Metalworking World 2/2012

ballooning:

a clear sky way to think 2/12

a business and technology magazine from sandvik coromant

italy:

feel the power

electronics:

metal fights back

Josh Coaplen, director of research and development, Cane Creek

Spain:

all cranked up

cane creek:

investment smooths the path

ride on!

editorial klas forsström president sandvik coromant

A giant leap every day

‘‘

about Virgin Galactic’s mission to take tourists into space (see page 5) reminds me of Neil Armstrong’s famous statement “ ... one giant leap for mankind,” uttered when he first stepped on the moon. Fortunately for us, we work in an industry that takes huge strides forward each and every day. In some cases that means finding new or more efficient processes or products; in others, it means acting on changes in the marketplace. The real-life cases we bring you in this issue of Metalworking World illustrate some of the ways we have helped our customers achieve their goals through our products, knowledge and services. A common theme running through each story is the long-term partnership each customer has with Sandvik Coromant. By focusing on cooperation and common challenges, we can look forward to a future together. At Italy’s Rössl&Dusso, the key to their success is producing custom-built machinery and guaranteeing absolute precision. Meanwhile, with the Spanish economy under pressure, machine tool specialist Bost is focusing outward, developing its export business. At the same time Cane Creek in the United States is looking inward, investing in heavy machinery to answer demands from customers who want local products and suppliers. On page 16 you can read about the company’s strategy and the results it achieved with added value from Sandvik Coromant engineers. Staying one step ahead is of course heavily dependent on R&D. It is well known that at Sandvik Coromant we continue to invest more in this area than other companies in our business.

ReadIng the story

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Fortunately for us, we work in an industry that takes huge strides forward each and every day.” Plastic, composite and other lightweight materials offer us and our customers exciting challenges and new opportunities, but at the same time metal still has a key role to play in all kinds of fields, not least in the manufacture of mobile phones (see page 34). There are challenges facing our industry in 2012, but with world-leading products, services and specialist know-how we can face those challenges together with our customers with confidence and from a position of strength. If we all continue to be innovative, forward thinking and creative, not even the sky is the limit.

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. Publisher under Swedish publishing law: Jessica Alm. Editor-in-chief: Mats Söderström. Account executive: Christina Hoffmann. Editor: Geoff Mortimore. Art director: Emily Ranneby. Technical editor: Börje Ahnlén. Sub editor: Valerie Mindel. Coordinator: Lianne Mills. Language coordination: Sergio Tenconi. Layout, language editions: Louise Holpp. Prepress: Markus Dahlstedt. Cover photo: Martin Adolfsson. 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 inquiries 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: [email protected]. Distribution inquiries: Robert Kogan, Sandvik Coromant. Email: [email protected] Printed in the USA. AutoTAS, CoroBore, Coromant Capto, CoroCut, CoroDrill, CoroGrip, CoroMill, CoroPlex, CoroTap, CoroThread, CoroTurn, GC, iLock, Silent Tools and Spectrum are all registered trademarks of Sandvik Coromant.

Pleasant reading!

klas forsström President Sandvik Coromant

Get your free copy of Metalworking World. Email your address to [email protected]. 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 user’s 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.

content

28

Bost: Custom-built progress in an unsteady climate.

22 Ballooning: Eyes to the sky.

10

A patented new technique puts Voith Turbo on the map.

9

Rössl&Duso generates success.

Quicktime: News from the world of metalworking ...........4

A smoother ride...........16

The final frontier............ 5

Experts in export........ 28

Dreamliner 787:

The composite plane ..............8

Feel the power ..............9

Lofty ambitions...........22

5

Out of this world.

Metal in electronics.... 34 Total solution:

Vertical turning lathes........ 38

Technology Spectrum Turning

InvoMilling

Tapping

A new family of inserts and geometry grades aimed at the mixed production environment, offering a “one insert does it all” capability.

The most flexible way to improve gear milling, using indexable insert tooling.

How can threaded holes be best machined – economically and productively?

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metalworking world 3

Quicktime text: geoff mortimore

photo: K.J. Historical/Corbis

Life in the fast lane Leena Gade sports. British-born Leena Gade was hooked on motor racing from the first time she saw Formula 1 on television as a youngster growing up in India. But unlike most fans, she ended up making a career out of it and in 2011 became the first female race engineer ever to lead a team to victory in the prestigious Le Mans 24 Hours race. Following jobs in automotive and aerospace engineering, she started her racing career as a part-time mechanic and data analyst and worked her way up – first to assistant race engineer and finally to head engineer for the Audi Sport Team. Finally, last year, Gade’s talent and efforts were rewarded at Le Mans when she guided driver Benoit Treluyer for 2,800 miles, to give Audi its 10th victory at the event since 1999. Treluyer’s vehicle was one of three Audis taking part in the race; the other two failed to finish. As race engineer, Gade’s job is to monitor every aspect of the race – from tire pressure to fuel level, temperature and weather conditions – and guide “her” car (in this case the No. 2 Audi) over the finish line. Gade shares her interest in motor sport with her younger sister Teena, who is also a race engineer and looking to emulate her sister’s achievement by helping Kris Meeke and MINI win their first-ever event in the World Rally Championship. n

4 4 metalworking metalworkingworld world

Gade led her Audi driver to victory at last year’s Le Mans 24 Hours race.

Quicktime

nasa image gallery

Bolt from the blue science. Scientists at a laboratory in Wales have developed artificial lightning almost as strong as the most violent bolts ever recorded. The discovery, at the Morgan-Botti Lightning Laboratory at Cardiff University in Wales, will be used to test new materials being used to construct airplanes and could be a vital breakthrough in increasing aerospace safety. Scientists will be able to use the facility, the only noncommercial artificial lightning lab in the U.K., for testing composites and other materials used in aircraft construction. Safety, especially in difficult weather conditions, will be a primary focus for the construction of new planes, making the Morgan-Botti Lightning Laboratory at Cardiff University a perfect testing ground. Scientists will use the facility primarily to test the strength of new components being used in wing manufacturing. n

Spaceship factory opens in Mojave

space tourism. Space tourism moved a step nearer at the end of last year when California’s Mojave Air and Space Port opened an assembly plant to produce the first passenger spaceship fleet. The operation, called The Spaceship Company (TSC), is a joint venture between Mojave-based Scaled Composites and British billionaire Richard Branson’s space tourism company, Virgin Galactic. The new factory is 30 miles north of a plant where 1,800 workers assembled the space shuttles. The last space shuttle made its final voyage in July 2011. “This is a big day for Galactic,” says

George Whitesides, chief executive officer of Virgin Galactic. “We’re moving closer and closer to bringing paying passengers into space.” When Burt Rutan won the first X-PRIZE challenge to fly a man into suborbital space without government support he attracted the attention of Branson, who bought the rights to the technology. To develop the prototype for the new fleet of space liners, he then hired Scaled Composites, a company specializing in developing composite material aircraft. The mother ship for the project, WhiteKnightTwo, is currently the world’s largest all-composite aircraft. n

More than 400 people have already paid either a deposit or the full $200,000 ticket price for a trip on the shuttles being made in Mojave.

