Manufacturers should accelerate their product development cycles to meet the rapidly-changing high-performance and safety standards. On-demand manufacturing is made possible by the latest additive manufacturing (AM) technologies, like 3D printing, which speeds-up manufacturing and prototyping. Elsewhere, manufacturers use artificial intelligence (AI) and Industry 4.0 concepts to optimise their processes.
These technologies have clear advantages. However, manufacturers mustn’t overlook the latest cutting-edge developments in CNC machining. Manufacturing concepts that, at first glance, are decades-old also have the potential to greatly improve product development cycles. Modifications can be made to the angle at which the workpiece is cut by an insert, how the tool itself moves — faster directional changes for example — and the performance characteristics of tools designed with greater wear resistance, or to support improved process security.
These approaches go hand-in-hand with the continued evolution of computer aided manufacturing (CAM) software. With them, manufacturers can realise more complex and innovative designs without sacrificing product quality — for faster product development cycles overall.
The CAM software is capable of telling a machine how to make a product by generating toolpaths. With CAM software, it’s possible to program the cutting tool to engage with the workpiece at the best possible entering angle, and maintain this consistency for greatly improved chip control. Software can optimise when the tool either cuts into, or retracts from, the workpiece, before moving quickly and safely to the next point and repeating the process.
However, CAM software alone cannot satisfy manufacturers’ needs to produce more complex and innovative shapes. Requirements expressed by Sandvik Coromant’s own customers — machine shops in automotive, aerospace, general engineering and more — include the need for higher metal cutting efficiency and improved predictability in their machining processes. Another major requirement is increased machine utilisation.
These are the reasons why Sandvik Coromant’s specialists sought to develop a solution that would make it possible to machine several features with just one tool. It was decided these methods should ensure cutting forces are directed into the tool holder, for higher process stability, with a constant, fixed entering angle for drastically improved chip control. The result was a Y-axis turning.
As the name implies, the new method makes use of the Y-axis, and all three axes are used simultaneously when machining. The tool rotates around its own centre, the insert is placed for machining in the Y-Z plane and the milling spindle axis interpolates during turning. This way, intricate shapes can be machined with a single tool. Y-axis turning offers numerous benefits. The possibility to machine several features with only one tool reduces cycle time. The fact that no tool changes are required also minimises the risk of ‘blend points’, i.e. irregularities between adjacent machined surfaces.
With Y-axis turning, it’s possible to influence the cutting forces directed into the tool that directly impact machining stability. This also minimises vibrations between the tool and workpiece that cause imperfections on the product’s surface and gives higher output and process security. Meanwhile, a constant entering angle drastically improves chip control and makes it easier to avoid chip jamming. Wiper inserts can also be kept perpendicular to the surface, and on a tapered surface. Wiper inserts are designed with a wiper edge that is situated where the straight edge meets the corner radius. In comparison to conventional breakers, the surface finish does not deteriorate even if the feed rate is doubled. Machining at high feed rates improves cutting efficiency, as well as supporting product quality.
In addition, Sandvik Coromant has developed two new tools to support Y-axis turning. The new CoroTurn® Prime variant is suitable for shafts, flanges and components with undercuts. And there is the CoroPlex® YT twin-tool, which features CoroTurn® TR profiling inserts and is best used at an entering angle of between 60 to 90⁰ for more efficient and productive machining.