Metalworking World 2/2014

W s W ar M ye 10

2/14

a business and technology magazine from sandvik coromant

innovation:

Ideas on wheels

Gone in

2 seconds The secret behind the success of the Infiniti Red Bull Formula 1 racing team is teamwork and attention to detail.

Automatic magic Tech How much has changed? usa Big savings - big smiles Tech Deep down solutions Tech New grade beats all China Working 25/7 Tech Fine-tuned transmission the netherlands

editorial klas forsström president sandvik coromant

Prepared for transition Australia has undergone a huge industrial

transformation in the past decades. Rather than depend on the declining auto industry, many Australian companies are now focusing on aerospace. Although the Australian aerospace segment is still relatively small compared with the auto industry, it comprises some 800 companies and 14,000 employees, and the annual revenue for the industry is more than $4 billion and rising. I wanted to see the transition for myself. Thus, during a recent trip to Australia, I visited several of our aerospace customers. Some had seen the shift coming and began preparing for it as early as the 1980s; others are undergoing the move now. One of our customers is responsible for manufacturing the wing segments for all Boeing Dreamliner airplanes produced globally. This once again confirmed just how global many of our customers are or have to prepare to be. The Australian aerospace industry is geographically well positioned to supply the Asia-Pacific region, which is forecast to become a center of major aviation growth. The large industrial transition I witnessed in Australia confirmed my belief in the significance of being able to adapt and conform to new situations and challenges. This is true for Sandvik Coromant as well. As the aerospace industry has increasingly turned to composite materials for use in airplane bodies, we as a company have had to create new tools and new methods – for example, orbital drilling – to work with these complex materials. We have had to apply our knowledge from other industries to support the aerospace industry as it breaks new ground. The transition in Australia from automotive to aerospace is impressive, in particular the

2

metalworking world

courage and determination companies have shown in making the shift. We are likely to see this need to adapt in other areas in the future. What innovations will the use of lighter materials and rising fuel prices generate? And how will environmental regulations and the need for clean fuel affect the automotive industry and its infrastructure? Whether it’s the small details or the larger landscape – a new technique for hole-making or stricter regulations – we can be sure change will occur. The question is, are you prepared for the transition? Pleasant reading.

klas forsström President Sandvik Coromant

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 responsible under Swedish publishing law: Björn Roodzandt. Editorin-chief: Mats Söderström. Account executive: Christina Hoffmann. Editor: Henrik Emilson. Art director: Niklas Thulin. Technical editors: Börje Ahnlén, Martin Brunnander. Sub editor: Valerie Mindel. Coordinator: Lianne Mills. Language coordination: Sergio Tenconi. Layout, language editions: Louise Holpp. Prepress: Markus Dahlstedt. Cover photo: Mark Thompson. 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, Rosenlundsgatan 40, 118 53 Stockholm, Sweden. Phone: +46 (8) 442 96 20. Distribution inquiries: Kristy Follett, Sandvik Coromant US. Email: [email protected] Coromant Capto, CoroMill, CoroCut, CoroPlex, CoroTurn, CoroThread, CoroDrill, CoroBore, CoroGrip, AutoTAS, GC, Silent Tools, iLock and Inveio are all registered trademarks of 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 metalworking world #2 2011

31

The Netherlands: Coromant Capto made unmanned 24/7 production possible

10

A patented new technique puts Voith Turbo on the map.

9

22

USA: The new GC4325 insert gave Infinity Machine Works its edge

China: Boosting crankshaft production for Changan Automobile

4

Profile:

5

Quicktime:

7

Riding on the wind:

8

Your own personal airline News from around the world Sustainable shipping solutions

Profile:

Emily Cummins on her smart refrigerator

28

Inspiration:

38

Final Note:

The secret to Red Bull's Formula 1 success is teamwork

16

Celebrating the best metalworking magazine in the world

Innovation: Skateboards, a company's work with innovation, and Tony Hawk

Technology Transmission in transition

How much has changed?

Creating unique new insert surfaces

Specialist tooling for tough environments

The shortening life cycles of vehicle models, and along with them transmission components, are necessitating faster lead times and lower production costs.

At first glance it might seem that the technology for cutting and holding tools remains the same in the solid round tools area, but the area has undergone fundamental changes.

A new breakthrough in tool material science with the Inveio coating technology has resulted in a unique new steel-turning insert that optimizes the large ISO P25 application area.

Meeting the demand for large, complex components from the oil and gas industry.

14

20

26

36

metalworking world 3

Quicktime text: Henrik emilson

photo: Lee Howell

Learning to fly As with many inventions, it started in a garage. This time the garage was in Christchurch, New Zealand, and belonged to Glenn Martin. His invention was a response to a personal jetpack with a one-minute flight-time limit. Martin figured he could do better. That was in 1981. In 2005, after a number of attempts and back-to-the-drawing-board moments as well as a search for sponsors, his jetpack took off, with his wife, Vanessa, as test pilot. Today the Martin Jetpack has blossomed into an impressive reality. The airframe has been developed using the latest composite technologies and materials. Each component or assembly has

been engineered to be lightweight, strong and rigid to meet the unique demands of the 400-pound jetpack. The personal flight system has a range of 20 miles and can carry a payload of 220 pounds, with a recommended cruising height of about 500 feet. Martin’s venture, the Martin Air Company, aims to launch its first product in mid-2014. The product, the First Responder Jetpack, is targeted at fire services, search and rescue teams, border security, beach lifeguards and other emergency services that work to save lives. n

Want to go for a ride?

The Jetpack comes with a rapid-opening parachute system.

Watch the jetpack in action on the ipad

4

metalworking world

Quicktime

mini trio race

Petronas Towers, with its mere 1,483 feet.

automotive – If you are planning to drive between Turin and Trento, Italy, at the end of October, keep an extra eye on the road. This is the route of the Italian Job rally, which means a lot of Mini cars will be cruising the scenic stretch. The Italian Job is the 1969 Michael Caine heist movie, where the small cars are used to steal a shipment of gold by creating a traffic jam on the streets of Turin (the film was remade in an American version in 2003, in which Minis also played a vital part in another heist). The rally was launched in 1990 for fun as an “adventure holiday on four wheels” and as a way to raise money for children’s charities. The race is open to anyone over the age of 21 who drives a Mini or another car featured in the 1969 film – a Jaguar E-type, Aston Martin DB4 or Fiat Dino Coupe. The Manufacturing Technology Centre in Coventry, England, has three groups of students entering the race as part of a student project. During the year they will buy, build and repair their cars and compete in the rally. Sandvik Coromant is sponsoring the trio of cars, aptly named Mike, Tango and Charlie (MTC). Watch for more coverage of the Mini trio and the race in Metalworking World. n the number:

The screw comes with software for analysis of gathered data.

1,601 Length of the Prelude FLNG hull, in feet. The ship, which is being assembled at Samsung Heavy Industries’ Geoje shipyard in South Korea, will be the largest floating vessel ever constructed. It will be the world’s first floating platform for condensing natural gas and is destined for a natural gas field off the coast of Australia.

did you know?

African winds

Turn of the screw automation – An age-old engineering problem: How do you precisely measure the forces that act between two components inside a machine? The solution: Use a screw with an integrated sensor, say researchers at the Technische Universität Darmstadt in Germany. Attaching sensors can be problematic. Adhesive compounds dissolve easily in harsh real-world environments, and

externally mounted sensors pick up information from outside the machine. The sensor screw can be located exactly where readings must be taken, improving precision. It can also be screwed on to the component for readings throughout the production chain, instead of just in the final stage. The screw, under development, is called ConSenses and is expected to be marketable soon. n

New energy – Ethiopia’s Ashegoda Wind Farm recently opened with 84 wind towers, making it the largest wind farm in Africa. The wind farm is one part of an ambitious plan to diversify the country’s energy resources and reduce blackouts as well as to export energy to seven neighboring countries.


Quicktime

Hard cases

Composites – American design duo Exovault has seen how smartphones have become a more integrated part of our daily lives, and also how users are demanding phones that are more personal. Handmade cases in composite materials, such as combinations of pau ferro wood, goldplated brass, titanium and phenolic resin fiber composites, give the cases the unique look that many are after. “In our art we work a lot with older tools and equipment – things from old hot rods and hoop dresses,” says designer Amelia Biewald. “Metalwork is something that we are very comfortable with. Using rosewood accents in a lot of the pieces is suggestive of old brass and rosewood hand tools. And really, the iPhone is just the hand tool of the 21st century – the thing you use to get other things done.” n

Mats Söderström

editor in chief of Metalworking World. Q: Metalworking World celebrates 10 years in its current shape and form in 2014. What is the secret behind this successful publication?