3.3 billion out Check ur iPad,

on yo e MW W w in th ble no a il a v a stor e . iTunes

New app points the right way ipad . A new iPad app from Sandvik Coromant will make it easier for engineers, programmers and machinists to find the right inserts for drilling, turning, threading and milling operations. The new app, CoroKey, is designed to offer the best tools in all machining

applications and safe, reliable cutting data. It provides recommendations for all classifications in steel, stainless steel, iron, nickel-based alloys, super alloys and hard materials. Based on the principle “easy to choose, easy to use,” the app will guide you to the correct grade

The number of mobile phones currently being used globally.

Find out more at www.sandvik. coromant.com

and geometry for whatever specific material group you are working with. Helping you select the best insert for each job, the CoroKey app works with both metric and inch measurements. n


Quicktime Stronger partnership

Höfler, Sandvik Coromant forge stronger link

trade shows

Björn Roodzant

1.

Why was it necessary to relaunch the website? Today’s way of doing business is changing all the time. People in the marketplace expect to find information and answers to their queries right here, right now, and more and more often online. We want to have the best setup to serve our customers and partners in the industry, and to have best possible dialogue online with them. We want to make the search for information and decision-making easy and convenient.

2.

What will it mean to Sandvik Coromant customers? We want our website to be the best possible meeting place for people to do business and be the best possible partner online for users. Our aim is always to be one click away. We have to be able to offer support and work with our customers online as well as we do on a face-to-face basis – in short, to be a “virtual yellow coat” and deliver the best possible online experience.

3.

What advantages does it offer Sandvik Coromant from the supply side? It is our goal to be able to work globally and be able to offer an instant reaction to all user needs around the world. This is the ideal tool for us to be able to do that, both toward the customer and toward our suppliers.

mmts

In terms of business, what results do you expect? The new website is part of the Sandvik Coromant overall global strategy to make it easier for our customers to do business with us. We expect it to have significant influence in terms of support and sales, because our customers will have access to information and support so much more readily. It will make their purchasing decisions quicker and better.

5.

What are your Web plans moving forward? We will look to make improvements continually and integrate services more into our offering, always keeping our customers’ success in mind. n

If you cycle regularly, you can expect to be as fit as an average person 10 years younger. More on page 16.

Farnborough International airshow

July 9–15 Farnborough, Hampshire, U.K. IMTS

September 10–15 Chicago, Illinois amb

September 18–22 Stuttgart, Germany maktek eurasia

October 2–7 Istanbul, Turkey jimtof

November 1–6 Tokyo, Japan Application Center will help meet Indian demand. metalworking world

4.

DID YOU KNOW?

May 14–16 Montreal, Canada

6

Björn Roodzant, senior manager, global Web and e-marketing, on the new website.

Application Center gets green light productivity. Sandvik Coromant India has been given the go-ahead by the Sandvik Group to build an Application Center at its plant in Pune, set to open by September 2012. The new facility will complement an already existing Productivity Center at Pune and will differ from other Application Centers by being more feature-based, covering different segments, rather than being dedicated to any

getty images

particular industry segment. “We are really excited to get this approval as it will enable us to further increase our value services to our customers enabling improved customer relations. This will be a huge differentiator with our competitors and further increase the gap in our market leadership,” says Kawal Saigal, Sandvik Coromant Manager in India. n

Brian Lacey Studios

collaboration. Sandvik Coromant is furthering its linkup with Höfler Maschinenbau to increase presence and business in North America. The two companies will share facilities and machinery at the Sandvik Coromant Productivity Center in Schaumburg just outside Chicago, where a Höfler HF 1000 gear hobbing machine, equipped with the latest indexable insert tooling solutions, is now available for training, demonstrations and joint activities with North American customers. The collaboration began in 2009. Since then it has developed into several joint activities including successful turnkey solutions delivered to the global market. “Höfler enjoys a technology leadership in gear manufacturing,” says Kenneth Sundberg, business development manager for gear milling at Sandvik Coromant. “The combination of the market presence and competence of Sandvik Coromant in cutting tools, along with Höfler’s expertise in gear manufacturing, is already now taking gear manufacturing to new levels.” n

five questions:

Quicktime text: geoff mortimore

photo: getty images

Blade breakthrough Turbine technology energy. A new polyurethane-based composite technology that will help create stronger and longer blades for wind turbines has been developed in the United States. Scientists at Bayer MaterialScience LLC discovered that polyurethane chemistry improves fatigue and fracture toughness properties over epoxy-based systems currently used commercially. Proof that the government is taking an interest in the new material came when Bayer was asked to display a prototype wind-turbine blade root ring, which wraps around the base of the blade, at the American Wind Energy Association Off-Shore Windpower Conference and Exhibition in Baltimore last year. “It’s gratifying for our development to be highlighted, particularly in light of the many wind technology projects funded by the Department of Energy’s Energy Efficiency and Renewable Energy program in the past year,” says Mike Gallagher, director, public sector business, Bayer. Making blades longer and lower can have considerable impact on productivity. The power generated by a wind turbine is related to the area swept by the blades, with the result that a turbine with blades twice the normal length can generate four times more power. Meanwhile, reducing blade height means less strain is put on turbine components, which will reduce operation and maintenance costs. n

Longer blades promise up to 300 percent greater strength and productivity.


Quicktime text: chi an gramfors

ILLUSTRATION: kjell thorsson

The Boeing 787 family:

Dream machine The Boeing 787 — A composite game-changer

Boeing has established two world records with its 787 Dreamliner, setting new marks for both speed and distance for the weight class. “These records are a great way to demonstrate that this airplane is the game-changer we have promised,” says Scott Fancher, vice president and general manager of the 787 program. From a materials point of view, the 787 Dreamliner is

one of the most revolutionary leaps in the history of manufacturing. The use of carbon fiber reinforced plastics in the construction reduces weight significantly, allowing fuel savings and extended flying range. The airplane uses 20 percent less fuel than similar-sized airplanes, and now holds the distance record with a 12,325-mile flight (which gave credit for

787-8

210–250 passengers in three classes

11,896 miles) from Seattle to Dhaka, Bangladesh. The former record was held by the Airbus A330, which traveled 10,503 miles in 2002. Composites are used on wings, tail, doors, fuselage and interior. Passenger comfort will improve thanks to the material, as the internal cabin pressure will be increased. Also, the humidity in the passenger cabin can be increased. n

Length: 186 feet Wingspan: 197 feet

787-9 250–290 passengers in three classes Length: 206 feet Wingspan: 197 feet

Internal pressure is the equivalent of 6,000 feet of altitude instead of 8,000 feet.

Humidity can be increased to 15 percent instead of 4 percent in the passenger cabin.

The 20 percent fuel reduction results in a 20 percent reduction of carbon dioxide emissions as well.

The structure of the 787 is like one giant macromolecule — everything is fastened through cross-linked chemical bonds reinforced with carbon fiber.

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The Boeing 787 is the first fully computerized aircraft. Mechanics will now have to be equipped with PCs to work on the aircraft’s computer settings.

text: Gea scancarello photo: maurizio camagna

no room for error Vedelago, Italy. Italian company Rössl&Duso has shifted into the business of providing power generation equipment — in particular the huge turbines that light up whole cities — to areas where power generation is lagging behind energy consumption. An ability to custom-design its machines is a crucial part of meeting customer demands.

