Unmanned production & double capacity
Sandvik Coromant entered into a partnership with Teenees from Trondheim in 1970 to produce the so-called Silent Tools. Equipped with a damping system, the unique range of tools and adapters minimizes vibration even with a long tool overhang.
Sandvik Coromant took over the partner in 2008 and has continuously developed this product division. With 105 specialists and modern machine tools, the tool manufacturer ensures that customers from all over the world and all industries receive first-class solutions, from standard products to special developments. Since 2001, Sandvik Coromant Trondheim has often relied on automated CNC technology from DMG MORI. After the initial use of gantry solutions, DMG MORI installed an NZX 1500 with robot handling for the first time in 2020. This was followed in 2023 by an automated NTX 3000. The manufacturing solution enables highly flexible production of a wide variety of CAPTO tool bodies.
We manufacture 450 standard products in Trondheim, and ten percent of our business is customer-specific tool solutions,” says Steinar Løkken, Manager Technical Operations at Sandvik Coromant Trondheim, about the scope of production. Silent tools are a core business. Inside these turning, milling and drilling tools is a pre-set damping system consisting of a heavy damping body supported by two springs. When vibration occurs, the kinetic energy is absorbed by the damping system. This minimizes the vibration, improves surface quality and increases productivity.
Competitive for over 20 years thanks to automation solutions
Sandvik Coromant works continuously on improving cost efficiency. Manufacturing of the high-quality tools is no exception, explains Steinar Løkken: “That’s why we have been using automated manufacturing solutions for over 20 years.” Norway is a typical high-cost country, where automation really pays off. “Gantry systems and robots increase component quality because manual handling is no longer necessary.” In view of the small to medium batch sizes and a large number of product variants, flexibility in production is another challenge. For Kristoffer Bjørnstad, Process Development Engineer at Sandvik Coromant Trondheim, robot solutions therefore play a major role. “The NZX 1500 has convinced us to continue along this path.” The automation solution is loaded with raw parts via a conveyor. The robot recognizes the position using a camera and takes over loading and unloading of the machine.
NTX 3000 with customized automation solution
With the automation solution based around the NTX 3000, Sandvik Coromant Trondheim has reached a new level of unattended production. “Our aim was to double our capacity and at the same time machine a wide range of CAPTO tool bodies,” says Steinar Løkken, recalling the start of the concept. DMG MORI was able to implement all the requirements. The system has three loading stations, each of which can accommodate a Euro pallet with pre-machined blanks and simultaneously deposit the finished parts. The robot removes the raw parts with a magnetic gripper, repositions them and removes a protective cap. Each part is then cleaned in a washing machine before being centered in another station. The robot uses one of four different grippers to load and unload the tool bodies – Capto C3 and C4, C5 and C6, C8 or a magnetic gripper for handling the blanks. In addition, a vacuum gripper is used to remove the wooden intermediate bases from the pallets of blanks.
Doubling the production capacity
“Handling is always fast enough that the next tool body can be inserted seamlessly after processing,” explains Kristoffer Bjørnstad. “We can run up to 150 parts of different sizes without human interaction, which enables high-capacity utilization with processing times of up to 15 minutes. It runs up to four shifts – unattended, with double the output.”
Process integration: Precise turn & mill machining including in-process measuring
Thanks to the large work area of the NTX 3000, Sandvik Coromant Trondheim can easily machine tool bodies with diameters from ø 16 mm to ø 80 mm. The longest tool bodies reach 561 mm. A tailstock and a steady rest in the lower turret provide the necessary stability, while the simultaneous use of tools in the lower turret and the milling spindle contributes to high productivity. Thanks to the turn & mill spindle, complete machining is carried out on just one machine.
DMG MORI has also implemented the integration of in-process measuring. The accuracy of the machined tool bodies is to within tens of microns and is a prerequisite for the assembly of the damping systems. “We use in-process measurement to check every workpiece,” says Kristoffer Bjørnstad. “This reduces the need for measurement outside the machine to occasional spot checks.” In-process measurement can also be used to feed back offsets automatically to the machine control.
Long-standing partnership with DMG MORI as a win-win situation
"Automation solutions like these help us to work moreeconomically and remain competitive,” summarizes Steinar Løkken. They are also a means of becoming more sustainable. Sandvik is pursuing ambitious goals here. “Our aim is to manufacture as resource-efficiently as possible and to utilize our production capacity as efficiently as possible.” DMG MORI also has this in mind. He sees the long-standing cooperation with the machine tool manufacturer as profitable for both sides, because such complex manufacturing solutions always involve learning: “We would like to benefit from this when investing in new automation solutions in the future.”
Sandvik Coromant Trondheim
Ranheimsvegen 127
7053 Trondheim, Norway
www.sandvik.coromant.com