no one knows exactly how or why. Nazca artists could have drawn straight lines with the help of sticks and string, but it is a mystery how they kept the lines so perfectly straight over such long distances without any overview. Or perhaps they didnt. Some theorists speculate that the Nazca people flew with the help of air balloons. Evidence of this can be found in the balloon-like drawings on local pottery and the large round burn marks ingrained on the nearby cliffs.

george steinmetZ

there are more than 300 geometric shapes and some 1,300 kilometres of straight lines.

metalworking world

21

inspiration beyond the metalcutting world

other ancient mysteries

the nazca Lines site is by no means the only hard-toexplain ancient site that has tourists and archeologists theorizing over its origins. From the uK to the South Pacific, here are a few examples:

JeFF overs

easTer IslaNd Located in the southeastern Pacific Ocean, Easter Island boasts more than 800 giant statues, called moai, which were carved between 500 and 700 years ago.

ggaNTIja Two ancient temples, each more than 5,500 years old, can be found on the Mediterranean island of Gozo. According to folklore, the temples were constructed by a giantess and used as a place of worship. Some scientists now believe the temples were used by a fertility cult at the time. Small, spherical stones discovered around the temples may have been used to transport the incredibly heavy stones for construction.
nUno silva

The goseck cIrcle The Goseck Circle in Germany, consisting of earth, gravel and wooden palisades, is regarded as one of the earliest examples of a solar observatory.

The carNac sToNes More than 3,000 prehistoric standing stones in Brittany.

mUseUms BlaUBeUren

yoNaguNI moNumeNT About five metres below the surface of the sea off the coast of Yonaguni in Japan lies a huge underwater rock formation of various platforms and walls. A diver discovered the area in 1987, and debate has raged since as to whether the formation is a man-made or natural phenomenon.

sToNeheNge Thousands of years old, Stonehenge is situated in the English county of wiltshire.

maria de la iglesia

ClaUdio ColomBo

IN facT, if one stands on the adjacent mountain during the summer solstice, it is clear that the mornings sunrays precisely follow one of the longest lines. At the winter solstice the same thing happens along another line. Many of the lines end in a thin triangle that points towards wall writings. Every line and triangle is believed to contain information leading to more information. In different ways, these triangles may have been used to work out the time of year when water enters the

maria Reiche

creaTiVe Thinking

Ingrid reineck, research and development manager at Sandvik Coromant, talks with Metalworking world about creative thinking and how ancient sites such as the Nazca Lines are evidence of the long history of outside-the-box thinking in human evolution.
1. are There sImIlarITIes IN The creaTIve aPProach of Those Who dreW The Nazca lINes aNd your research aNd develoPmeNT meThods? The Nazca Lines must have 2. WhaT qualITIes do you ThINk are The mosT ImPorTaNT IN WorkINg IN r&d?

been created by someone who thought beyond the existing cultural framework of the time. we need to do the same today within R&D. Thats how completely new things are invented. However, R&D today must build on facts and not only on free fantasy. You may not always be able to explain the facts in deep detail, but the fundamental, solid base must be there or else you will probably not be able to repeat your experiment, and definitely not bring the process into production, which is a must for industrial R&D. But you never know; maybe the Nazca culture knew something that we do not understand today.

Curiosity and the patience required to convert research findings to products. You also need team spirit to share your knowledge and experiences. This is valid not only within the R&D group. You must have the ability to create a network extending into the markets as well as into the production organization.
3. saNdvIk coromaNT INvesTs aT leasT TWIce as much IN research aNd develoPmeNT as The INdusTry average every year. Why? Investment in new technology has been

important for Sandvik since the days of Gran Fredrik Gransson in the 1860s. This is how the company not only survives long-term but also how it grows and prospers as one of the most successful companies within the engineering business area.

Bettmann/CorBis

But the Nazca mystery attracts all types of people from scientists to mystics and madmen many of whom are more than happy to share their opinions over a glass of beer in one of the local bars. Theories range from the otherworldly (UFO runways and hallucinogenic visions) to the practical (works of art and mathematical drawings). Even though scientists dont agree on the purpose of the lines, most agree that they are more than just pretty pictures. Maria Reiche, a mathematician who studied the lines for almost 60 years, believed the lines track the positions of the sun, moon, stars and planets. In her seminal book on the subject, Mystery on the Desert, shes clearly fascinated by the geometrical patterns. Looking down on plains, terraces and tablelands there appear in different places triangles, rectangles and trapezoids neatly outlined in a lighter colour on the brownish surface, she wrote.