Gianni Bordignon, production manager, Rössl&Duso

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nnn In Italy’s northeastern corner, above the beautiful waters of Venice and the arcaded streets of Padua, lies the municipality of Vedelago, in the province of Treviso, an area that for decades has been an industrial center. Here you can find the headquarters of Rössl&Duso, a family-owned company that serves as a third-party producer for the precision machinery industry. “We design our machines,” says Gianni Bordignon, production manager at Rössl&Duso. “Often there’s no other way to do something if you need to be accurate, flexible and quick.” Bordignon has hands that tell you right away that he, like most others in the region, has spent every day of his life working. Turbine half shell He was at Rössl&Duso 42 years ago when the company opened its doors with a few people and orders to deliver heavy industrial components and was still there years later when the company began a strategic shift into new businesses. That was the beginning of the 2000s. China and India were rapidly evolving into industrial giants, with an energy consumption that was

Blueprint check before programming a milling machine.

outpacing power generation. “We figured we had to throw ourselves into the power generation business, and it was a good bet,” says Bordignon, who was part of the restructured management group. “In the past 10 years, the company has grown from 40 to 150 employees, despite two world crises,” he says. “It’s been and remains a huge daily challenge.” Rössl&Duso, already a supplier to the naval and steel industries, learned everything about energy and turbines. Today it manufactures parts that make up some of the largest gas, steam and hydroelectric turbines available in the world. These turbines are capable of

delivering electricity to a city of some 150,000 people. Building such behemoths is no easy task. “Lathes to perform such tasks cannot be bought,” says Renzo Cecchetto, plant turning department chief. “You have to make your own." He describes a typical challenge: dealing with a 200-ton steel piece that is 30 feet long and 10 feet in diameter, where the turning operation must be executed with a 0.001-inch run out. The tools have to be up to the job, he says. “We’ve had to experiment, to design our machines internally to find out which tools were needed,” explains Bordignon. “We’ve had to build machines that didn’t exist before, and that required that we have faith both in ourselves and in our partner.” This is where Sandvik Coromant comes in.

Rössl&Duso Italian company Rössl&Duso

focuses on precision machinery construction in a variety of fields, from heavy machining to power generation. Headquartered in Vedelago in northeastern Italy, the 42-yearold family company has grown over the years into a 150-person business. It now has a second workshop in Piemonte, in Italy’s western region, and a third in Pula, Croatia. Rössl&Duso acts as a third-party producer for international giants such as Ansaldo Energy, Alstom Power Systems, Siemens, General Electric and Bhel, who are among the leading power generation companies worldwide. It also serves the global naval, steel and oil industries. In the late 1990s, with the progressive decline of heavy industry in Europe and the rise of China as an industrial power, Rössl&Duso shifted toward the production of highly precise

CoroMill 390 cutter carrying out milling operations on a shoulder in a compressor half shell.

machinery that could satisfy the energy appetite of this and other emerging economic giants. The company rapidly began specializing in the production of gas, eolic (wind), steam and hydroelectric turbines, forging a quality-focused policy aimed at responding quickly to customer needs in a demanding and rapidly changing market. metalworking world 11

Mauro Rossi, sales engineer, Sandvik Coromant (right), showing the new iOS app to Gianni Bordignon (left).

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Sandvik Coromant has been working with Rössl&Duso for the past 25 years. Thus when Rössl&Duso took on the daunting task of building a precision drilling machine that could operate at a depth of 8.2 feet and 14 inches in diameter, it looked to Sandvik Coromant for support. “None of us would give up, but we were all anxious,” Dino Duso, recalls Sandvik owner Coromant sales

engineer Mauro Rossi. “Rössl&Duso was ready to risk its own resources to innovate and adapt to market needs. Sandvik Coromant was there to support the company and grow with it.” The experiment worked. Gas turbines are now one of the company’s primary products, but as the industry changes and evolves, so do its tools and machines. “You can only achieve success if you’re dynamic and versatile,” says Bordignon. “But you also need technology, assistance and 24/7 reliability. Bringing energy to the world is a tough job.” n

technical insight

strong partner Cutting-edge technology, extreme reliability and unparalleled support are reasons Rössl&Duso’s management gives to explain its choice of Sandvik Coromant as a long-time partner. “We work night and day,” explains Gianni Bordignon, production manager at Rössl&Duso, “and may need assistance at any time. The more delicate the alterations we make, the more expensive the product and the more important it is to have support from somebody who really knows our business.” Starting some 10 years ago, Sandvik Coromant has fitted all of Rössl&Duso lathes with Coromant Capto (C6 and C8), Sandvik Coromant’s original coupling system. Since then Rössl&Duso’s tool changing times have been reduced by 80 percent. In addition, says Bordignon, “Coromant Capto has given us 50 percent more rigidity, which means technically that you can increase your working parameters or, practically speaking, reduce the execution time of any part.” This in turn has meant decreased costs. Sandvik Coromant has also provided Rössl&Duso with anti-vibrations bars, essential in precision jobs such as the drilling required on huge gas turbines. Last but not least, it has provided Rössl&Duso with continuous service at the plant. Sandvik Coromant specialists and engineers know every machine, having helped to design and build many of them. “The main reason we picked Sandvik Coromant was that they were always here,” says Bordignon. “When you do such delicate work as ours, this is important.”

Roughing operation in a Christmas tree seat.


technology text: elaine mcclarence

Challenge: How to combine flexibility and security in a mixed production environment.

solution: Choose Spectrum Turn, the new insert range from Sandvik Coromant.

Keep it in the family In a metalcutting production environment,

with mixed production and limited time for optimal planning particularly for small batch runs, a versatile yet simple and effective solution that can cut a range of materials from mild steel to the most exotic super alloys has always been on the wish list. While optimized solutions are always the desired choice, in these environments the need is for a versatile, flexible and reliable solution with high security and predictability, while minimizing both inventory and setup time often demands a different solution. To address these broad production needs, Sandvik Coromant has created a new family, Spectrum Turn, which encompasses a compact range of inserts and material grades that are suitable across a broad range of materials and turning operations.It makes insert choice simple through a rational tool assortment and meets the needs of secure and predictable production.

The new range offers a safe, reliable and

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economic production that is suitable for most machining environments. It is engineered to give customers a “one insert does it all” capability. With a carefully chosen assortment that covers six insert geometries in two grades, Spectrum Turn can meet the requirements of up to 80 percent of all general turning applications. Thanks to developments in both macro and micro geometries, Spectrum Turn inserts have a large area of overlap, which provides significant backup capability across applications that span medium roughing and finishing applications. In medium roughing, the grades have sufficient toughness to cope with the harsh environment. When used in finishing, the insert coating supports sustained tool life. Spectrum Turn grades are the GC30 and the GC15. The GC30 has a tough substrate to machine securely in roughing applications. Its wear-resistant coating makes it more durable and long lasting when machining both stainless and steel materials, especially in finishing applications. This

combination makes the grade very versatile and useful in applications ranging from medium roughing to finishing. GC15 is a versatile grade developed for both stainless steel and HRSA materials. At moderate cutting data it also works very well in steel and in cast iron materials when finish machining/boring. In general, the insert grades are suitable for cutting speeds below 656 ft/min. cover both external and internal operations. The XF geometry is developed for light cutting action and durability in finishing applications. Thanks to an open chip breaker design, it can also be used as a medium cutting geometry by increasing the feed rate. When insert cost is important, the insert can be reused in medium machining applications after it reaches the worn-out criteria for finishing operations. This geometry is suitable to be used either when the workpiece setup in the machine or the machine itself is