I think the mix of technical details and the bigger picture of global trends is appealing to our readers. We know that the technical articles are particularly popular and that our innovation articles provide an interesting insight into the world of R&D. Personally I also like the attractive layout, which is simple and easy to browse, with high-quality pictures. Often it’s the pictures that tell a big part of the story.

watch a video about Exovault on your iPad.

Q: The magazine also exists as an awardwinning iPad app. Why iPad, and can we expect other technical platforms ahead?

Fill ’er up Automotive – After more than a decade in development, the Hyundai ix35 Fuel Cell has been launched commercially worldwide. In 2013, the hydrogen-powered car was introduced on a small scale in Europe. The city of Copenhagen, for example, bought 15 H2 SUVs for its municipal fleet, to help meet its carbon-neutral goals. The

Hello there…

Danish capital also opened the country’s first hydrogen refueling station, which was built in just 48 hours. The hydrogen cars have a range of about 370 miles and take about three minutes to refill. Honda, Toyota, Chrysler, General Motors and Ford also plan to introduce fuel-cell cars before 2016. n

Its only exhuast is water vapor.

As a company we strive to be where our customers want us to be, and that also goes for Metalworking World. Our ambition is that you should be able to read it wherever and whenever you want. That’s why we constantly look for new ways of reaching out. With digital versions we have the opportunity to offer the reader extra material in the form of videos, animations and interactive features. Q: What is your vision for the next 10 years?

Digital will of course play an even bigger part in the future of the magazine. Integrating the content of the magazine with the total offering online will make the reader experience even more valuable. Video and interactive media will play a bigger role in our storytelling moving forward. I know one thing for sure: The coming 10 years will be very exciting for manufacturing. Our ambition is to keep telling the most interesting stories from the metalworking industry.

-------------------------------------Have you seen the Metalworking World app?

Like the magazine, it’s free. Check out the Download section on www.sandvik.coromant.com

6

metalworking world

Quicktime text: HENRIK EMILSON

ILLUSTRATION: Niklas thulin

Modern shipping – With rising oil prices and the need to reduce emissions, sustainable shipping depends on the use of energy from renewable sources. But shipping companies don’t have to look far for solutions. Apart from traditional sailing vessels, there are several techniques to harvest wind to help drive the ships. One is to use large towing kites that fly at altitudes of 660 feet. These generate 25 times more energy per square foot than conventional sails. The output amounts to a 20 percent reduction in fuel use. Another is to use the actual ship as a sail. This is the innovation of a Norwegian company’s Vindskip (Windship). Its hull is shaped like a giant airfoil, which harnesses a force akin to aerodynamic lift that pulls the ship along. In the right conditions it could produce fuel savings of up to 60 percent and reduce emissions by 80 percent. While solar power can be used on smaller boats, the amount of fuel saved on larger ships through the use of solar panels has been relatively small. By combining wind and sun in “sun sails,” solar panels can act as rigid sails, potentially making a powerful contribution to the ship’s propulsion. The E/S Orcelle – the E/S stands for “environmentally sound ship” – takes the use of alternative energy sources to the limit by combining fuel cells, wind, solar and wave power. Now, why didn’t anyone think of harnessing the waves before? The ocean is literally filled with them. n

The vindskip

The hull functions as a sail.

660 ft Maximum power

Kites are up to three times more efficient than fixed sails. Wind strength increases with altitude.

490 ft

330 ft

165 ft


Quicktime text: Henrik emilson

photo: emily cummins Design philosophy.

A cool invention When she was 4 years old she received a hammer from her granddad, who taught her to make toys from scraps of materials she found in the garden shed. Now, 23 years later, British innovator Emily Cummins is focusing her efforts on sustainable designs that change lives. She has learned about the properties of different materials and is experienced using a range of tools. Her latest innovation is a sustainable fridge that is “powered” by dirty water but keeps medicines and small food items clean, dry and cool. The prototype consists of two metallic cylinders, one inside the other, between a locally sourced material such as sand or wool that is packed tightly before being soaked in water. When the fridge is placed in a warm environment, the sun’s energy causes the outer part of the fridge to “sweat”; the heat energy is transferred away from the inner cylinder, which becomes cooler. Unlike other pot-in-pot coolers, the contents are kept dry and hygienic, since the water is kept separate from the product. “I refined my fridge during a gap year in Namibia and then decided to give away the design plans in townships across southern Africa because I wanted to enable as many people as possible to build their own fridges,” Cummins says.n

8

metalworking world

Emily Cummins’ design approach is back-to-basics with an eye on the future.

text: Alexandra Leyton Photo: James Wasserman

Working 25/7 Chongqing, China. Fast-growing

Chinese car brand Changan is expanding its capacity, with Sandvik Coromant as major supplier of tools.

[1] The engine is the “heart” of a car – and the crankshaft directly affects the vehicle’s efficiency and performance. [2] Quality control of the crankshaft is of utmost importance.

Changan Automobile

has nearly 60,000 employees and an annual capacity of 2.3 million vehicles and 2.3 million engines. Company headquarters are in Chongqing, a major city in the west of China. The company has a large network that includes eight major production bases in Chongqing, Beijing, Hebei, Jiangsu, Anhui, Jiangxi, Zhejiang and Guangdong provinces, three overseas production bases and 27 vehicle factories. Changan Automobile also operates joint ventures with Suzuki, Ford, Mazda and PSA (Peugeot Citroën). Its main products include passenger cars in all series, mini commercial cars, light trucks, minivans, midsize coaches and engines for all series.

10

metalworking world

[1] [2]

[3]

[3] In order to expand production, Changan has since 2011 worked closely with partners MAG and Sandvik Coromant.

nnn Changan Automobile is one of the fastest-growing car manufacturers in China. The company’s CS35 model, launched in 2012, is a popular SUV on the Chinese market, and the Changan Eado XT hatchback, introduced in 2013, is already gaining major market share. To expand its production capacity and meet the challenges that currently face automobile manufacturers, Changan Automobile is working with MAG, a global machine-tool manufacturer, in partnership with Sandvik Coromant. “As everyone knows, the car engine is the heart of the car,” says Zhou Jingxi, director of the Manufacturing Project Department at Jiangbei Engine Plant of Changan Automobile. “To create a first-class vision for Changan Automobile we needed to invest in the construction of the type EA-series and H-series crankshafts. The current demand in the automotive industry is that the production line and construction needs must adhere to international standards. “The crankshaft directly affects the vehicle’s engine efficiency and performance,” he continues. “The machining process, machining equipment and quality control must produce the performance required for every crankshaft that is produced in the production line. This part of the vehicle has always been closely tied to the development of the automobile and creates significant challenges in the production process.” Zhou considers MAG to be one of the leading companies in machine-tool manufacturing: “We chose to cooperate with MAG based on its efficient execution, after-sales service and previous successful experience in the production process,” he explains. WHEN THE PROJECT STARTED in May 2011, MAG contacted Sandvik Coromant’s Center of Competence in the German city of Düsseldorf for support in fitting the four new crankshaft production lines, making Sandvik Coromant the main supplier of tools. “The reason why we agreed to engage Sandvik Coromant is entirely thanks to the company’s long-term unrelenting investment in new technology,” says Pu Shi, technical department director, Jiangbei Engine Plant of Changan Automobile. “Sandvik Coromant has won over the market and its customers’ recognition with its superior

[1] Stephen Zhou, senior productivity improvement engineer at Sandvik Coromant, with Pu Shi of Changan Automobile.

[3] Changan Automobile has a three-step strategy to achieve its goals for the next six years.

[2] Changan Automobile’s company mission statement is “Lead automotive civilization and benefit human life.”

reputation globally. It is Changan’s vision to cooperate with the very best companies, and Sandvik Coromant is the world’s leading supplier of tools, tooling solutions and manufacturing. For us it was a win-win decision.” He points out that Sandvik Coromant provides a unique

set of products, technology and solutions. It also fulfills strict quality-control procedures and delivers on time. “They are totally committed to the customer,” Pu says. “I found such words on their home page: What if you had a 25th hour? The idea is to create value through superior service and leadership in the field of metalcutting and by providing clients with innovative ideas that really do save the extra hour. Combined with our own mission statement, ‘Lead automotive civilization and benefit human life,’ we believe we share the same values and vision as Sandvik Coromant.” According to Tu Ling, head of the manufacturing logistics planning department, even if the project schedule was tight, Sandvik Coromant’s investment in R&D, which is twice the average amount in the industry, led to the favorable outcome and high efficiency. “We hope the company continues to optimize and improve,” Tu says. “Sandvik Coromant always puts its customers first. The support we received on site allowed us to identify problems quickly, analyze the situation and develop a solution. This ability to solve problems reflects the quality of the product itself, along with efficient after-sales service.”