2,000 60

the number of years some of the oldest lines are thought to have been in existence.

the number of years that mathematician maria Reiche studied the nazca Lines.

rivers, when to harvest and when to save resources. The chaos we saw from the window of the plane is an optical illusion. The Nazca Lines are apparently carefully arranged, flowing like rays of the sun into several centres. All the lines are located near water, and it seems logical that they provide a map to water (an important piece of information if one lives in the desert). It is also possible that the lines provide an astrological guide. At this point scientists still dont know. Anthony F Aveni, a professor of astronomy and anthropology, spent years studying the lines and believes they probably had multiple uses. We can no longer view the Nazca Lines as the product of a massive superhuman work effort undertaken as a single-minded grand project, he explains in an article in Archaeology magazine. Rather than finding a grand explanation, Aveni suggests that the lines should be used to understand the everyday lives of the people who constructed them. There is order a pattern and a system behind the geoglyphs [lines] and it tells us about the people who lived there, writes Aveni. On my way back I think about how the lines may disappear as El Nio gets closer. For 2,000 years the lines may have shown people the path to survival in one of the worlds driest places. If Nazca becomes a wetter place, perhaps the reason they were created will also disappear. n

TExT: JASON THOE

PHOTO: SASH ALExANDER

flying high in Malaysia

shah alam, malaysia. In 2009, uPeCA Aerotech was awarded a major contract for various aerospace components. To fulfil its commitments, the company needed a strategic partner.
.Co istoCkPhoto m/tang9024 6

Malaysia may not be traditionally associated with the aerospace industry. However, UPECA Aerotech Sdn Bhd (UAT), located in Shah Alam, about 25 kilometres west of Malaysias capital, Kuala Lumpur, has established itself as a key supplier to a number of major aerospace companies from around the world. The path taken to this point, however, contained many challenges and hurdles, all of which were very real to the operations director at UAT, Kavan Jeet Singh. Tasked with overseeing the complete operations at UAT since its inception, Kavan is particularly proud of how UAT has evolved to where it is today under his leadership. In 2009, UAT was awarded a significant 10-year contract for the manufacturing of wing and structural components by the European division of the worlds largest supplier of commercial aeroplane assemblies and components, Spirit Aerosystems, triggering expansion and the development of a vast range of special process capabilities. However, Kavan points out, the stakes are always high when undertaking new aerospace programmes. Youre only as good as your last failure, he says. Thats why detailed planning and risk mitigation are of vital importance. From the onset, Kavan explains, we realized that,

as an organization looking to gain credibility and traction within this industry, we had to move away from the tag of being just a low-cost manufacturer. We needed to build the organization on a foundation that values innovation. He says the excellent infrastructure the country provides is an ideal foundation to allow UAT to compete globally in the aerospace manufacturing industry. The cost of labour is still comparatively low and the skill level of the workforce is adequate, he says. However, we must recognize that we will not be able to leverage our lower labour costs to remain competitive for long. The industrialized nations have done phenomenal work in technological advances to counter their high labour costs, and we have to learn from that. The challenge for us is to find the optimum balance between investment in technology and utilization of labour.
hoWever, brINgINg improved outcomes wasnt just

istoCk

Photo

.Com/

raClr

about possessing excellent infrastructure. It was also about having the right people for the job. We have evolved UAT through having the right people with the right expertise in ensuring that we could deliver efficiently and effectively, Kavan says. Even after the millions we have invested in machinery, the employees are still our greatest asset. A key result of this shift in mindset was the establish-

24

metalworking world

kaVan JeeT singh

aGe: 35 FamiLY: wife, Manveet Kaur Bajaj, and two children: son Nikhil Singh Khash, 4, and daughter Natasha Kaur Khash, 1. LiVeS: In Bangsar, a suburb of Kuala Lumpur, about four kilometres southwest of the city centre. eDuCation: Honours degree in Aeronautical Engineering from Loughborough university in the uK. enjoYS: Intelligent movies, good humour, tasty food and cold beer.