The Spectrum Turn geometries

The new range offers safe, reliable and economic production that is suitable for most machining environments.

weak or when chip breaking is required at lower feed rates. XM is a versatile geometry and the first choice for most applications. The cutting edge has a balance between sharpness and edge strength to enhance its performance in the medium to the finishing area. That means that this geometry can do both the medium and the finishing cut, giving better total productivity. Finally, the XMR geometry is designed to be a medium-roughing insert for tougher machining conditions and materials. One example could be the first cut in a forged stainless material. Even though the edge strength is increased, the cutting action is still lower. This geometry can to be regarded as complementary to the

XM geometry, when extra edge toughness is needed, such as: • When machining in such tough materials as Duplex stainless steels or HRSA. • For intermittent cuts in combination with higher depth of cut (above 0.08 inches). • When machining workpieces in a forged or cast condition. • When there are unstable conditions in the machine or workpiece setup. ANOther benefit in a mixed-material

production environment is that the broad application area reduces setup time between batches and simplifies setup. n

Summary Spectrum Turn is a new family of inserts and geometry grades aimed at the mixed production environment. Offering a “one insert does it all” capability for safe, reliable and economic production, this compact range is suitable for most machining environments. Developments in both macro and micro geometries provide Spectrum Turn inserts with a large area of overlap to give a useful backup capability across medium roughing and finishing applications.


Machining parts like the 110 EC49 headset in-house helped Cane Creek reduce costs by 25 percent in the first year alone.

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text: kip hanson photo: martin adolfsson

two wheels good Fletcher, North Carolina. Cane Creek, a cycle components specialist in North Carolina, took the plunge and made its first machine investment to machine its own parts. The results started the wheels rolling, and they haven't stopped since. nnn Cane Creek is a small entrepreneurial company situated deep in the mountains of North Carolina in the southern United States. It produces high-performance products for cyclists worldwide. The staff at this employeeowned company are passionate about their work. “If we can’t be the best at what we make, we don’t want to make it,” says Josh Coaplen, director of research and development at Cane Creek. It’s that attitude that drove Cane Creek to begin machining its own products in-house. Plagued for years by long lead times and unpredictable quality from its suppliers, Cane Creek made the decision in 2008 to buy a Mazak CNC mill-turn center and learn how to machine its products in-house. With the help of application engineer Greg Ward of JIT Industries, Cane Creek’s local Sandvik Coromant distributor, and support from Sandvik productivity engineer Chuck Scarbrough, the company did just that. “Prior to the Mazak, we didn’t have a single piece of

capital equipment,” says Coaplen. “We had no idea how to make parts.” But with a lot of late-night studying and some application advice from Ward and Scarbrough, the company was able to get up to speed quickly. “We ended up being a lot more efficient than we anticipated,” he says. Coaplen explains that in many cases Cane Creek can actually make products cheaper in-house than buying them from Taiwan. “We reduced our product costs by 25 percent in the first year,” he says. “We were also able to scale back on our production quantities, so we weren’t sitting on so much inventory.” Production lead times have also dropped, from 90 days to as little as one week. “We can turn things around in three days in an emergency situation,” he says. Within five months of buying the machine, Cane Creek was 200 percent ahead of financial projections. In fact, results were so good that the company bought a second machine just a year later. With its own

Josh Coaplen, director of research and development, Cane Creek. metalworking world 17

cane creek since 1994, employee-owned Cane Creek

has made its home in the small town of Fletcher, North Carolina. Situated just south of Asheville in the Blue Ridge mountains, the company designs, produces and distributes a broad range of high-quality products for the performance cycling industry, including suspension components, seatposts, headsets and braking systems. Cane Creek boasts an impressive number of patents on its technology. Early on, it established itself as a leader in this unique market by developing the AheadSet, the world’s first threadless headset. Later additions to its product line included such industry-recognized names as Thudbuster, Angleset and the 110-series, a headset line offering an unheard-of 110-year warranty. The company is competitive yet collaborative and has partnered with companies such as Ohlins and Saint-Gobain, giving it bragging rights to the AER, a cutting-edge design that uses a composite Norglide bearing to provide the world’s lightest headset, and the Double Barrel twin-tube shock absorber, which allows riders to easily adjust and fine-tune their riding experience. The work environment at Cane Creek is geared toward creativity and honesty, and individual ideas and contributions are encouraged. The 39 employees share a passion for cycling and enjoy regular group outings and team events that give them a chance to test and use the products they make. Over the years, Cane Creek has participated in a number of charitable partnerships such as Cycle Youth, Bikes Belong and Trips for Kids — programs designed to support at-risk children and provide a positive impact on young lives. Cane Creek’s goal is not only to provide high-quality, cutting-edge products, but also to make the world a better place via a simple mechanism — a bike.

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DBair shock on dyno with John Fennell

Cane Creek bike shop. John Fennell (left), Gary Maltby (right).

‘‘

We were also able to scale back on our production quantities, so we weren’t sitting on so much inventory.”


Peter Gilbert, VP of sales, Cane Creek

of manufacturing, and the education of young people about the machining industry. Cane Creek and others will support Reality Redesigned by first judging and then manufacturing the winning entries.

Getty Images

So what’s next for Cane Creek? Says Coaplen,

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out how to cut the stuff,” Coaplen recalls. Cane Creek turned to Sandvik Coromant, and together they tooled up the machine and turned out 500 headsets. As a result, Cane Creek was able to donate more than $26,000 in profits to the World Bicycle Relief, enabling health workers in subSaharan Africa to care for AIDS victims. Both Cane Creek and Sandvik Coromant are participating in Reality Redesigned, a design contest with a reality show twist. Reality Redesigned is hosted by Edge Factor (www.edgefactor.com), which is partnered with the Society of Manufacturing Engineers Educational Foundation. According to their website, Edge Factor is dedicated to the promotion Getty Images

equipment, Cane Creek now has the ability to quickly introduce prototypes, test design changes and build specials for its customers without having to wait weeks and sometimes months as was the case before. All this has allowed it to increase sales by more than 20 percent in the past year. Says Coaplen, “We have a whole new product line because of that equipment.” And even though Cane Creek keeps busy making parts, the company still has time for other things. In 2010 it designed and distributed a custom headset for the World Bicycle Relief, a nonprofit relief organization. The new headset was constructed of LDX2101 stainless steel, a material that Cane Creek was unfamiliar with. “We had to figure Thudbuster LT Seatpost

