In 2014 Sandvik identified and documented a total of seven projects that improved quality, reduced downtime and extended tool life to deliver a 39.8% saving in tooling costs.
For example, Sandvik Coromant recently proposed the testing and implementation of CoroMill 5B90 to machine the combustion face of cylinder heads and overcome excessive burr. The solution delivered three times greater tool life, far fewer burrs and much quicker tool set-up.
Other recent tooling projects in cooperation with the Volvo Cars engineering team include the implementation of the CoroTurn SL system of modular adaptors and exchangeable heads to facilitate quicker tool change; new insert geometry for grooving camshafts that increased tool life from 125 to 500 pieces; new inserts for crankshaft machining that led to longer tool life and shorter cycles; and a new grade and geometry for a boring tool that increased tool life and reduced downtime due to fewer tool changes.
Moving forward, current projects involving new tooling concepts include cost reduction and process security for cylinder boring, and an increase in quality and tool life for wheel hub spline milling. Sandvik Coromant is also delivering support in upgrading tool holders that will allow the next generation of crankshafts to be accommodated.
Sandvik Coromant has established a long partnership with the Volvo engine manufacturing plant in Skövde and the component manufacturing plant in Floby, although support also extends beyond Sweden. For instance, Sandvik Coromant recently helped with the transfer of knowledge on tooling for machines at a brand new facility in China.