metalworking world

upeca aeroTech
uPECA Aerotech Sdn Bhd, based in Selangor, Malaysia, is a key player in the Malaysian aerospace manufacturing industry. As one of only a few Malaysian companies approved and certified by Airbus for metal component manufacturing, uPECA Aerotech produces a range of aircraft components that include aerostructures, avionic components and aircraft engine casings. uAT currently employs more than 230 highly skilled employees and plans to grow to more than 300 employees within 2011. Achieving the AS/EN-9100 approval in 2007 for the Manufacturing of Precision Engineering & Aircraft Components, uAT manufactures components for significant clients, which include leading aircraft manufacturers Spirit, Honeywell, Goodrich and Meggitt, amongst others.

Raymond tan, productivity improvement engineer, Sandvik Coromant, with Ronnie Yong (left), Yew Seik Wai and manufacturing manager allan tan.

istoCkP hoto.C om/ra Clro

Ronnie Yong (left), Yew Seik Wai and Kavan jeet Singh.

Demanding aerospace components need the best tooling package.

ment of the Product Development Centre (PDC), led by its manager, Yew Seik Wai, with a team geared for intelligent engineering. Yew, in collaboration with Ronnie Yong, UATs supply chain manager, was responsible for the engineering development and delivery of the first articles. These functions were key to ensuring the development of the overall process for manufacturing readiness. In order to successfully execute the project, Yong explains, we were faced with a key challenge of identifying and acquiring the right cutting tools that were reliable and effective to enable the production of such a large number of unique parts. Yew and Yong spoke to various cutting tool suppliers. There were many cutting tool suppliers 26
metalworking world

keen to participate when news of the award of business spread within the industry, says Yew. After extensive review of the various proposals, we finally decided to award Sandvik Coromant the opportunity to jointly develop the engineering and act as our strategic partner in milling and turning operations. Within the working framework, Sandvik Coromant became an extension of UATs Product Development Centre, he says. Together, we worked towards producing the critical first articles as well as conceptualizing and designing the production process that would follow. We put a lot of faith in their ability to provide tooling solutions. This was important to allow the PDC to ultimately deliver the most efficient machining process to our production, headed by Allan Tan.

The success we have today is a result of a combined and focused effort, Yew emphasizes. The collaborative effort between the PDC, Supply Chain, Production and our partner Sandvik Coromant does not just stop after the development phase. Our partnership will continue into manufacturing readiness, continuous improvements and hopefully a lot more cost savings.
WITh saNdvIk coromaNT

on board, the first shipment of the parts was delivered according to specifications within the span of only nine months. There were many technical challenges faced along the way, due to the scale of the project and tight delivery deadlines, Yew says. Everyone contributed a tremendous effort to ultimately deliver a high-quality product with

ken Bro wn

one of uats cells for manufacturing aerospace components.

the most efficient manufacturing process. Kavan adds: In this day and age, a business must continue to evolve to stay relevant. We cannot just rely on internal capabilities. That is why we need strong, capable partners to help us continually improve and remain competitive. Established in 2005, UAT has a bright potential for growth. Currently serving clients that include leading aircraft component manufacturers Spirit, Honeywell, Goodrich and Meggitt, UAT is anticipating a growth of at least 30 percent year-on-year for the next five years. Moving forward, UAT is focused on developing its key customer base and building on its current work packages. In addition to conceptualizing and developing the production process alongside UAT,

custom-made tools, says Sandvik Coromant was chalPulkit Datta, aerospace lenged to create a cost-optimized manager for Sandvik tooling package to improve Coromant in Asia Pacific. UATs productivity. The tooling All that led to minimal package was required to cut bottlenecks during the first components in various materials articles as well as regular such as titanium, stainless steel production. and aluminium. The challenge Sandvik Coromant serviced was further compounded by the UAT through a team consisting need to rethink current solutions of a central technical staff on critical aerospace components. member, a machine investment The challenge was met specialist and a productivity throughout the process. Pulkit Datta, aerospace manager, improvement engineer. All the different features on Sandvik Coromant The success in the project the components were discussed can be attributed to the fact that we managed to in detail, and the most optimized machining understand UATs objectives and got involved techniques and programming methods right from the start, says Pulkit. n were agreed upon, incorporating even some
metalworking world

27

technology
TExT: TuRKKA KuLMALA

challenge: CAx and CNC technologies provide an automated manufacturing environment but lack an efficient means for transferring tool-related information.

soluTion: The ISo 13399 standard offers a common information model for describing cutting tools and efficiently communicating this information.