“We’ve already increased our American-made products fivefold, but we still want to bring more and more work in-house.” To assist in this new venture, Sandvik Coromant is planning to bring in the local tech team to help spec out the best tooling package, support fixturing and process efforts and even assist with programming. Beginning in 2012, Cane Creek will use the machine to roll out its newest product, the DBair. According to Cane Creek, the DBair is the bicycling world’s first air-sprung rear shock with twin-tube damping, enabling “custom, rider-tuned damping performance.” As usual, Sandvik Coromant is there to help, offering application advice and high-performance tooling. Coaplen is even talking about going lights-out. “We bought the new machine with unattended machining in mind,” he says, “but we should probably learn how to run it first.” Cane Creek is a good example of what U.S. innovation is capable of, especially when it is supported by and can collaborate with knowledgeable tooling experts. Sandvik Coromant and JIT Industries have provided the manufacturing team at Cane Creek with “good tools and great advice,” says Coaplen. So the next time you’re flying down a steep hillside on your mountain bike, think about the team effort from Cane Creek, JIT and Sandvik Coromant, and be glad they share your passion for excellence. n

technical insight

Tooling up Sandvik Coromant and its Yellow

Coat Elite distributor JIT Industries share in the credit for bicycle component manufacturer Cane Creek’s machining success. Throughout Cane Creek’s steep learning curve, Sandvik Coromant and JIT have been there to support the company with tooling and application advice — anything from what the letters in CNMG mean to what speeds and feeds should be used to cut 6061 aluminum. When Cane Creek came to JIT Industries for advice on tooling up its first turning center, the company made it clear it didn’t want to see any tools left sitting on the shelf. It wasn’t disappointed. The teams from Sandvik Coromant and JIT helped Cane Creek design a tooling system that could machine all of the desired parts with minimal setup. For general turning, Sandvik Coromant engineers recommended that Cane Creek use CoroTurn 107 -AL-style inserts. With a PVD-coated up-sharp edge and positive cutting geometry, -AL in grade H13 is specifically designed for cutting low-silicon aluminum. For threading, Cane Creek uses CoroThread 266 laydown-style tools with GC1125 grade inserts, allowing them to cut a variety of threads quickly and burr-free. Since Cane Creek does detailed internal work, XS-style quick-change solid carbide tools were recommended for its small boring and internal grooving operations and where frequent tool changes are required.

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inspiration Hot air ballooning

text: chi an gramfors photo: getty images

High management Hot air ballooning requires strategic thinking, an open mind and a love of the unpredictable. You’re high in the sky in a device that you can’t steer, but still you can dictate its direction by reading the wind and weather.

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Hot air balloons flying over unusual mountains in Cappadocia, Turkey.

nnn In a hot air balloon, every flight is unique and magical. One moment you are drifting just above the treetops, and the next you’re 3,000 feet in the air with mountaintops at eye level. Being high in the sky at the mercy of ever-changing weather evolves your way of thinking, promoting fast decision-making and the ability to re-evaluate situations in an instant. In fact, it has much in common with the best business management. Blaser Swisslube in Switzerland recognizes this commonality and has incorporated ballooning into its business. All staff members can join the company-run ballooning club, participating in the ground crew or training to become a pilot. “It’s good for company teambuilding,” says Marc Blaser, CEO of Blaser Swisslube, himself a balloon pilot. His father, Peter Blaser, started the club in 1988 when he was CEO, so son Marc was steeped in the sport. “Everybody involved in the flight has to help,” he says. “It motivates everyone at the company and strengthens team spirit. When you’re high up in the sky together in a small basket, it’s a very personal experience that you share together.” What you learn from ballooning may even change how you approach your company, he says. “It is only natural that the way we manage the balloon is something that we bring into our company,” Blaser explains. “You need to have a good overall perspective and be able to analyze a situation. If you meet an obstacle or the wind doesn’t exactly blow in the calculated direction, you must adapt your plan to reach the desired destination. The same thing applies in a work situation. Sometimes you have to realize that something is developing differently than planned and that you must take another course to correct it. In the long run this actually increases productivity over the whole line.”

Strategic thinking is key in piloting a balloon. The only way you can steer it is to climb or descend into wind currents that are blowing in the direction you want to go. You can’t actually see the wind, but there are many ways to find out the direction it is blowing at different altitudes. “You need to have an open mind and observe everything around you,” says Blaser. “To see how wind currents move, you have to read the signs everywhere. You look at the trees to see which way the leaves are moving. Smoke coming from chimneys helps, too. You look at the sun and how shadows fall on the mountains.” Flags on flagpoles may also give clues to how the wind is blowing further down, he says. One trick balloon pilots use is to drop foam and watch how it falls. This helps determine where to make a turn. It is also useful in detecting the speed of wind currents, which affect the speed of the balloon.

Ballooning innovation Peter Blaser, who led the metalworking fluid company Blaser Swisslube in the second generation from 1973 until 2010, designed a small balloon that can be flown by one person. He has also helped to perfect lightweight balloons that are especially suitable for traveling throughout the world, because they’re almost small enough to pack in your suitcase.


Ballooning facts The first hot air balloon was built

by the brothers Joseph-Michel and Jacques-Étienne Montgolfier in Annonay, France, in 1782. The first tethered balloon flight

with humans on board took place on October 19, 1783, in Faubourg SaintAntoine, France. The first manned untethered hot air

balloon flight took place on November 21, 1783, also in France (in Paris). The first hydrogen (gas) balloon flight took place in Paris on December 1, 1783. The first modern hot air balloon was

designed and built in the United States by Paul Edward Yost in 1960. The world altitude record for a hot air balloon flight is 69,850 feet, set on November 26, 2005, by Vijaypat Singhania. The longest-ever hot air balloon flight was 19 days, 21 hours and 55 minutes, a record set on March 21, 1999. At the same time, the record for the longest distance ever covered was set at 29,055 miles.

Bertrand Piccard and Brian Jones set these records when they were the first to fly around the world nonstop.

A print depicting the first manned hydrogen (gas) balloon flight, 1783.

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Sometimes balloons are flown while still tied to the ground by ropes, referred to as tethers. This is especially common at balloon festivals or other special events.

The ground crew help out during takeoff and landing. They keep in contact with the pilot and report weather changes and other information. They follow the balloon in a chase car to the estimated landing spot, where they prepare for the landing.

The envelope

The burner The basket

Ground crew members

Armin Graessl

Blaser Swisslube

and unique experience. You use all “In the sky you are completely exposed to your senses, and even though the weather and the winds,” says Blaser. “It’s one you’re floating with the wind, you of the most weather-dependent sports. There don’t feel the wind in the basket. can be a blue sky, but you can’t fly because of It’s fascinating; you get a different unfavorable or rough winds, the biggest danger perception of nature and the world of all. Observing the weather all the time and around you.” understanding general trends is most important. The topography on the ground also influences the wind currents. A pilot needs to continuously What kind of person is best Inside the balloon, getting evaluate all these combined factors.” suited to fly a balloon? the envelope inflated. Although most dangers are weather related, “I think it’s good to be openobstacles on the ground are also something to consider. minded, as the balloon isn’t 100 percent controllable,” Most fatal accidents are caused by collisions with says balloon pilot Marc Blaser, CEO of Blaser Swisshigh-voltage power lines. lube. “An ability to analyze is good, as you need to be “Power lines are dangerous,” Blaser stresses. “You able to read the wind and various other signals around need to climb quickly if you come too close, and it takes you. Every flight is different, so the experience is always 30 to 40 seconds after you unique. You experience so many sensations and different hit the burner before the impressions while flying that have to be processed by balloon starts to react and your mind during and especially after the flight. climb higher. “This is something balloonists learn to really “Ballooning is very treasure,” he says. “That way of looking at things can intense,” he continues. be brought into daily life in every meeting with other “There is constant people, and in your awareness of your surroundings. interaction with everything Bringing this way of relating to things into the work around you. For me, space and business management makes strategic though, that is something decision-making and planning a natural part of the High above the Alps positive. It is a peaceful in Switzerland. process instead of a complicated effort.” n

Marc Blaser CEO of Blaser Swisslube and a hot air balloon pilot. Has flown balloons as a crew member since 1988. Became a ballooning pilot in 1994. Has close to 700 hours of flying time as a pilot.


technology text: christer richt

Challenge: Improve the flexibility and economics of gear milling.

solution: Make use of new highprecision indexable insert tooling and multi-axis capability of machine tools.

