According to the 17 global sustainable development goals set by the United Nations (UN), manufacturers must not only optimize energy use, but also minimize their impact on the environment. While corporate social responsibility is important to the company, Sandvik Coromant estimates that manufacturers waste between 10 and 30 percent of material during processing, with typical processing efficiency of less than 50 percent, including the design, planning and cutting phases.
So what can manufacturers do? The UN goals recommend two main paths, taking into account factors such as population growth, limited resources, and a linear economy. First, use technology to solve these problems. Industry 4.0 concepts such as cyber-physical systems, big data or the Internet of Things (IoT) are often cited as the way forward for manufacturers looking to reduce waste. However, this does not take into account the fact that most manufacturers have not yet implemented modern machine tools with digital capabilities into their steel turning operations.
Most manufacturers recognize how important insert grade selection is to the efficiency and productivity of steel turning and how it affects overall productivity and tool life. However, many people miss the trick by not considering the whole concept of the tool. Everything from advanced blades and handles to easy-to-use digital solutions. Each of these factors can help make steel turning greener by reducing energy consumption and minimizing waste.
Manufacturers face many challenges when turning steel. These include getting more chips per edge from a single blade, increasing metal removal rates, reducing cycle times, optimizing inventory levels and, of course, minimizing material waste. But what if there was a way to solve all these problems, but in general move towards greater sustainability? One way to reduce power consumption is to slow down the cutting speed. Manufacturers can maintain productivity by proportionally increasing feed rates and depth of cut. In addition to saving energy, this increases tool life. In steel turning, Sandvik Coromant has found that a 25% increase in average tool life, combined with reliable and predictable productivity, minimizes material loss on the workpiece and insert.
The right choice of blade material can achieve this goal to a certain extent. That’s why Sandvik Coromant has added two new turning carbide grades, GC4415 and GC4425, to its portfolio. GC4425 provides improved wear resistance, heat resistance and toughness, while GC4415 grade is designed to complement GC4425 when improved performance and higher temperature resistance are required. It is important to note that both grades can be used with strong materials such as Inconel and ISO-P grades of unalloyed stainless steel, which are particularly difficult and durable for machines. The right grade can help machine more parts in high volume and/or series production.
Grade GC4425 maintains an intact edge line for high process safety. Because the inserts can machine more workpieces per cutting edge, less carbide is used to machine the same number of parts. In addition, inserts with consistent and predictable performance avoid workpiece damage while minimizing workpiece material waste. Both of these benefits reduce the amount of waste generated.
In addition, for the GC4425 and GC4415, the substrate and insert coating have been specially designed to better withstand high temperatures. This reduces the effects that cause excessive wear, so the material retains its edge very well at higher temperatures.
However, manufacturers should also consider using coolant on the blades. If a tool is being used with both a subcoolant and a subcoolant, it may be useful in some operations to disable the subcoolant. The main function of a cutting fluid is to remove chips, cool and lubricate between the tool and the workpiece material. When applied correctly, it maximizes productivity, enhances process safety, and enhances tool performance and part quality. Using a holder with internal coolant will also extend the life of the cutter.
Both GC4425 and GC4415 feature a second generation Inveio® layer, a CVD textured alumina (Al2O3) coating specifically designed for machining. Inveio research at the microscopic level showed that the surface of the material is characterized by a unidirectional crystal orientation. In addition, the crystal orientation of the second generation Inveio coating has been significantly improved. More importantly than before, each crystal in the alumina coating is aligned in the same direction, creating a strong barrier to the cut zone.
Inveio provides high wear resistance and long insert life. Of course, stronger tools are good for reducing part cost. In addition, the material’s cemented carbide matrix contains a high percentage of recycled carbide, making it one of the most environmentally friendly grades. To test these claims, Sandvik Coromant customers conducted pre-sale tests on GC4425. One General Engineering company used both a competitor blade and a GC4425 blade in its pinch rollers. The ISO-P grade provides continuous external axial machining and semi-finishing at a cutting speed (vc) of 200 m/min, a feed rate of 0.4 mm/rev (fn) and a depth (ap) of 4 mm.
Manufacturers usually measure tool life by the number of parts machined (pieces). Competitor grades can cut 12 parts before plastic deformation wear, while Sandvik Coromant inserts can cut 18 parts, increasing tool life by 50% and providing consistent and predictable wear. This case study shows the benefits that can be gained by combining the right machining elements and how recommendations on preferred tools and cutting data from a trusted partner such as Sandvik Coromant can help ensure process safety and reduce lost search process time. the right tool. Online tools such as the CoroPlus® Tool Guide have also proven to be popular in helping manufacturers evaluate the turning inserts and grades best suited to their requirements.
To assist with process monitoring itself, Sandvik Coromant has also developed CoroPlus® process control software that monitors machining in real time and takes action according to programmed protocols when specific problems occur, such as machine shutdown or replacement of worn cutting tools. This brings us to the second UN recommendation for more sustainable tools: move towards a circular economy, treating waste as a raw material and reinvesting it in resource-neutral cycles. It is becoming increasingly clear that the circular economy is environmentally friendly and profitable for manufacturers.
This includes recycling solid carbide tools – after all, we all benefit when worn tools don’t end up in landfills and landfills. Both GC4415 and GC4425 contain significant amounts of recovered carbides. The production of new tools from recycled carbide requires 70% less energy than the production of new tools from virgin materials, which also results in a 40% reduction in CO2 emissions. In addition, Sandvik Coromant’s carbide recycling program is available to all of our customers worldwide. The company buys back worn blades and round knives from customers regardless of their origin. This is indeed necessary given how scarce and limited raw materials will be in the long run. For example, the estimated reserves of tungsten are about 7 million tons, which will last us about 100 years. The Sandvik Coromant takeback program is 80% recyclable through the carbide buyback program.
Despite the current market uncertainty, manufacturers cannot forget their other obligations, including corporate social responsibility. Fortunately, by implementing new machining methods and suitable carbide inserts, manufacturers can increase sustainability without sacrificing process safety and respond more effectively to the challenges COVID-19 has brought to the market.
Rolf is Product Manager at Sandvik Coromant. Experience in the development and management of products in the field of cutting tool materials. He leads projects to develop new alloys for various types of clients such as aerospace, automotive and general engineering.
The Made in India story had far-reaching implications. But who is the manufacturer of “Made in India”? What is their history? “Mashinostroitel” is a specialized magazine created to tell incredible stories… read more
Post time: Aug-18-2023