Tool library sets the standard

ImagINe a PerfecT facTory:

Product specifications are received at one end, all the information, tools and materials flow seamlessly, and the finished product emerges at the other end. A nave utopia? Perhaps, but new tool library services based on an international standard are bringing this ideal a step closer to reality. The ISO 13399 standard in reality a family of standards defines a common information model for communicating data on cutting tools between various manufacturing systems. Information flow from the designers CAD environment to the CAM and CNC systems on the shop floor is fairly fluent and well standardized. For cutting tools, the picture is different. Information on tools, such as dimensions and geometries, insert and holder combinations and CAD models, has long been available digitally but only in proprietary formats. As most manufacturers are likely to use several tool brands, it has been

a new iSo standard defines a common information model for communicating data on cutting tools.

necessary to use several mutually incompatible software systems. Furthermore, as direct communication between these systems and CAM software has been poor, cutting tool data cannot easily be transferred to CNC machine tools. Due to these problems, manufacturers have been reluctant to make use of even existing tool library functionalities available in CAM systems. All this results in a significant untapped

productivity reserve. According to CAM system suppliers, automated input of cutting tool data to CNC systems can increase the productivity of a machining process by as much as 50 percent. Manufacturers are aware of these issues and are keen to find practical solutions. During Chicagos International Manufacturing Technology Show 2010 (IMTS) in September, a range of manufacturers from both large and small companies and various industries expressed interest in Sandvik Coromants tool library services. An increasing need for digital cutting tool information exists in the marketplace. This is precisely where ISO 13399 offers a solution (see sidebar). All the standardized tool data recorded by the supplier will be available to any of the customers CAx, tool management and CNC systems. Tool crib personnel can receive assembly instructions for building the tool, including all the required inserts, holders and adaptors.

28

metalworking world

From the crib, the tool assembly goes to the machine tool, where the operator can again access the tool data. After finishing the job, the operator can make any necessary corrections or amendments in the data and relay the files back to the tool room and other systems. A crucial requirement is the quality of information. For example, any tool dimension stated by the supplier must remain unaltered

throughout the process all the way to the machine tool. An additional benefit of ISO 13399 is the ability to handle tool offset data. ISO 13399 offers a relatively simple transfer process for any kind of cutting tool-related information. However, the real challenge, as well as the potential for greater efficiency, is offered in more ambitious applications such as machining simulation and process optimization. n

iso 13399
The ISO 13399 standard series Cutting tool data representation and exchange defines a general data model for representing the main categories of cutting tool data and the relationships between them and outlines the principles for exchanging such data. A publicly available application programming interface has been developed to ensure that all users can create and/or access information according to ISO 13399 without detailed knowledge of the standard. The standard was developed by a team of representatives from Ferroday Ltd, Kennametal Inc, Sandvik Coromant (the project leader) and the Royal Institute of Technology of Sweden. n

practical solution
The new standard divides cutting tools and their components into four main groups:
Tool ITems. The holders or tool bodies supporting the cutting items.

cuTTINg ITems. The inserts or cutting edges that directly remove material from the workpiece.

assembly ITems. Components

required for assembling the tool, such as shims or screws.

adaPTIve ITems. For example,

extension or reduction adaptors that provide the connection between a tool item and the machine tool.