Sophisticated simplicity Gear manufacturing is a relatively complex area, spanning over a broad spectrum of components, where volume, complexity, size, quality and costs are the main factors that determine production methods and machinery. Moreover, it is an area where conventional methods have been applied to meet the demands that these factors make. Now, however, an innovative approach to method and cutting tools is creating a lot of interest for machining spur and helical gears. Gears are generally made in dedicated gear-production machines, which use gear-milling tools in the form of hobs and disc cutters. For components having many features, including at least one gear element, there is an increasing trend toward 5-axis machines capable of multi-tasking. The ability to completly machine components in one or two setups, for quality and cost reasons, is a strong driver of change. The high-productive solution for large-volume batches normally involves the use of a solid or indexable-insert hob, either held at one end or using a driven-arbor head. To provide the versatility needed for small to medium batches in multi-task machines,

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case study: From complex to simple Helical-toothed drive shafts with gears, with module 6, DIN 867, having 39 gear teeth and a gear width of 2.8 inches in material 18CrNiMo7-6, were successfully completed using the following cutting data: InvoMilling cutter: 346

240212R4 Cutting speed:

820 ft/min Diameter: 4.9 in Feed per tooth:

0.011 in No. of teeth: 22 Feed rate: 13 ft (158 in)/min Indexable insert: MACL 3 250-T Spindle speed: 637 rpm complete machining time: 23 minutes

an innovative solution has now been developed by Sandvik Coromant. This method truly harnesses the flexibility available in multi-tasking machines – such as allowing the machining of different gear modules and sizes with the same cutting tool. The development builds on the success of recent advances in gear milling with Sandvik Coromant's new generation of indexable insert milling cutters, combined with broad experience in applying turn-milling to machine complex profiles. The result is a new process for machining external spur and helical gears on multi-task machines, the objective of which is to manufacture a range of gear profiles with only a minimum number of tools. This is achieved by making use of the simultaneous movements available with a 5-axis machine to generate the gear-tooth profile. The InvoMilling method is a combination of slot- and turn-milling, enabling the machining of gears with any module and helix angle, both involute- and noninvolute profiles. The number of cuts depends on the size of the gear, the size of the cutter and, as always,

InvoMilling takes full advantage of the flexibility offered by multi-tasking machines to produce a range of gear profiles with a minimum number of tools.

Machining of root and protuberance

Turn-milling of lower gear tooth profile

Slot milling Turn-milling of upper gear tooth profile

Finished tooth space

on the available machine power. The method makes use of modern machine controls and the high accuracy of multi-task machines as well as on the precision of the tool. Applying the latest developments in insert grades has also enabled higher cutting data to be applied. Chamfers on the outer diameter of the gear-tooth can also be incorporated, as well as different protuberance angles. Each InvoMilling tool covers several module sizes, where 1 to 4, for example, can be machined using the same cutter. The chip cross-sections involved in the method are comparatively small, minimizing cutting forces and vibration tendency. To date, the largest gearwheel milled using the InvoMilling method has a module 18 and a diameter of 32 inches. With the InvoMilling method, gear teeth with quality level 6, DIN 3962, or better can be achieved. Moreover, surface finish better than Rz 3 microns is achieved through the right application of tools in sufficiently rigid machines. n

Higher-quality gear teeth and an improved surface finish are achievable by using the PB053225.

Summary InvoMilling provides: • High flexibility and cost savings • One tool for different tooth profiles, modules and helix angles • Different grinding allowances can be generated • Dry cutting • Hard machining applications are possible • The whole component can be made in one setup, saving time and increasing precision • Standard inserts, easily indexed and set outside the machine • Low cutting forces enable high cutting data and ensure accurate profiles for closer tolerance ranges.


about bost bost is a machine-tool company based in Asteasu, in northern Spain, 12 miles from the Basque city of San Sebastián. The company specializes in heavy machinery such as vertical and horizontal lathes, rotary tables, drilling machines and boring machines as well as turnkey solutions for railways, crankshafts and cylinder manufacturers. Bost, which means “five” in the Basque language, is a family company. It was founded in 1972. The company’s revenues in 2011 were $32 million, and according to Karlos Aranbarri, Bost CEO and the son of one of the founders, 2012 is likely to be better, with a predicted revenues of $36 to $38 million. Bost has been steadily growing over the past five years, expanding its workforce from 74 to 112 and shifting focus to more international business. The company is currently looking to expand its operations in emerging markets and has a dedicated sales representative working exclusively to create business in Brazil and Russia. As China accounts for 50 percent of Bost's production, it has a Beijing office for sales and technical service.

A wind-turbine gear machined by Bost's VTL20C vertical lathe.

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text: simon hunter photo: markel redondo

farther horizons Asteasu, Spain. Spanish machine-tool manufacturer Bost is expanding its business into markets all over the globe. It’s found the global partner it needs in Sandvik Coromant.

nnn “When people think about Spain, they think about sun, the beach, flamenco,” says Karlos Aranbarri, the 30-year-old CEO of Bost, as he flips through a presentation of his company. “So we like to show them this photo of the factory in winter, all covered in snow.” The location of this machine-tool manufacturer in Asteasu, just over 10 miles from the charming city of San Sebastián in the rolling hills of Spain’s Basque Country, is about as far from the stereotype of the country as you can get. But then the northern part of Spain is markedly different from the rest, and not just due to its climate. This has long been the industrial heartland of the Iberian Peninsula, with a high concentration of Spain’s manufacturing and construction companies based in the region. Bost, a family company, will be celebrating its 40th anniversary in 2012. It offers a complete range of milling machines and lathes as well as turnkey solutions for railways, crankshafts and cylinder manufacturers. Despite the troubled Spanish economy, Bost is expanding, thanks to its focus on foreign markets, particularly emerging markets such as China. “We’ve always exported,” explains Aranbarri, “but not at the levels we do now. We sell some machines in Spain, but 90 percent of our product is for export.”

“Everything we sell is tailormade. We offer a complete solution, including the tool package and the training, to show the customer how to get the best out of the machine.”

Karlos Aranbarri, CEO, Bost

Bost already has an office up and running in Beijing and customers in Saudi Arabia, India, Russia, the United States, Poland, Germany, France and elsewhere. “We don’t just sell machines,” Aranbarri says.

“Everything we sell is tailor-made. We offer a complete solution, including the tool package and the training, to show the customer how to get the best out of the machine.” Currently under construction in the 85,000-squarefoot headquarters is a vertical lathe for a client in France, which, according to Aranbarri, is going to be the biggest machine tool ever manufactured in Spain. “The column, which is a single piece, was forged in Germany,” says Aranbarri. He explains that the machine weighs 90 tons, has a 26-foot table and a 33-foot swing and is designed for pieces weighing up to 385 tons. With its global focus Bost wanted a global partner, Aranbarri says. It turned to Sandvik Coromant. “I’ve spent my whole life working with Sandvik Coromant,” says Bost application manager Antonio Mangas, a 23-year veteran of the company. “But we have been working more intensely with Sandvik Coromant in the past few years, in particular in important turnkey projects such as crankshafts.” metalworking world 29

Continuous support from Sandvik Coromant engineers has been vital for Bost's success.