[1] [2]

[3]

In 2013, Changan Automobile manufactured more than

2.12 million passenger cars. The production and sales of its self-owned car brands reached 380,000. The company enjoyed 66 percent year-on-year growth, a Chinese industry first. “This gave the Chinese car industry a vital boost on the global stage,” says Du Zijian, vice factory director of the Changan Jiangbei Engine Plant. “People see the future in Chinese cars. The industry is starting to wake up to China. Changan’s rapid rise to success is a result of partnerships with major enterprises such as Sandvik Coromant. “Initially, 10 years ago, Changan’s cooperation with Sandvik Coromant aimed to provide support for rod connections, effectively machining cylinder heads and


[1]

“Together we face many challenges, such as improving efficiency and lowering cost of the production line, and car upgrading.”

[2] [3]

[1] One Chinese proverb says “It’s hard to find a friend that knows you well,” but once you do success is at hand. [2] Last year Changan manufactured 2.12 million passenger cars.

[3] Changan’s goal for 2020 is to grow to three times its present capacity. [4] Sandvik Coromant provides a full range of training on cutting tools, helping Changan to meet the demands of development and the challenges of the market. [4]

Zhou Jingxi, manufacturing project department director, Jiangbei Engine Plant of Chongqing Changan Automobile

supporting us with tools for machining crankshafts,” says Du. “Our companies have now developed a collaborative partnership that develops total solutions for the automobile industry. The production efficiency and quality assurance this tested partnership brings is born out of many years of mutual respect and a deep understanding of each other’s business. Ultimately we trust each other.” CHANGAN automobile HAS set up a goal to achieve growth

three times its present capacity by 2020. The goal also includes upgrades of the competence, quality and brand. Changan Automobile hopes Sandvik Coromant can provide even stronger technical support to help it achieve the goals. Changan Automobile continues to innovate in partnership with Sandvik Coromant on the journey to create a first-class automobile manufacturer. “Together we face many challenges, such as improving efficiency and lowering cost of the production line, and car upgrading,” according to Zhou. “Sandvik Coromant will help Changan Automobile to build a world-class brand,” he says. “Cooperation is the way to go in the future. A friend [like Sandvik Coromant] is hard to find.” n

12

metalworking world

technical insight

Four new production lines were set up to manufacture 200,000 crankshafts.

Chongqing Changan Automobile ordered four new crankshaft production lines

with a total of 76 machines including the supply of tools for production of 200,000 crankshafts at the starting stage of the production line construction. Sandvik Coromant was sole tools supplier and thus responsible for the total tooling and engineering solutions. It’s a large project that gets support from both China and other organizations within Sandvik Coromant across the world. The huge challenges of the project include the large variety of different methods and operations of manufacturing and the tight schedule. In addition to general applications such as turn-turn broaching of flange ends, post-end and main bearings, the customer also needed special tooling and external milling of pin bearings, specific tapping operations and deep-hole drilling. The timing of this project was also very strict, with only seven weeks between receipt of the order and the first delivery.


technology text: turkka kulmala

image: borgs

The automotive industry is up against huge challenges. Environmental concerns and soaring fuel prices are shifting demand to smaller, lighter, greener and more economical vehicles. The shortening life cycles of vehicle models, and along with them transmission components, are necessitating faster lead times and lower production costs.

Transmission in transition

Transmission components are high-volume products

that above all need to be made at a low unit cost, but there are also other requirements such as high process security, short cycle times and consistent quality that are critical in achieving faster lead times and lower production costs. Alloyed case-hardened steel is the traditional raw material for transmission components. The steel is typically heat-treated to have a hard surface layer on top of a tough core. Up-and-coming future alternatives include powder metals and induction-hardened low-carbon steel grades. Sandvik Coromant helps the industry to deliver top-quality components as well as to reduce total production costs and lead times. n

14

metalworking world

CoroTurn TR The precise and secure iLock T-rail locking surfaces of CoroTurn TR holders provide maximum accuracy and repeatability for positive inserts and prevent any insert movement in order to achieve close tolerances. Both carbide and CBN grades are available to enable profiling operations in a soft as well as a hard state.

Coromant Capto and RC Good stability, fundamental to any productive turning operation, is crucial for slender, vibration-sensitive and complex transmission components. The modular Coromant Capto holders and the CoroTurn RC insert clamping system for negative inserts deliver the stability, repeatability and security required to avoid vibrations and to get the right component quality.

CoroDrill 460 This versatile range of solid carbide drills and tailor-made options offers high productivity and consistent tool life as well as exceptional economy for the drilling of oil holes.

CoroCut The precise rail-shaped insert seats of the CoroCut 1-2 tools updated with a rigid patented spring clamping mechanism team up with CBN-tipped inserts in the GE geometry to offer a productive and secure solution for seal and lock ring grooves, particularly for the interrupted cuts of hardened splined shaft ends. Hard-part turning Hard-part turning (HPT) is a competitive alternative for the grinding of hardened components, thanks to a simpler process, lower costs, shorter lead times and higher sustainability due to the elimination of coolant and grinding waste. Sandvik Coromant’s strong HPT solutions include the CBN grades CB7015 and CB7025 with optimized edge preparations.

Soft-stage turning The new Sandvik Coromant carbide grades GC4315 and GC4325 with the Inveio coating technology enable higher cutting data without sacrificing component quality. If the spindle speed limit prevents the full use of their excellent hot hardness, maximum productivity can be achieved by higher feed rates instead. Wiper-style inserts still provide the required surface finish. If using higher cutting data is not needed or possible, a much longer tool life can be expected.

Summary While the machining of automotive transmission components depends on a low cost per component, a secure process, surface integrity and effective chip control are also vital requirements. Sandvik Coromant supports the automotive industry with new technologies and machining processes and offers productive, economical solutions for the entire process from soft-stage turning to hard-part turning, including grooving operations.


text: Henrik Emilson

Keep on trucking! Innovation. A skateboard consists of just three parts – wheels, board

and trucks. Still, this simple device is a constant source of development, in many ways similar to how a company works with its ideas. Metalworking World talked about innovation and skateboards with Sandvik Coromant’s innovation group and skateboard superstar Tony Hawk.

16

metalworking world

“There is no such thing as a bad idea, since you can learn as much from a mistake as a success.” nnn Recently, Sandvik Coromant in the United States and China collaborated with partners in a large customer event, the 2013 International Machining Competence Development program. Skateboards played a vital role. The actual workpiece for the event was a skateboard truck (the metal assembly that holds the wheels to the board), which the customers were to manufacture. The trucks were complex enough for the group to handle, with the instructions from truck manufacturer Rey Trucks, who provided the basis for the machining design. In addition, Sandvik Coromant application and industry specialist Jason Hout held a seminar on best practices in metalcutting, with a specific discussion on the technical aspects of machining aluminum, as well as direct hands-on instruction at the machines to provide the best learning experience for the group. He was joined by senior project leader JoAnn Mitchell, who held a seminar on manufacturing economics and process analysis. In many ways, the customer event epitomizes how Sandvik Coromant works with ideas and drives innovation. Accumulated knowledge is mixed with new ideas and techniques for methods, products and materials, combined with economic considerations. But an idea doesn’t become an innovation until it has spread – either as a product on the market or as knowledge, such as the seminars at the event for the seven major manufacturing organizations in China. Anna Karlsson, research engineer and innovation leader in the company’s innovation group, describes the group’s model. “We define an innovation as an idea that can be tested and implemented to create market value,” she says. The original idea behind the skateboard has similarities to the

innovation group’s philosophy. Innovation comes from an idea that might or might not work but compels you to try. “Like with skateboards,” explains Karlsson. “It was the surfers in California who thought, when the waves were down, ‘Man, we can’t surf, but if we put wheels on our boards we might be able to surf on the streets.’” The innovation group operates on the same “get an idea and test it” model. The group comprises four people, from both research and development and product management, whose task is to support individuals, departments and organizations with ways of working and methods to benefit innovation. “We work in cooperation with our customers, and when they need something we get going and create an innovative solution that is useful for them and that we can then take to market,” says Stefan Hedström, product portfolio manager.