summary
Tool library services based on the international ISO 13399 standard offer significant productivity improvements by efficiently linking up CAx and CNC systems. The standard enables open data transfer between proprietary tool management, CAx and CNC systems. n

metalworking world

29

TExT: HENRIK EK, GEOFF MORTIMORE PHOTO: MARTIN ADOLFSSON

super size Me
nnn In Lewis Carrolls Alice in Wonderland, the heroine drinks from a bottle that shrinks her to a tiny size. You get the same feeling standing in front of the electric mining shovel unit at US manufacturer Bucyrus main shop south of Milwaukee, Wisconsin. Lets put things in perspective. The assembled unit weighs nearly 1,400 tonnes as much as five doubledecker Airbus 380 planes. The bucket reaches a height of 18 metres when it stretches out to scoop rocks. Its as tall as a seven-storey building, and its 120-tonne payload capacity is as big as that of two fully loaded trailer trucks. Big is beautiful here. Since its founding in 1880 in Ohio, Bucyrus has been large-scale by every possible definition. Almost all the parts for the companys different mining machines, including shafts, gears, sheaves, pulleys and frame components, are produced at the main shop. A walk around the facilities in the complex reveals an array of giant steel parts, not always easy for the untrained eye to identify. One of the biggest is a swing rack, a giant gear wheel that sits horizontally under the shovels body and makes the unit turn. Its our biggest part and one of three main parts we had to craft more efficiently, says John Matysiak, manufacturing engineer at Bucyrus. When it comes to the companys electric mining shovel, we are really talking about massive scales. A 30
metalworking world

milwaukee, Wisconsin, us. It looks like a cross between a tank, a tractor and a crane. when demand for this enormous electric mining shovel more than doubled in two years, size became an issue for maker bucyrus.
single part for such a piece of equipment could measure up to 5.5 metres in diameter. The electric mining shovel is powered by an electric motor, one of the few parts that are not made in-house. It works as well for open-pit gold and copper mining in the Australian heat as for oil sand operations in the northern Canadian cold. But the gigantic scale of the machines can present a challenge when it comes to mobility. Some of these parts weigh around 110,000 kilos, Matysiak says. It means we cant possibly ship our whole units to the customer assembled. We do some sub-assembly right here, but sometimes the mines are at very remote locations. We have to ship everything in parts. Just creating the three biggest parts included several steps at different locations around the complex. We had to move the parts so many times when machining them, Matysiak says. We had to do turning at one place and then use a crane to put the part on one of our internal railway carts to get it to another facility for gear cutting. Sometimes a part travelled several miles before [it was] finished. This logistical problem was highlighted by a study that pointed to a future capacity squeeze. In 2005, when Bucyrus announced the first phase of its multimilliondollar expansion of its South Milwaukee manufacturing facility, the company believed that demand for electric

john matysiak, manufacturing engineer at Bucyrus.

aT a glance
FounDeD: 1880 in Bucyrus, Ohio oWneRShiP: Entered into merger agreement with Caterpillar in 2010 Line oF BuSineSS: Maker of surface and underground mining equipment main PRoDuCtS: Draglines, electric mining shovels, blast hole drills numBeR oF emPLoYeeS: 10,000 tuRnoVeR (2009): 2.65 billion uS dollars.

Single parts can be 5.5 metres in diameter and weigh well over 100,000 kilograms.

metalworking world

technicAl insight

big business
The objectives were clear. A study showed that Bucyrus weakest point was in the big turning facility. The company needed a new machine centre, but it also wanted: morecost-efficientcuttingprocess A machinethatwouldhelpreducehandling A and transport of large parts machinethatwouldfitinthelarge A turning facility. Not many manufacturers could meet those demands, says John Matysiak, manufacturing engineer at Bucyrus. Italian machine tool builder Pietro Carnaghi could. At the same time, Bucyrus faced tooling options, and Sandvik Coromant was involved from the start to find the most efficient solution. we hadnt worked with Sandvik Coromant before, but we knew they were capable when it came to turning, Matysiak says. The order to Pietro Carnaghi included turn keys for the three main parts: the swing rack, which enables pivoting for the shovel body; the hoist drum, which hoists the cable for the shovel; and the hoist gear, which turns the drum. Lyle Schmaus, sales The machine was to be engineer at Sandvik fitted with Coromant Coromant. Capto C8 clamping units from Sandvik Coromant for all the OD and ID tool blocks. Sandvik Coromant Italy prepared process layouts, time studies and tool lists. Bucyrus received this information from Pietro Carnaghi and contacted Sandvik Coromant uS for input. To deal with process and tool selection issues, Sandvik