In some cases the end product could weigh anywhere from one to 24 tons. Bost needed tools from Sandvik Coromant that could work in difficult-to-reach areas with great precision and could accommodate the varying requirements of each job. Most recently, Bost’s partnership with Sandvik Coromant has been tied to a different vertical lathe, the VTL20C, created by Bost for Siemens for the manufacture of wind-turbine gears. “The aim is that when a piece enters the machine, it can be finished in one clamping, without having to be moved to another machine,” explains Aranbarri. “We have worked hand in hand with Sandvik Coromant from the beginning on this, mostly on the slot machining,” adds Mangas. “We used the Coromant Capto C6 system, and thanks to two special headstocks, we have been able to create the keyways with great precision. This is the advantage of this machine. We can create an internal slot without a Y axis just using two linear axes.” An added benefit for Bost is that once the machine is delivered to the customer, Sandvik Coromant will be there to offer support. “A machine tool is a very big investment for a customer,” says Mangas. “The return does not come back in a matter of months. It takes some years. But of course the benefits must be clear from the beginning. “The good thing about working with a big company like Sandvik Coromant is that you can find it all around the world,” he continues. “I have worked in a lot of countries on several different continents, and sometimes we need a fast solution. We prefer to work with companies like Sandvik Coromant that can help us quickly and get tools to us within 24 hours.”

Sandvik Coromant has also played an integral role with Bost’s máquina de casa – an in-house vertical lathe with a swing of 20 feet. It incorporates Sandvik Coromant’s Capto C10 system. “That machine is very different from what much of the competition offers,” explains Javier Guerra, Sandvik Coromant Customer Operations and Distribution Manager in Iberia. “When we started thinking about this machine more than two years ago, we decided we wanted to use just one system,” explains Mangas. “Most vertical lathes use two different systems. My idea was that if we had a new machine, with a robot for quick changes, we could use the same system for turning and milling. That’s why we thought about the Coromant Capto C10. It’s very strong for turning operations, but also very strong for milling.” The multimillion-dollar investment in the machine provides Bost with a test environment. It is also available for customers’ use. “It’s here for any company that wants to try something out,” Mangas says. “There aren’t many machines of this size in the area. We can’t sell this particular machine, but we can of course manufacture an identical model for a customer.” So visitors are welcome to check out the Bost máquina de casa any time they like; just watch out for the snow come wintertime. n

Sandvik Coromant Capto C10 system has had a major impact on turning and drilling jobs.

technical insight

teamwork works Teamwork is the focus for Sandvik Coromant

in Iberia, says the company’s customer operations and distribution manager, Javier Guerra. “It’s fundamental,” he says. To that end, Sandvik Coromant is involved in projects at Bost from their inception to ensure that the right tools, processes and time scales are determined from the start. “Often customers only think about price when they are in the planning stage,” says

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Guerra, “which means that when they get to the production phase, the time scales are much greater because they haven’t compared the full range of solutions. What we recommend is that they spend more time in the planning stage to ensure that production is faster.” Sandvik Coromant has worked hand in hand with Bost, supporting the manufacturer with time studies and analyzing the impact its products will have on the production process. With Sandvik Coromant’s global network, it can also be available to offer support on the customer’s end, wherever the customer might be located.

“That’s why teamwork is so important to us,” says Guerra. “We need to coordinate our work not just on a national level, but also on an international level. “We worked closely with Bost on the Coromant Capto system, bringing in a specialist from abroad to share our know-how about this tooling system as applied to crankshaft manufacturing,” he says. “That’s all part of the investment work that we do with our customers.”

A vertical lathe for a client in France, which will be the biggest machine tool ever manufactured in Spain.


technology text: turkka kulmala

Challenge: How to machine threaded holes economically and productively?

solution: Find a supplier of optimal tools and application knowledge for the highest productivity in a specific job or the best economy in mixed production.

Tapping into top taps The manufacture of holes and threads is a

critical aspect of modern technology. The production of threaded holes requires high quality in both the tapping process and the preceding holemaking stage. Even the best of taps cannot save a hole ruined by poor drilling. The key requirement for tapping a hole is accuracy – in other words, meeting the required locational, geometrical and surface finish tolerances. Any errors in position, circularity, straightness or cylindricity are difficult to compensate for during tapping. Factors affecting the drilling include the manufacturing tolerance of the drill, its sharpness and, obviously, the conditions: material, cooling, lubrication, stability and cutting data. As long as these requirements are met, the drill selection follows the conventional path, taking into account the workpiece, material and machine, and aiming at the best possible productivity and economy. Various standards, such as ISO 2306, give drill diameter recommendations for holes to be threaded. Using as large a drill size as

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The large tool assortment available guarantees hole accuracy.

possible within the tolerance range improves the machining economy and minimizes the risk of tap breakage. The drill should always be sharp to minimize work hardening of the hole walls. To eliminate any positioning errors, a hole is best drilled and tapped in the same machine with a single setup. This is usually also the most productive solution. The workpiece must be securely clamped to prevent

New level of productivity: Field test U.S. Material Alloy steel 28–32Rc Blind hole EX03P (M16 x 2.0) Thread depth 1xD 3,000

2,500

2,000

1,500

Number of holes

1,000

500

0

Competitor A vc=60 ft/min

any lateral movement, which can easily result in poor thread quality and even tap breakage. If drilling and tapping in separate settings is necessary, any slight misalignment between the machine spindle axis and the hole axis can be accounted for by a radially floating holder. Taps are selected according to criteria

similar to those for drills: the type of thread, required tolerances and workpiece material. The tap should always be sharp to have neat thread flanks. A fundamental choice is the balance between a dedicated tool for a specific application and a flexible tool for many types of work in varying materials. This is always a trade-off between the best productivity and the highest flexibility. Cold-forming (i.e., fluteless taps) requires a larger hole than conventional fluted taps. In relatively soft materials, a minor diameter lower than the hole diameter may be achieved, due to deformation of the hole walls during tapping. Countersinking the hole entry with a 90-degree tool makes it easier

for the tap to enter the hole and start cutting and minimizes burr formation. Smooth entry into the hole is important to avoid “bell mouthing” – a conical-shaped error at the entry into the hole. Cutting data must be selected carefully. The cutting speed should be significantly lower than in drilling. Selecting the correct feed is also important, particularly in synchronized tapping. When using a floating tap holder, the recommended feed is 95 to 97 percent of the tap pitch, to allow the tap to generate a thread with the correct pitch. Using a floating tap holder with a torque-limiting functionality such as SynchroFlex® is always recommended to ensure free axial movement of the tap and to protect the tap from breakage if it should “bottom” in a blind hole. The safety clutch must have a correct torque setting. Finally, using large amounts of cutting oil decreases friction and improves the surface finish. Coolant also enhances chip removal, which may be problematic in blind holes. n

CoroTap 370 P Vc=88 ft/min

Summary A successful tapping operation is based on a balanced, accurate process from drilling through to tapping, preferably in a single setup. The tools must comply with the material and conditions, focusing either on the best productivity or high flexibility. A torque-limiting tap holder is always recommended.