Sandvik Coromant adapts to trends, gathering ideas and feedback from the sales organization, which is in daily contact with customers. This input is combined with intelligence and analysis from both the industry and global movements. Sometimes a market need develops suddenly. “After the accident in Fukushima, Japanese companies were told to save energy,” Karlsson recalls. “We were asked to develop tooling solutions that use less energy. These signals from Japanese companies indicated new demands.” And thus, from need springs innovation. Innovation can be as much about an object as a method. The innovation group and the company experts spend considerable time on specific components that are important to the customers, to develop the best methods for manufacturing them. The findings and knowledge are then shared through events such as the International Machining Competency Development program, or in Productivity Centers and in training courses. Sometimes the method itself becomes a product, Karlsson explains, citing InvoMilling as an example. “In 2009 we invested in gear milling, a new area for us,” she says. “After studying how gear milling works, we launched InvoMilling, which is a new method packaged as software. Instead of only supplying gear mills, we also supplied software that allows the customer to use the tools in a more flexible way.” The innovation group is constantly exploring new ideas. Marianne

Sjölund Olsson, communications officer and innovation leader in the innovation group, explains that an important part of this is engaging staff members and having open communication and methods for how ideas are handled. Ideas and innovation are created throughout the organization, she explains, not just within R&D. It is important to have an environment that is open and allows rules to be broken. “There is no such thing as a bad idea, since you can learn as much from a mistake as a success,” Olsson says. “We have to dare to invest in ideas that are a little bit mad, where you don’t know if they will come to anything. We also want to develop ideas that are outside our core business.” At the end of the week-long customer event in the U.S. and China, the trucks were mounted on skateboards and were tried and tested. No one got hurt. n


Can you remember your first board? “My first one was a blue fiberglass board. This was in 1977, and I was 9 years old. It was plain and simple and had something similar to rollerblade wheels on it.”

The Hawk man has landed Tony Hawk, one of the biggest stars in skateboarding, talks about the development of the board and the future of the sport. text: Marcus Joons

photo: Daniel Månsson

nnn At 14 Tony Hawk wasn’t much to look at. With a long blond fringe and matchstick legs, the Southern California boy looked like Macaulay Culkin in Home Alone rather than the “cool” skateboarders and their followers. But for Hawk it was never about being the coolest on the block. The only thing that counted was being the world’s best skateboarder – jumping highest, doing the most tricks and executing the most aerial turns in a single run. And in fact, he was the first rider in the world to nail the 900 (two-and-a-half turns in the air), at the 1999 X-Games. Now, at 45, Hawk still skates several hours every day, runs his own skating company, Birdhouse, does exhibition skateboarding around the world – PR for his company and everything else he has licensed his name to – and generates some $200 million annually. Hawk says his early years as a skateboarder were less than idyllic. For one thing, he was disliked for his technically perfect style. “They used to call me ‘Robot,’” Hawk recalls. “The cool Northern California guys around [skateboard legend] Christian Hosoi certainly didn’t like that I, who didn’t look like a rock star, ran off with all the trophies.” Hawk now lives in a palatial house in Encinitas outside his hometown of San Diego. Here he’s built a private skate park next to the pool. What was the secret to his skateboard success? Early on, Hawk says, he stopped worrying about his idols. As soon as he learned the basic tricks, he focused on new tricks – ones that no one had seen. “Even though my father was head of the then newly started National Skateboard Association, we never talked about skateboard during our dinners,” Hawk says. “Because we never had any. I was always in the park learning new tricks, and I kept my energy up with [energy] bars.”

18

metalworking world

And then? How have they changed? “Well, it depends on whether you look at vert [skating on a curved ramp that becomes vertical at the top, a practice that originated in empty backyard swimming pools in the 1970s] or freestyle. Vert, as pool riding was called, came back in the form of ramp riding back in the ’80s, and boards got wide again, up to 9 inches wide. They had big concaves, upturned noses, with a lot more tricks being done than in the late ’70s, so the upturned nose stayed on those boards. Then with vert really dying down and street skating going crazy, which is still where we’re at right now, the boards have gotten down even narrower than what was called a freestyle board back in the late ’70s. These boards are 7 1/2 to 7 3/4 inches wide, with a big upturned nose, big tail and a lot of concave, varying in thickness from 3/8 inch to 420/1000.” Hawk says his innovative style comes not only from constantly developing new tricks but also from embracing adversity. He views his setbacks as learning experiences rather than impediments. “For instance,” he says, “breaking my pelvis was definitely a learning experience, and I got through it. Something like that teaches me that I can persevere.”

What do you think skateboards will look like in the future? “That’s hard to say. I’ve tried many different boards in different lighter materials, without finding one that is better than the ones we have right now. There’s something about wood that you can’t take away. I think the sport has come very far. Just look at this 16-year-old kid Mitchie Brusco, who completed a 1080 [a triple turn] at the Big Air at the X-Games last year.” How did you react when he got it? “Well, I can show you on YouTube,” he says. We go into his office where his X-Games medals – nine golds, three silvers and two bronzes – hang framed on the wall. Hawk launches a video that shows him on-site as a commentator for the competition. After Brusco does his trick, Hawk reappears in the picture, looking even more pleased than when he did his own 900. “I’m just so happy when I see that skateboarding naturally evolves into the future,” he says. “I love when new skaters don’t try to imitate but instead, like me, try to complete tricks that no one else before them has completed.” n

Evolution of an invention 1950s Surfers put rollerskate wheels on a board or box and “surf” the streets.

1978 Alan “Ollie” Gelfland invents the “The Ollie,” a now-common trick that revolutionized skateboarding.

1980s Street skating takes over from skateparks and “vert” (pool riding), changing the shape of the board to wider.

1960s The new sport peaks in popularity with many companies and riders, only to die down in 1965.

1970s The invention of urethane wheels in 1972 helps skateboarding make a comeback, and skateparks become popular.

1975 When the ball bearings were put inside each side of the wheel it meant they could go a lot faster and lasted longer. Since the introduction of urethane and sealed bearings, the construction of the wheels has basically remained the same.

The boards become “concave” with upturned tail and nose, making them stronger and giving the rider more control of the board.

1999 Tony Hawk performs the first-ever documented 900, 2.5 mid-air revolutions, becoming a legend. Mitchie Brusco tops the feat in 2013.

1990s Wheels become smaller, aiding in faster board rotation in flip tricks.

1990s In 1995 American sports channel ESPN holds the first X Games, bringing skateboarding to mainstream audiences.

2000s Skateboarding becomes mainstream, and professionals make money from the sport. Videogames, music and YouTube videos play a big part in inspiring the talent of tomorrow, and new boards are constantly being developed, such as the OneWheel prototype.


technology text: christer richt

How much has changed? At first glance it might seem that the technology for cutting and holding tools remains the same in the solid round tools area. Francis Richt, line and business manager responsible for product management of solid round tools, and Jenny Claus, product manager of chucks, answer the question “How much has really changed?”

20

metalworking world

The solid round tools product and application area covers the drilling, tapping and reaming of holes with diameters of less than 20 millimeters [0.8 inch] as well as the milling of small component features using solid-carbide tools in high-speed applications. This is a large and growing area with its own demands in applications. The technology of the cutting and holding tools for this area may seem static, but actually a lot has changed.

How are tools different today and how much better are they? Francis Richt: Today’s newly developed,

solid cemented-carbide successor to the twist-drill, CoroDrill 860-PM, focuses on efficiency in metalcutting and reducing the cost of hole-making in today’s demanding manufacturing environment. The traditional all-round drill is not competitive enough to fully optimize the production of numerous holes within close limits. In machining with a focus on flexibility and repeatability of hole quality in various materials, we now have CoroDrill 460-XM. This drill has been developed to provide another perspective on machine utilization – another way of looking at productivity – where an even and secure production flow takes priority over speed. Today’s manufacturing demands need modern, state-of-the-art concepts that have been developed to optimize hole-making, whatever the priorities. In drilling, we have found that dedication to the workpiece material is essential in achieving top performance. In steel, the focus on higher cutting speeds, and thereby higher penetration rates, is important in reducing the cost per hole without compromising the hole quality. The ability to consistently make holes within a close tolerance band, common to a large number of hole types, and to maintain machining security throughout a long tool life are essential properties. A drill also has to be easy to apply and able to work at top capacity from the start and also have the potential for optimization, particularly on high-spec machines. Productivity improvements in hole-making are mostly based on higher penetration rates. The CoroDrill 860-PM for steel and CoroDrill

860-MM for stainless steel are part of a new generation of solid carbide drills that provide higher cutting-speed capacity combined with higher process security. These drills have exceeded user expectations in this area. What about generating screw threads through tapping? How would you summarize developments and user improvements here? Francis Richt: The CoroTap concept has

developed tapping of all thread types. Far-reaching evolution of taps has been ongoing and provided the means to optimize what is often experienced as “sensitive” operations due to the slender nature of the tools, machining demands, quality demands and being out of sight. Improving security in the tapping operation, usually one of the last operations on a component, has been an important objective. Tool material improvements such as newly developed coatings, powder metallurgy, high-speed steel and solid cemented carbide have been instrumental in achieving this. Also, there have been developments in cutting geometry, micro-edge geometry, flutes and chamfer designs. So even the old-fashioned thread tap has undergone changes to raise performance and security in modern machines. Does tool holding, in particular the chuck, play a significant role in performance and results? Have there been any major new developments in chucks?