with demand ramping up fast, bucyrus had only one option: to get a new and efficient machine centre.
Coromant uS worked as a mediator between Pietro Carnaghi, Sandvik Coromant Italy and Bucyrus. The Sandvik Coromant uS group out of Pontiac, Michigan, was also involved. The finalized list of required tools, including Coromant Capto C8 clamping units, CoroDrill 880 drills, Duobore and CoroBore boring tools and a variety of milling cutters, was approved by the customer and by Pietro Carnaghi. when the machine was shipped, Sandvik Coromant uS provided daily support to Pietro Carnaghi and Bucyrus through all the required run-off parts. Numerous changes had to be made to tool type, insert grade and geometry and processes in real time in order to achieve the aggressive run-off schedule. The people at Pietro Carnaghi had only seen two-dimensional drawings of the parts. Sometimes you have to see a part in real life to fully understand how to craft it, says Lyle Schmaus, sales engineer at Sandvik Coromant. Lyle and Sandvik Coromant were with us from the start and gave us real-time support in the early stages, says Matysiak. Lyle spent about five weeks here. The Pietro Carnaghi machine was installed in 2009 and became fully operational in mid-2010. Its even on over-capacity, says programmer Neil Cramer. Its working so well that all the engineers have started putting everything in here, not only the three original main parts. According to the numbers, Bucyrus has made all the right choices. Says Matysiak: we were aiming for a 25 percent cost reduction. On average were at 44 percent, which is very exciting. In transportation were down 66 percent and in lead time 19 percent. That equals many, many days. n

32

metalworking world

operator jason j Reynolds at Bucyrus prepares a swing rack for the next step in the cutting process.

metalworking world

33

the five-metre table Pietro Carnaghi machine can turn, drill, bore, tap and mill in one setup.

The challenge in brief

the challenge:
Rollers on the swing rack help to rotate the electric shovel.

To meet rising demand for the electric mining shovels, forecast to increase significantly, as well as capacity constraints in three key components.

the solution:

Previously we made eight to 10 units a year. We were told that over a two-year period that number would go up to 24.
john matYSiaK, manuFaCtuRinG enGineeR at BuCYRuS.

Sandvik Coromant had to find the most efficient tooling solution for the machine, which could handle turning, milling, drilling, boring and tapping of these components. It did so in a twin-column, live-tooled five-metre table 200 HP VTC from Pietro Carnaghi.

mining shovels would increase significantly in the coming years because of growing global demand for coal, copper, iron ore, oil sands and other commodities. Previously we made eight to 10 units a year, Matysiak says. We were told that over a two-year period that number would go up to 24. The current capacity for electric mining shovels is just over 30. Bucyrus also manufactures blasthole drills, used to drill holes and plant explosives in harder types of rocks. Occasionally it also receives an order for a dragline, a huge crane-like shovel. As orders increased, it became clear that the existing process wasnt fast enough to meet the demand. The company took a close look at the capacity constraints on three key components 34
metalworking world

the swing rack, hoist drum and hoist drum gear all very large and manufactured in the same time-consuming process that required shipment to various departments for completion. Bucyrus found what it was looking for in a twin-column, live-tooled five-metre table 200 HP VTC from Italian manufacturer Pietro Carnaghi, which can turn, drill, bore, tap and mill in one setup. This instantly reduced the number of setups on any given part, saving significant time and money. Sandvik Coromant was chosen to find the most efficient tooling solution for the machine, involving both the Italian and American Sandvik Coromant organizations (see sidebar). Bucyrus also reduced lead time, according

the result:
The new machine reduced the number of setups on all parts, leading to considerable cost savings and 19 percent in lead time, equal to several days. n

to Matysiak. Additional savings came through reduced queue time and transport costs as well as improved quality of the components. For Sandvik Coromant, not only is it the first time it has been involved in a start-up project with Bucyrus, but it also marks a success for its Right from the Start campaign on an international level, involving many different levels of Sandvik Coromant in two countries. n

technology
TExT: TuRKKA KuLMALA

challenge: what to do if cemented carbides do not deliver in hrSA machining?

soluTion: Move to ceramic insert grades, which when correctly applied offer a powerful alternative.