Drilling and tapping are areas of particular emphasis for Sandvik Coromant in 2012 and 2013. The CoroPak 12.1 catalog supplement features two extensive assortments of taps: the CoroTap family for maximum productivity in dedicated applications and the Spectrum range for mixed production in varying conditions.


innovation metals in electronics

text: Elaine McClarence photo: getty images

Metal bares its teeth in electronics As consumers look for ever better and more durable electronic products to feed their desire to manage their lives digitally while on the move, the electronics industry is turning to metal for solutions.

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innovation metals in electronics

‘‘

Market forecasts put the demand for digital tablets alone at almost 400 million units by 2015. In that short time some 250 new models of smart phones will be unleashed on world markets.”

The increased demand on mobile technology is encouraging manufacturers to rethink the materials used in the devices. Metals are becoming increasingly desirable for parts where wear resistance and robustness are key attributes. But, says Holst, “if metals are to compete with plastics and polymers and live up to consumer expectations, they have

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to help make electronic devices not only more long-lived but also more attractive.” The casing is the major component contributing to overall robustness. In choosing a casing material, several factors Aluminum and its alloys must be taken into account, represent a viable option. including noninterference with wireless functionality, temperature tolerance, the ability to withstand corrosion, ergonomics and high-quality sealing mechanisms to ensure that the device is water-resistant and that its environmental impact is minimized. Aluminum and its alloys are already making inroads in this area. One leading computer manufacturer set the standard when it launched a laptop with an aluminum casing less than 0.08 inches in depth. The unibody design covers both the main enclosure and the display, and the unibody construction offers a higher-precision, less-complex design with fewer parts. For the user this translates to a notebook that’s exceptionally thin and light yet durable enough to handle the rigors of everyday use. This same company was one of the first to launch computers with titanium casings for another of its laptop ranges. “Stainless steel is another material that is forecast to grow for use in a range of electronics goods, particularly in those parts such as on/off buttons that need greater wear resistance,” explains Bertil Isaksson, senior manager, application development, at Sandvik Coromant. In addition, companies are turning to more exotic alloys that combine aluminum, copper, titanium and nickel to provide the strength of a metal with Plastics have been the flexibility of a plastic. widely used in casings.

nnn Whatever name companies give to their latest mobile gadgets, consumers appear to have an insatiable desire to own them – and increasingly little compunction about putting them to rigorous use. The boom in consumer electronics use, combined with the higher expectations of gadget owners in terms of availability and durability, is driving manufacturers to employ novel materials such as metals. This in turn is creating demand for improved manufacturing processes to support higher productivity and better quality finishes. “Market forecasts put the demand for digital tablets alone at almost 400 million units by 2015,” says Magnus Holst, business developer at Sandvik Coromant. “In that short time some 250 new models of smart phones will be unleashed on world markets. Research shows that consumers are very active users of their devices, in a way that previous generations were not.” To ensure that people have constant access to the Internet, online shopping and digital books and games (as well as the ability to download applications and make and receive phone calls and text messages), designers realize that they need to make their electronic devices more robust, allowing them not only to function well but also to hold up despite continual use and abuse.

The right solution Tools help metal fight back

Demand for mobile technology has led to a rethinking of materials usage.

“In many respects, the material developments [such as titanium alloys] in aerospace provide an insight into the trends that will be followed by industries such as electronics a few years later,” says Isaksson. The use of carbon-fiber materials pioneered for military aircraft and exclusive sport equipment is also growing in the electronics industry. For consumer electronics manufacturers, the

challenge is not only to incorporate a broader use of materials in their products to meet performance criteria but also to make significant productivity improvements with existing capacity in order to meet

Within Sandvik Coromant, research and development is increasingly focusing on providing tooling solutions for the electronics industry. The company’s long experience in providing engineering solutions helps manufacturers raise their productivity by offering increased parts production per tool, reducing the number of operations and machine cycle time and increasing component quality. During its 50 years in the manufacturing industry, Sandvik Coromant has developed a broad range of tooling solutions, including those that support reduced lead times and cost-cutting in the production of stamping dies, forging dies and die-casting dies for the sheet-metal forming widely used in electronics. These tooling solutions can be delivered in a number of ways, through direct contact with Sandvik Coromant engineers or, for complex components, via one of the company’s dedicated Application Centers that are positioned around the globe.

high-demand forecasts in a competitive way. At the same time, manufacturers need to maintain final product quality to live up to customer expectations. “Plastics and polymers have been the key casing materials in electronic products, so many contractors have yet to apply optimized manufacturing processes for the new metal components to meet market requirements,” says Holst. While most contractors are equipped with sophisticated production machinery such as 3-axis machining centers, the implementation of modern milling methods and specific processes such as turn-milling developed over the past few years can deliver considerable productivity, cost and quality benefits. n metalworking world 37

total solution text: TURKKA KULMALA

Vertical renaissance The vertical turning lathe (VTL) is a time-honored solution for turning large, heavy and/or asymmetric workpieces. While always an efficient machine tool, it has been hampered by poor utility rates, due to lengthy tool changes and setups. Increased demand from industries such as energy and aerospace has pressed the need to remedy these problems. New technologies are now catalyzing the evolution of VTL to a truly multifunctional manufacturing with extensive possibilities for multi-axis operations — including drilling, milling and gear hobbing — with less need to move large, heavy components back and forth between different machines.

Boring head

Main milling spindle with cover plate

Turning head

90° head

Versatility’s the key Multiple heads

A key to the versatility of a modern VTL is its ability to accept many different types of toolholder systems on the end of the vertical ram. Hydraulic four-corner clamping or curvic coupling securely holds turning, boring and 90° milling heads with the main milling spindle permanently in the end of the ram. The attachments are changed automatically and stored in the tool magazine, much like individual tools.

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Want to learn more ? Visit www.sandvik.coromant.com/us

Attachment magazine

Tool magazine

RAM without attachment. Four-corner clamping and main milling spindle.

Time saver

A firm grip

Stable choice

The commonly known benefits of an ATC come into play in VTLs as well: minimum downtime and possibilities for tool presetting and unmanned production. Traditional disc magazines are increasingly being replaced by larger chain-type magazines. The advantages of ATC can be further enhanced by standardizing all tools with a single type of coupling, such as Coromant Capto (sizes C6, C8 and C10).

The structure of a VTL is based on one or in large machines two vertical columns carrying the horizontal slideway (X axis) that provides crosswise movement for the vertical ram (Z axis). Rigidity in terms of the ratio of ram deflection to its extension is crucial in matching the high power capability of the turning table.

The modular CoroTurn SL70 blade and adapter system is a standard solution for most profiling and pocketing operations in complex components, often eliminating the need for special or modified tools. The strong oval coupling provides high stability and accessibility in confined workpieces. The possibility of a high-pressure coolant supply is a standard feature in these tools.

automatic tool changer

Vertical ram

CoroTurn SL70


Long overhang - optimizing

Hobbing technique

Grooving trochoidal turning

Ceramic milling in super alloy

Plunge milling

Insert geometry

Milling cutter pitches

Helical interpolation

Milling cutter maintenance

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Gearmilling of windmill slewing

Deep hole machining

Roll in technique in milling

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45 degree entering angle in...

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High pressure coolant