Jenny Claus: To start with, an inadequate

chuck is a very weak link in the chain of machinery, holding tools and cutting tools. However, a really good, modern chuck provides the means to improve utilization. Most of the problems, such as end mills being pulled out of the chuck, vibrations leading to unsatisfactory surface finish and poor tool life, can often be traced back to poor tool holding. In addition, the quality and design of a chuck will either limit or increase the reach of the tool as well as productivity levels. The role of the chuck as an integral part of the performance chain cannot be overemphasized. The main development today is the very big step forward in hydraulic chucks, where we are experiencing a generation shift with huge

benefits to users. The development of the hydraulic chuck CoroChuck 930 provides a high-tech solution for holding round tools that will give very high precision, clamping force, security against tool pull-out tendency, high-torque transmission, vibrationdampening effect, ease of handling, dedication choices for operation parameters and balancing features. It moves ahead in every direction needed to upgrade tool holding and is available with interface options to provide an optimum solution for all machines. What about alternatives to a high-tech hydraulic chuck? How do collet chucks and shrink-fit tool holding fit into the range of choices? Jenny Claus: The CoroChuck 930 has been

shown to provide a huge increase in tool life. Recently, in a test, when it replaced a goodquality collet chuck that held 6.8-millimeter [0.27-inch] drills making holes in steel on a modern machining center, the tool life was extended fivefold. Collet chucks and shrink-fit tool holding still have a role to play, but it is very much up to the application and results required as well as how production is organized. A collet chuck offers high all-round flexibility as regards tool size but will not provide really high precision. Shrink-fit does provide high precision through minimal run-out but needs equipment and a machine shop/tool room dedicated to the tool-change procedure involved with strictly dedicated holder sizes. The modern hydraulic chuck, however, can fit into any type of application and setup. It provides high precision and security, and tool change is very straightforward – very much a change for the better. n

Big change in hole-making: The CoroDrill 860 drill has brought a new combination of speed, hole quality and process security to hole-making in steel. This is a high-tech, very fast solid cemented-carbide drill covering a diameter range of 3 to 20 millimeters (0.1 to 0.8 inch), drill depths of three to eight times the diameter, hole tolerances of IT 8 to 9, surface finishes Ra 0.8 to 1.8 microns, straightness limits of down to 0.07 millimeters per drilled 100 millimeters and demands for minimized entry and exit burring. Big change in tapping: The development of the CoroTap has meant that there is no reason why compromises in efficiency for tapping operations should have to be made today for fear of machine stoppages and scrapped components. Technology steps in tap development have made these tools far more efficient, reliable and capable of improved quality. The range includes both universal and dedicated taps for all materials and hole types to optimize applications depending mainly on the volume of holes to be machined. Big change in holding tools: CoroChuck 930 is an innovation in chuck technology for holding round tools. New Fulcrum technology provides the ideal support when the tool shank is clamped in any of three versions of the chuck: heavy-duty, slender or pencil models, all optimized for specific areas of chuck application. Precision run-out is within 4 microns, with high repetitive precision, and balancing is within DIN69888. They are available with the all-important machine interfaces to provide high pull-out resistance, through-tool coolant supply and easy handling. A combination with the best in solid round tools provides a state-of-the-art means for machining.

Summary Solid round tools and hydraulic chucks have undergone fundamental changes. A combination of these developments is especially interesting from a user point of view, as it provides a new means with which to solve applications, especially in high-spec machinery. The precision of the tools and chuck together provides a new level of consistency in maintaining very close machined tolerances with higher efficiency and security – and a considerably extended tool life.


text: Chuck Thompson photo: Daniel Månsson

sweet emotion Pacific, Washington. When

Infinity Machine Works participated in a pioneering program to test the new GC4325 cutting insert, the results were immediate and the reactions enthusiastic.

Infinity Machine Works produces components for the tunnel boring industry.

22

metalworking world

With the GC4325, insert life and productivity more than doubled for Infinity Machine Works.

nnn “Sweet!” That was what Infinity Machine Works founder Dave Markham heard when he walked into the small production machine shop he runs in Pacific, a town near Seattle, Washington, and it made him smile. “Sweet!” was confirmation that Markham’s decision to take part in a pioneering program to test a new grade of cutting insert had paid off. “I remember it well,” says Markham, whose company produces components for the tunnel boring industry. “We’d gotten the new inserts in the afternoon, and the guys ran them on the night shift. When I came into the shop the next day, one of the operators had a big grin on his face. “‘These things rock!’ he told me. That was nice to hear first thing in the morning.” The inserts that Markham’s machine operators were

so excited about were Sandvik Coromant’s GC4325, a groundbreaking new grade for machine turning. Atomically designed to increase tool life, the inserts are revolutionizing the world of metalcutting. Markham, as head of a small business, is constantly looking for ways to increase output and reduce costs.

That’s why in 2013 he agreed to be take part in a pilot program to test the new technology. “We’ve worked with Sandvik Coromant for a quite a while, and when they say something is going to work, we know it’s going to work,” Markham explains. But even expecting positive results he was astonished at the extent to which the GC4325 improved his business. “We more than doubled our insert life and productivity with the GC4325,” says Markham. Proof of this can be seen on Infinity’s loading dock. Wooden crates of monohubs and cutter rings fashioned from H13 steel move in and out, being sent for heat treatment, then onward to Infinity client Herrenknecht, a German manufacturer of tunnel boring machines whose U.S. headquarters are in nearby Auburn, Washington. “We’re taking out a lot of material to make these parts,” says Markham. “The inserts we’d been using before were wearing out after maybe five or six parts. We’re getting up to 15 or 16 parts each with the new grade.”

Infinity Machine Works

An independent shop situated just south of Seattle in the town of Pacific, Infinity Machine Works has carved a niche as a top-quality producer of components for the tunnel boring industry. Area native Dave Markham founded the company in 2002. Opting to avoid the region’s dominant aerospace industry (Boeing’s main manufacturing facility is just up the road), Infinity has focused instead on the needs of clients such as Herrenknecht, a German manufacturer of tunnel boring machines. Infinity employs between six and 12 workers, depending on the project load.


“The simple fact is this product works better,” says Dave Markham.

For a small company, increased production and process stability are vital.

“When they say something is going to work, we know it’s going to work,” says Infinity Machine Works’ Dave Markham, left, with Sandvik Coromant partner Eric Sleater.

24

metalworking world

The incredible boost in efficiency means increased profits. For Infinity, that means more cash flow to invest during boom times and more “rainy day” capital for weathering slack periods. Markham appreciates the molecular complexities of the GC4325 technology. But what gets him really fired up is pretty basic. “The simple fact is this product works better,” he says. “I’m all about getting our costs down and our profits up. We’re not making money if the spindle’s not turning, and the new inserts allow us to keep them turning longer and faster.” That’s good news for Infinity and its customers, as well its machine operators. These days, what greets Markham when he comes in each morning is the constant rumble of spindles turning. That’s the kind of feedback Markham values most of all. n

technical insight

“We’re not making money if the spindle’s not turning, and the new inserts allow us to keep them turning longer and faster.” Dave Markham, founder, Infinity Machine Works

GC4325

Sandvik Coromant’s new insert grade for turning is redefining metalcutting with an elaborate technology called Inveio. The design packs atoms more tightly and in a unidirectional position toward the tungsten carbide cutting edge. The result is outstanding gains in insert strength, wear resistance and tool life, allowing operators, in the vernacular of their trade, to increase feeds and speeds and, ultimately, productivity.


technology text: christer richt

Challenge: Achieve new levels of consistent performance for steel turning and extend predictable, safe tool life at higher cutting data.

solution: Develop a new generation of coated cemented carbide insert grades through innovative insert coating technology and insert manufacturing processes.