Ceramics like it hot

sIaloN aNd WhIsker ceramIcs are viable alternatives for both turning and milling heat-resistant super alloys (HRSA). One subgroup is the Inconel alloys, typically used for high-temperature applications in aircraft engines and energy production. Another increasing application is welded-on hard materials in the oil and gas industry. Ceramics are strong in hot-hardness and low reactivity with workpiece materials; their downside is lower toughness compared with cemented carbides. This requires a rigid process with minimal vibrations. Tool overhangs should be short, entries and exits smooth and, in milling, full slotting should be avoided. Ceramic turning and milling operations

show some major differences. In turning, the cutting speeds top at around 300 m/min, while milling cutters may reach as high as 1000 m/min. Ceramic turning requires abundant, uninterrupted coolant flow, whereas milling tolerates no coolant at all to avoid thermal stress. Round inserts are optimal for both turning and milling, and low depths of cut are recommended. The principal guideline for ceramic milling is to use relatively low feed rates (0.05 0.08 mm/tooth) compared with carbides to achieve very high cutting speeds. The heat around the cutting zone enhances the cutting action and efficient removal of the resultant small, red-hot chips. n

sTrong ceramic inserT

Sandvik Coromants Sialon grades CC6060 and CC6065 and the whisker ceramic CC670 complement a strong ceramic insert programme for both turning and milling. Read more at www.sandvik.coromant.com.

case sTuDy: INCoNeL CoMPoNeNT

Tool: INserT: cuTTINg sPeed vc (m/mIN): feed Per TooTh fz (mm): Table feed vf (mm/mIN): cuTTINg dePTh aP (mm):

Sandvik Coromant S-R120R-051C6-12x4 Sandvik Coromant RNGN 12 07 00 E 800 0.13 2000 1.5

Competitor, high-feed cutter Competitor, carbide 38 0.71 600 0.7

summary
with optimal methods, the extreme speed capacity of ceramic tools can offer substantially higher metal removal rates in demanding HRSA applications. n
the high temperature helps the removal of red-hot chips.

resulTs:

A total of 42 hours of cutting time was saved per year, and the productivity increased by 469 percent.

metalworking world

35

outlook

South Pole record broken

solutions. A British-led expedition team has completed the first-ever there-and-back vehicle crossing of Antarctica. Andrew Regan led the 11-person team, which used a variety of space-age machines including the one-man Bio-Inspired Ice Vehicle on the 20-day trip from the union glacier in late November. On reaching the geographic South Pole, they turned around and retraced their steps back to the glacier, travelling the 4,000 kilometres to arrive back on December 17. n
moon regan transantarCtiC eXPedition

deUtsChe messe

megawatts was Chinas total wind power capacity in 2010, making it no. 1 in the world in wind power, ahead of the united States (40,180 mW).
Source: Global Wind Energy Council

42,287
joIN The CoMPoSITe DISCuSSIoNS!
machining in composites is demanding and complex. at the same time it is an area with huge potential. in a new blog, www.compositemachining.org, you can share common experiences and solutions.

DID YOU KNOW

Strong focus at eMo the worlds tallest wind turbine is the 160-metre-tall Laasow turbine in Brandenburg, Germany?

getting the show on the road

exhibition. The 12th China International Machine Tool Show (CIMT) in Beijing provided Sandvik Coromant with an ideal opportunity to demonstrate its latest technology and services. This years Smart Hub was the largest stand in the companys history in China. The stand was modelled as a Chinese city, blending traditional architecture with modern towers. It featured gear milling, aerospace and power generation in the three main towers, and included applications such as hard part machining and automotive in different areas. Alongside the display of products, the stand focused on services such as CTLS (Coromant Tool Library Services) and training solutions from the Sandvik Coromant Academy. n

aPPleUZr

eMo. EMO Hannover is the largest trade show in the metalcutting industry. This year Sandvik Coromant will present the latest solutions for gear milling and hard part machining. n

