CoroMill® MF80 milling concept gives more than 67% increased tool life
In the realm of machining operations, achieving precision and reliability is an ongoing pursuit. Sandvik Coromant has met this challenge head-on with a tool that promises to revolutionise milling processes. Here, Sangram Dash, Product Application Manager for Indexable Milling at Sandvik Coromant, explains how an innovative concept for milling applications in ISO K and ISO P materials, CoroMill® MF80, supports more precise and cost-effective machining.
Close to 90-degree shoulder milling is highly desirable in machining applications due to its ability to create precise components, which is a necessity as automotive engines grow more complex. Automotive original equipment manufacturers (OEMs) are striving to manufacture parts that comply with tighter tolerances and in accordance with more intricate and contemporary designs.
These more sophisticated components include engine block transmission cases, gearbox housings and steeling knuckles. Due to the intricate shape of these components and the resulting fixturing limitations, a close-to 90-degree shoulder milling tool is more desirable. That’s because the tool is able to efficiently machine intricate components with low axial loads, which leads to cost savings and increased efficiency in the manufacturing process. A close-to 90-degree shoulder mill also gives economic benefits.
However, in long overhang applications, shoulder milling often goes hand-in-hand with vibration issues. Tool vibrations in shoulder milling applications can cause detrimental effects such as uneven cutting forces, which result in poor surface finish and reduced accuracy.
Excessive vibrations also accelerate tool wear, diminishing tool life and increasing production costs. Furthermore, they can lead to workpiece inaccuracies and even machine damage. Therefore, minimising tool vibrations is crucial for achieving high-quality and precise shoulder milling operations.
All of these challenges led Sandvik Coromant to develop a milling concept for automotive milling applications in ISO K and ISO P materials. Based on Sandvik Coromant’s existing CoroMill® 345 technology, the CoroMill® MF80 milling concept is designed for secure face and shoulder milling in close to 90-degree operations with fixture constraints.
Specifically, the MF80 can offer an even closer approach angle of 89.5-degrees, compared with other solutions in the market which are capable of 84- to 88-degrees. The closer angle gives added benefits in terms of material removal and stock being left for the next operations.
In the automotive sector, where every investment is scrutinised, the importance of a reliable cutting tool cannot be overstated. That’s why the CoroMill® MF80 is offered with the protection of a shim, the protective carbide behind the insert, in the cutter body, that holds and locks the insert in a defined position when it is mounted. The shim minimises movement of the insert in order to reduce unwanted vibrations and insert damage, protecting the cutter in case of accidents. Lack of protection in the shim can therefore result in reduced reliability and potential damage.
Some tools may not prioritise vibration control which can lead to increased tool wear, decreased accuracy and potentially compromised workpiece quality. CoroMill® MF80 is offered with cutter bodies that are 40% lighter in weight, which plays an essential role for maintaining stability and precision in long overhang applications.