Creating unique new insert surfaces The main objective behind the coating of an insert is to increase the wear resistance and tool life of the inserts. In principle, adding a suitable multi-layer coating to an insert substrate adds considerable durability and potential for higher cutting data to a mechanically strong insert. Insert coating has evolved considerably since its introduction in 1970 with the first CVD-coated grades. Today, the seventh generation of steel-turning inserts for the large, mid-ISO P25 area is setting a new benchmark in productivity. A new coated cemented carbide grade with a tool material capability never seen before is providing the means with which to yet again raise productivity. Coating indexable inserts entails applying layers of protective

and wear-resistant material to the insert substrate. This is dominated by the chemical vapor deposition (CVD) process, which basically involves chemical reactions between gases being converted to solid coating on a substrate. Gaseous molecules react with each other under the influence of certain process parameters, which determine how the coating is to be deposited. The main parameters are temperature, pressure and gas type (and the relative amounts of these), along with the surface on which the coating is deposited. The CVD process today is an optimized high-tech process where not only the fine-tuning of the actual processes has taken place but also the efficient, consistent mass-manufacturing of inserts. The Sandvik Coromant CVD process of today is highly dependent upon modern science, know-how and the experience

26

metalworking world

accumulated as the pioneer and continual benchmark of performance with coated inserts. Alumina (aluminum oxide, Al2O3) is a proven tool material and is to a limited extent employed in bulk ceramic inserts for some machining applications in certain materials. Alumina has an excellent heat-insulating effect and high chemical stability in that it does not readily react with metallic materials. It is hard and highly wear-resistant but relatively brittle in bulk form. Being brittle is not an issue in coating, however, making alumina the CVD coating of choice for most inserts. The coating prevents excessive heat from finding its way into the insert substrate, thereby allowing higher cutting speeds and longer tool life. It is also a barrier to chemical reactions between the cemented carbide substrate and the workpiece material. As such, it is ideal as a secondary layer on an insert. Modern coating technology employs multi-layer combinations, where each layer provides a property that adds to the total of the coated insert capability. The inner layer in such a coating structure is most often titanium carbonitride (TiCN), which gives a good bonding to the substrate and provides the insert with a high amount of wear resistance. The aluminum oxide is deposited on top of this. As an outermost layer titanium nitride (TiN) is used, providing some lowering of friction and, being golden in color, is a good indicator of tool wear. The development of tool materials and process technologies has also contributed to establishing a better platform for a new generation of coated inserts for steel turning. Insert substrates,

Inveio technology is partly the development of crystal growth in unique orientation, which has been found to be decisive in regard to the evolvement of the well-packed foundation of this coating along the insert surface. This results in a completely new edge line and rake face being established on the insert, one that can cope with machining demands on a very different level than before – hence the improvements being experienced in the manufacturing industry.

The Inveio-coated grade GC4325 is a new generation ISO P25 steel-turning application area insert that represents a breakthrough in tool material science on a scale not seen since the introduction of coated carbides.

The insert face from the cutting-edge line to where the chip breaks away is where the chip load is the highest, where heat and pressure are at their maximum and where the outcome and capability of the tool are determined. This is where the Inveio coating technology has provided a new tool material that optimizes more operations in steel turning and a technology that forms the base for further insert grades for steel turning.

new edge treatments and new insert post-treatment methods are the main areas. An important contributing factor is the new coordinated approach to all parameters, including those that apply to making the new coated grades. The manufacturing processes deliver not only reliable and better performing tools but also consistency in performance in tools for machine shops that do steel turning. The alumina coating is made up of crystals that are roughly the size of a micron and, when applied conventionally, can grow in various directions. The orientation of these crystals has a considerable effect on the coating property and capability of the insert. By controlling the orientation of each crystal in the coating to the desired direction, a perfect coating with uniform properties can be achieved. Compare the effect with that of making a path with columnar stones, either strewn out together to form a surface or, if each stone is placed standing, packed with identical surfaces facing upward. The Inveio coating technology has provided a breakthrough

in controlling crystal orientation. Unidirectional crystals form the surface of the rake face of the indexable insert. It is the evolution to fine-tune the application of alumina crystals in the CVD process that has now taken place. The development of crystal growth in unique orientation forms the coating of well-packed crystal columns, resulting in a completely new insert surface. This new surface has a better distributing effect for the generated heat in metalcutting, spreading it across a

larger area and thus creating a temperature-reducing effect. A similar improved effect is seen on any cracking tendency that occurs in the coating: Instead of taking a direction into the material, indications tend to spread out across the surface, giving rise to a much less harmful effect. As a first step, the new Inveio technology has resulted in a very broad insert grade: GC4325, a new cutting edge for the dominant mid-area of steel turning. A critical criterion has been to achieve processes that provide insert users with a tool with no variation in regard to quality and capability. The Inveio coating with unidirectional growth is undergoing further development for more insert grades that can further optimize adjoining areas in steel turning. n

Summary A new breakthrough in tool material science with the Inveio coating technology has resulted in a unique new steel-turning insert that optimizes the large ISO P25 application area. The new innovation has made possible a marked step up in performance – one that beats any similar grade improvement in the past, and one that will form the basis for a range of steel-turning inserts. The scale of the development is reflected in the new opportunities for further efficiency within the manufacturing industry.


text: Marcus Joons photo: Daniel Månsson

Leading a team

to success Inspiration. Red Bull Racing Team Principal Christian

Horner explains how it is the small details that have led the 500-strong team to dominate Formula 1 in recent years.

Ready for a switch: The team works in two-second periods. THE CAR

Wheels on wheels: Stacks of tires are lined up, labeled and ready for mounting.

Formula 1 racing cars have to be built by the teams themselves. The cars are manufactured from carbon-fiber composites, titanium alloys and other ultra-light materials – but the car must still weigh at least 691 kilograms (1,500 pounds) including oil, water and driver. Before 2014 the rule was 642 kilograms (1,420 pounds). The engine, located between the driver and the rear wheels, has since 2008 been a V8 with a cylinder volume of a maximum 2.4 liters. From 2014 the engines are V6s, 1.6 liters. The gearboxes have eight sequential forward gears and are semi-automatic. Up and down gear changes are done with a paddle on each side of the back of the steering wheel. The brakes are disc, made of carbon fiber. The large front and back wings on the car are there so that air will press down on the car and give the broad tires optimal traction on the track. There are four different types of dry tires, with varying pressures and different grips and life expectancies, but only two types of tires, decided in advance, may be used in each race, and both must then be used on every car during a competition.

Each race is examined afterward, and the team practices to shave off more seconds.

The team works in synchronicity. See each step on the next page.

to be really hot during the days around the race. But when we come closer to the start, the clouds always when they accelerate from 0 to 220 mph on the Kemmel move over here.” Straight before they hit the brakes. There are two hours left before the start of one of the most classic races, Belgium’s Grand Prix on the Circuit The main reason the Formula 1 team doesn’t like rain de Spa-Francorchamps, and the team’s test drivers are – and even less, changes in the weather – is that it getting a feel for the cars and the track to check that becomes harder to choose tires. everything is as it should be. There are four different tires for dry weather (hard, Red Bull Racing Team Principal Christian Horner medium, soft and super-soft) and two for wet weather looks worried, peering up into the cloudy sky where a (intermediate and full wet), and this is where races camera-equipped helicopter circles over the track, with difficult weather conditions can be won or lost, filming on behalf of all the TV channels around the Horner says. world that hold commercial rights to the race. When you have chosen which two tires you are going He scrolls through his weather app and to use, Formula 1 rules dictate that you rings the team’s tactical manager and head have to then use them both in the race mechanic for an update on when the rain “It’s all about the details, but you can’t due that afternoon will fall. be effective if you’re obsessive,” he says. The track lies in a hilly area in east “You need to find a balance.” Wallonia, near the border with Germany You also need to be open to input. and Luxembourg, and has many microcli“I think the key to our success is that I am mates. The sun may be shining on some approachable for any of our 500-strong parts of the 4.3-mile track while rain team,” Horner says. “I try to get around pours down elsewhere. the factory at least once a week and after “This is what makes this one of the each race. And even though as a team we most difficult races,” Horner explains. have won the construction title and “I mean, this race is always held at the Sebastian Vettel has won the driver’s title Christian Horner, Red Bull racing team principal end of the European summer, and it tends for four years in a row, I can talk for the

Formula 1 cars sound like a swarm of giant angry bees

FORMULA 1 CIRCUS Like a circus tour of 20 races, Formula 1 tours around the world from March through November. Drivers compete for the title of World Drivers’ Championship and World Constructors’ Championship The World Championship in Formula 1 has been held since 1950, but it was in the 1970s that the sport became what it is today. That was when Lotus introduced ground-effect aerodynamics, which meant that the cars could hold their speed into the curves. The race became spectacular in terms of speed. The British former driver and business magnate Bernie Ecclestone, who had just bought the team Brabham, took the opportunity to commercialize the sport into a billion-dollar industry with expensive sponsors and TV contracts. No driver has died in a race since the Brazilian many-time world champion Ayrton Senna had a fatal crash on the Imola track in the San Marino Grand Prix in 1994.