trade shows 2011

illUstrations: hyPergon, danleaP

may
meTalloobraboTka

sept
emo

oct
Toolex 2011

2327 May Moscow, Russia

1924 September Hannover, Germany

subcoNTracTINg Trade faIr

57 October Sosnowiec, Poland

caNadIaN maNufacTurINg TechNology shoW

June
ITm Polska

1315 September Tampere, Finland

INTl TechNIcal faIr

1720 October Toronto, Canada

1417 June Poznan, Poland

ParIs aIr shoW

26 September 1 October Plovdiv, Bulgaria

2026 June Paris, France

36

metalworking world

Photo: James king-holmes

illUstrations: riChard Baird , gyPsy Bytes, BUBaone

Nobel superhero

unorthodox. rarely are Nobel Prize winners also known for their links with Spider-Man and the levitation of frogs, but Andre geim, who won the 2010 prize for physics, is at times less than conventional in his research focus.
graPheNe
andre Geim won the nobel Prize for developing graphene, the thinnest material in the world, and one of the strongest and hardest. the material has many potential applications and is considered an improvement over the alternative, silicon. there is potential for its use in composites used in aeroplanes and cars and also as an electronics component in computers, solar panels and tablets.

frogs
Known for his less-than-orthodox research interests, in 2000 Geim shared an alternative prize, the ig nobel Prize in Physics, for magnetically levitating a frog.

gecko TaPe
Geim helped develop super-strong, Gecko tape. the hope is that one day it will allow humans to scale walls like Spider-man.

Geims Gecko tape could leave Spider-man in a sticky situation.

metalworking world

CoUrtesy ColUmBia PiCtUres

37

the solution
TExT: GEOFF MORTIMORE ILLuSTRATION: KJELL THORSSON

POWERFUL GROOVING

The growing demand for clean and more efficient electric power creates a need for new gas and steam turbines with components manufactured in more high-alloyed and difficult-to-machine materials. Making a steam turbine requires hundreds of different tools, and one of the most common and challenging operations is grooving. here are some of the tools used:

months of difficult work

Compounding the dual challenges of time and precision in the manufacturing process is the sheer size of giant steam turbine components such as the casing, discs and shaft. For the shaft alone, it can take months of difficult work to machine away 20 tonnes of material for a 70-tonne, 10-metre long, 2-metre diameter final product. Grooving represents a large part of the machining process in steam turbine manufacturing. Streamlining this operation can potentially save several weeks in the overall machining operation. n

grade cc6060
TAKINg The heAT
Ceramics are becoming more and more popular as a tool material when machining components in heatresistant alloys, for example gas turbine discs. Grade CC6060 is the first choice and can be used at five to six times higher cutting data compared with the traditionally used cemented carbide tools.

38

metalworking world

Want to learn more? Visit www.sandvik.coromant.com/power dampening blades

vIbrATIoN Free
when performing the final finishing operation on a steam turbine shaft, casing or discs it is paramount that no vibrations occur; otherwise months of work can be wasted. That is why Sandvik Coromant developed the patented dampening mechanism for vibration-sensitive grooving operations.

discs

shaft

casing

coroturn sl and hP
CuSToMIzeD SoLuTIoN

corocut
reLIAbLe
The new chip breaker geometry GM, available for R-size inserts with 15-millimetre widths, gives perfect chip control. It enables machining of deep wide slots in a single in-feed without time-consuming stops and back-outs, which improves productivity and process security when grooving on the huge (10-metre-long) turbine shaft.

Many types of grooves in a turbine shaft normally require special grooving tools. Thanks to the modular tooling system, CoroTurn SL, you can build a tool made of standard cutting units. The SL cutting units can be ordered with HP (high-pressure) coolant supply technology. Build your own customized system at www.tool-builder.com.

metalworking world

39

Teeth like these need a different kind of dentist

One who understands the importance of consistent quality and accuracy in performance. One who can deliver productivity and cost efficiency, who works closely together with you to optimize tooling solutions. One who puts focus on good after-service with frequent check ups and support with discussions for development. One who wears a yellow coat. If gear milling is your business, call us today.

www.sandvik.coromant.com

Print n:o C-5000:550 ENG/01 AB Sandvik Coromant 2011:2