Gone in 2 seconds… whole team when I say that we are as thirsty for victory now as we were four years ago.” Horner describes how, after each lap, the team

Refueling has been banned in Formula 1 since 2010, making the pit stop a matter of a few seconds (cut down from around seven seconds with refueling). According to Red Bull, its team holds the record for the quickest pit stop ever. The record was set in 2013 at the United States Grand Prix. The time? 1.923 seconds.

Step 1 As the driver enters the pit lane he slows the car to the pit lane speed limit of 80 km/h. The car has to stop at exact marks on the ground, where the pit stop team is waiting (otherwise they would have to reposition themselves, losing precious seconds).

examines everything that happened, regardless of the outcome. “You ask yourself, what could we have done better? Could we have been more efficient? Could we have had better pit stops where we could have cut, say, the seven seconds of changing tires to six or at least six and a half?” Energy drink company Red Bull has long been associated with Formula 1. At the end of the 1980s and the beginning of the 1990s, Austrian owner Dietrich Mateschitz sponsored Formula 1 driver Gerhard Berger, a close friend, and in the late 1990s he produced and printed the Formula 1 Daily newspaper on site during the three competition days. In 2004 Red Bull was generating an annual revenue of $345 million and could afford to buy Jaguar Racing from Ford Motor. Former racing driver Christian Horner, then 32, was asked to be team principal – the youngest team manager in the history of the sport. Today at 40, Horner has his own fan club and website and his name is synonymous with Red Bull Racing. Horner says the Red Bull brand – epitomizing a love of action, explosiveness and youth – is made for Formula 1. From Horner, in his booth beside the track, to the mechanics who change tires and service the car down to the driver who is in contact throughout the race via a helmet cam, it’s about making lightning-quick decisions – and being top-notch in every way.

Step 2 Two jack men lever their jacks under the car – one in front, one in back –

“FIA, the car organization that runs Formula 1, now changes the rules every year to slow us and the sport down,” Horner says. “Now we have to have a V6 engine instead of a V8, the minimum weight of the cars has increased from 1,420 to 1,500 pounds [642 to 691 kilograms] and so on. Are the changes good or bad? I don’t know. I just feel that people think that Formula 1 is nothing more than a material sport and that the Red Bull cars are stronger and have more horsepower than the others. In fact we all have the same tools, the same manufacturer, the same engines, the same tires. So it’s all about the team and making the right decisions. Sebastian Vettel [the world’s youngest world master when he took his first title four years ago at age 23] is No. 1 because he’s the best driver with the best team. It’s as simple as that.” Later that afternoon a flurry of moisture falls on the Spa-Francorchamps track, but it’s not rain. Rather it’s the splash from Vettel’s bottle of champagne after he outclassed all the others to take first place – more than 36 seconds ahead of the runner-up. n

Step 4 When the four wheels have been changed, the car is lowered to the ground

30

metalworking world

and raise it two to four inches. There are three wheelmen assigned to each wheel. One operates the high-speed gun, removing and refitting the wheel nut. One removes the used wheel.

Step 3 The third wheelman positions the new wheel and the wheel nut is reattached and tightened to around 500 lb-ft.

and takes off. In total, the pit stop lasts two to five seconds.

Automagic!

Enschede, The Netherlands. A

wealth of innovation rescued manufacturing company Huima Specials when the greenhouse market collapsed in the Netherlands. Now the tempo of engineering and modernization is again moving up a notch with a new automatic production cell that allows unmanned manufacturing 24 hours a day, seven days a week. text: Tomas Lundin photo: Audrey Bardou

[1] [1] The special-made lower turret is equipped with Hydraulic Capto C4 clamping units. [2] Operator Javid in the machining center. [3] The production cell will soon be ready for 24-hour operation.

[2] [4]

32

metalworking world

[5]

[3]

[4] The system is suitable for series of up to 500 units. [5] For more than 70 years Huima Specials has delivered gear systems for the gardening and agricultural segments.

Bram de Koning, CEO Cellro, left, Ton Huitink, director Huima Specials, right.

nnn In 1938 Ton Huitink’s grandfather, a pioneer with considerable foresight, transformed the little smithy founded in 1902 by his father in Enschede in the Netherlands into a blossoming manufacturing company. Today Huitink, a visionary in his own right, leads and owns the company, Huima Specials, with his brother Andre. “We are 10 times smaller than our competitors,” says Huitink, sipping strong black coffee and now and then pulling at his tie. “But we are 10 times faster and 10 times more innovative.” Huitink is an engineer, technician and indefatigable inventor. He hates patents. “They just take time, involve a lot of bureaucracy and cost money,” he says. “We invest instead in always being at the front. That is our patent.” But in 2009 things weren’t looking so good. In Western Europe the market for greenhouse construction, a strong sector in the Dutch economy, fell to bits. “The greenhouse builders were our biggest customers,” recalls Huitink. “We practically had to change direction overnight and look for new customers.” In the space of nine months, Huima Specials produced a new drive system to meet the strong demand from Eastern Europe for stables for farming pigs and chickens. A new system was developed in parallel for the manufacturers of greenhouses. Additionally, they also developed a worldunique drive system for Emsflower, one of Europe’s largest horticultural companies, that had created a multifunctional, fully automated greenhouse. The new drive system allows Emsflower to change the equipment in their greenhouse by literally one push of a button. Today the company can produce potted plants in the first half of the year and easily switch to a greenhouse able to grow cucumbers and tomatoes during the next half, depending on market and market prices.

“We are 10 times smaller than our competitors, but we are 10 times faster and 10 times more innovative.” Ton Huitink, director, Huima Specials

Automation is the key word for Huitink. In 2007,

together with Sandvik Coromant and Dutch robot manufacturer Cellro, he had already begun to think about a production cell that could work around the clock and


[1] Emsflower, one of Europe's largest horticultural companies, is the first in the world with fully automated greenhouses, thanks to Huima Specials' new drive system.

[2] From left: Evert van den Hurk, production manager, Huima Specials; Ronny Booijink, Sandvik Coromant; Ton Huitink, director Huima Specials; and Bram de Koning, CEO of Cellro.

supply itself with tools and workpieces, carrying out the entire manufacturing process without outside intervention. “The idea was that if we received an order on Monday, the production cell could plan and manufacture the components by itself so that they could be assembled two days later and delivered to the customer at the end of the week,” says Huitink. “But it was easier said than done. We came up against a few problems.” The biggest challenge was that there wasn’t a CNC lathe on the market with two revolvers that could be equipped with the Sandvik Coromant tools Capto C4 and C6, which can be automatically changed. The eventual solution was a system based on a multi-tasking machine that manufacturer Mazak modified especially for Huima and a Cellro robot. The robot can do everything from loading and unloading components to switching Coromant Capto tools, which are clamped hydraulically, changing jaws from the spindle and controlling and measuring components and the process. Bram de Koning, CEO of Cellro, says this solution is

[1]

[2]

34

metalworking world

tailor-made to make small runs of up to 500 pieces profitable. This is only possible when all the tasks normally carried out by an operator are taken over by a robot. But what happens if demand changes and, for example, larger series are needed? “No problem,” says de Koning. “Cellro uses module solutions. The automatization can quickly be adapted to new production demands.” For Huitink, it was important for Huima Specials to have Sandvik Coromant in the boat and get it “right from the start.” “Sandvik Coromant is a partner we rely on 100 percent after years of working together and solving numerous problems together,” he says. “There was no question of asking anyone else.” Today “Willem,” as the production cell is affectionately known, stands on the workshop floor spitting out parts in two shifts. There are still a number of small things that need to be optimized before it is time for 24-hour operation. In the meantime “Tommy,” the next production cell, is being developed to work with the horizontal machining center. In the future Willem will be able to say to Tommy: “Look, I’m manufacturing 23 sets of gears, so you can start producing matching housings and covers.” “They can both get going and work all night while I am at home asleep,” says a happy Huitink. n

technical insight

HuimA Specials' production cell, designed for series of up to 500 pieces, will soon be in operation 24/7 and will require not more than 40 hours of monitoring a week. “For this to work, a robot is needed to take over all functions normally carried out by an operator,” says Bram de Koning, CEO of Cellro, which supplied the newly developed robot. Using the unique grip arm the robot can: Load and remove products. • • Change Coromant Capto tools in the top rotating

spindle and in the lower turret from the multitasking machine’s lower revolver with nine tool places. • Change jaws on the main and sub spindle. • Measure and correct deviations in the process.

The robot production cell is named "Willem.”

Automatic tool-changing takes place through a solution developed by Huima Specials together with Sandvik Coromant and Cellro. The robot then links to a modified multi-tasking machine. The rotating upper spindle is equipped with Sandvik Coromant’s tool coupling Capto C6 and the newly developed lower turret with Capto C4 in hydraulic tension. The upper spindle is used for rotating machining as well as milling and drilling. The lower turret is responsible for stationary machining such as large diameter turning. With the robot, this creates maximum flexibility. “It’s like changing Lego bricks,” de Koning says. Both the upper spindle and the turret have a 70 bar pressure pump for coolant, which along with the Capto Coroturn HP system gives better chip control and higher process certainty. “An automated production cell that manufactures 24/7 has to avoid long chips,” explains Ronny Booijink, Sandvik Coromant’s project engineer. “We need short chips that are simple to remove. That’s what Sandvik Coromant calls ‘Green Light Machining.’” The production cell has a tool magazine for C6

and C4, separated from the multi-tasking machine. That means that the tool magazine is “endless.” A pater noster elevator unit supplies raw materials, finished components and chuck jaws.


technology text: Elaine McClarence

image: Kjell thorsson

Challenge: How to meet the oil and gas industry’s demand for large, complex components.

solution: Use specialized solutions tailored for productivity and precision. 0

Specialist tooling for tough environments The expected growth in world demand for oil and gas

means that the industry needs to exploit reserves that are more difficult to reach and present significant technical challenges. The components needed for oil and gas exploration and production, whether they are destined for deepwater drilling or subsea production environments, have to face up to the rigors of difficult environmental conditions, increased depths, higher temperatures and greater forces.

A long service life is expected of these larger and more complex components, such as spool bodies, tubing hangers and valves found in the subsea systems controlling production flows on the seabed. In the downhole equipment, among many other components, collars house sophisticated controls such as steering mechanisms and measuring systems as they move through extremely harsh environments. The trend in the industry is toward the use of more difficult-to-machine materials such as Inconel, titanium and stainless steel, and end users require components made to exacting tolerances with excellent surface finishes. To meet these requirements, component makers need a high degree of process security and predictability and also want reduced downtime through more efficient machining approaches and higher productivity through longer-lasting tools. Sandvik Coromant has developed a range of tooling solutions that are suitable for the machining of oil and gas components and, in some cases, actually make the

36

metalworking world

machining possible. These solutions encompass low-vibration tools and tool holders for complex internal machining operations as well as quick tool changes. Together they result in higher productivity. The company’s range of Silent Tools minimizes vibrations and chatter during the machining process, enabling a more predictable and reliable process. These toolholders are particularly suitable in reaching longer overhangs in difficult-to-machine materials for a range of turning, milling and boring operations that are typical features for oil and gas components. Silent Tools adapters can enable machining up to 14 times the diameter in turning operations. To meet manufacturing needs for high productivity and reduced downtime, the machine-adapted clamping unit (MACU) facilitates a quick tool change for boring bars on most types of turning centers. MACUs are easily accommodated on turrets for stationary and rotating tools to provide better performance, higher stability and more cutting time. MACUs also provide an opportunity to adapt the turret to the type of components being machined within the machine option capabilities. When used with Coromant Capto, they combine stability and quick tool change. The CoroTurn SL range of adapters and cutting heads can also be used with Silent Tools; the quick change feature provides a modular and flexible answer for turning and grooving, threading and for other internal operations such as bottle boring. The launch of new grades such as the GC4325 will further contribute to improved tool life, precision and productivity. n

1,000

2 000

3,000

4,000

5,000

6,000 (meters)

Customer case Bottle boring or chamber boring is an internal turning operation involving long overhangs, typically carried out in large turning centers. A larger diameter is machined behind a part of the component with a smaller diameter so the entry and/or exit holes have a smaller diameter than the feature being machined. The challenge is to keep vibrations low and cutting data high without frequent and long production disruptions. The solutions: Silent Tools dampened boring bars minimize vibrations, enabling a high metal removal rate. If possible, choose one larger Coromant Capto size for highest stability. CoroTurn SL cutting heads, available in four stages of offset up to 23 millimeters (0.906 inch), offer good reach and the largest possible boring bar diameter. The nozzle technology of CoroTurn SL takes care of chip control to minimize the number of unplanned production interruptions. Coromant Capto quick change clamping units keep tool change time under one minute. This is an ideal solution to avoid collisions and still keep the machine running.

Summary Sandvik Coromant offers specialist tooling solutions for machining the advanced components needed in the challenging requirements of the oil and gas industry. Because the industry operates at great depths and in remote and difficult-to-reach locations, the components that form the heart of advanced exploration and production require a long service life and must meet exacting environmental demands.


the final note text: henrik emilson

You've read stories from...

Argentina, Australia, Belarus, Brazil, Canada, China, Denmark, England, France, Germany, Hungary, Hong Kong, India, Italy, Japan, Malaysia, New Guinea, New Zealand, Norway, Peru, Romania, Russia, Singapore, Slovenia, South Africa, South Korea, Spain, Sweden, Switzerland, Turkey, the United States and …even space.

Where the talent is Attracting new engineering talent to the universities, to the industry – and to the magazine – is vital. In MWW 1-2012 we covered the cooperation between Sandvik Coromant and Beihang University.

LOOKING BACK

10 YEARS OF MWW

"Safety and speed with next-generation grade" The GC4225 insert was introduced in MWW 1-2006. Seven years later its successor, GC4325, Sandvik Coromant’s biggest turning grade introduction ever, was launched with the words: “The wait is over.”

25 Number of minutes the average reader (in a readership of 250,000) spends reading Metalworking World.

A gear milling milestone In MWW 1-2013 you could read about how new indexable insert technology is about to transform gear milling production.

Previous life… Metalworking World is celebrating 10 years in its current concept, shape and form. The magazine was originally launched 30 years ago, in 1984. As today, the outlook was global and featured stories from around the world. The Metalworking World 1.0 magazine had 20 local editions, and you might have known it as Welt der Fertigunstechnik, Il Mondo delle Lavaorazioni Meccaniche, Le monde de l’usinage, El Mundo del Mecanizado or Skärskådat.

38

metalworking world

“My original thought with Coromant Capto was ‘Why use different holders for the different tools?’” In MWW 1-2004 Ken Andersson, the man behind Coromant Capto, explained how the system that became a standard in 1990 was conceived.

Metalworking World includes the super big… Magna Machine Co. in Cincinnati, Ohio, MWW 3-2012. …and the tiny. . . France’s Arve Valley is the center of small-part machining, MWW 1-2006. More and more, video has become a natural part of storytelling outside of the printed pages, bringing more dimensions to the Metalworking World experience. One video that has garnered a lot of interest is the story about Cane Creek, a small mountain bike manufacturer in the United States, which can be seen on the Sandvik Coromant web and in the MWW iPad 2-2012.

15,000,000,000

Windfall business: The growing segment of wind power earned a special report in MWW 1-2009.

The $15 billion question: In the first issue of MWW, 1-2004, it was stated that the manufacturing industry in the United States could save $15 billion by using the right tools from the start. The question: Are you getting your share of that $15 billion? Are you?

Great feats of engineering Whether it is driverless cars, nano technology or architecture on a grand scale – such as the national stadium for the Olympic Games in China 2008 – it’s all inspiring ingredients of the magazine's content mix.

Our first iPad edition was launched with the 3-2011 issue. metalworking world 39

Print n:o C-5000:577 USA © AB Sandvik Coromant 2014:2

CoroCut®QD – Twice as cool CoroCut QD takes your parting off to new heights. Optimized for bar-feed lathes, it brings unbeatable strength and security for deep grooves and long overhangs with a helping hand from unique new technology: over- and under-coolant for the most effective, troublefree machining.

The concept includes parting blades, adaptors and shanks, plus tools for sliding head machines.

80%

reas *tool life inc

Unbeatable security: stronger blade design, advanced grade technology and the most stable insert clamping.

Ultimate chip control and tool life: over- and under-coolant with two high pressure jets and dedicated insert geometries.

e

recorded ol life gains *average to s petitor system m co t ns ai ag s uctivity (feed od Pr . de wi world increased so al ) ds ee and sp by 64%.

www.sandvik.coromant.com/corocutqd

Easy handling: quick and easy coolant connection with plug-and-play adaptors for many machine types.