Challenge: How can you handle demanding or heavy-duty machining applications efficiently?

Solution: Take advantage of the C10 coupling of Coromant Capto– the largest in the range.

A recent trend in manufacturing has been towards increased cutting data to meet the demands of ever-higher productivity. This is particularly true for a range of challenging heavy-duty machining operations, which represents a growing business in several industrial sectors. To help achieve productivity improvements, Sandvik Coromant has extended the standard range of its modular tooling system with the addition of the size C10 Coromant Capto coupling. The C10 is designed to benefit companies that need to carry out heavy-duty machining operations and/or have applications involving difficult-to-machine materials.

The introduction of size C10 provides a stable tooling platform that supports higher cutting data. In addition, as part of a modular tooling concept, it offers the same advantages while offering new levels of performance under challenging conditions.

As its designation suggests, the C10 is a coupling 100 millimeters in diameter that extends beyond the range of previous C8 couplings and offers manufacturers the opportunity to use Coromant Capto modular tooling solutions in new application areas. For heavy machining operations with large indexable inserts, it offers a more efficient tooling solution combined with great rigidity, high changing accuracy and easy handling. The increased diameter plays an important role in this respect, as the larger diameter gives greater bending stiffness.

The C10 is an important addition to the standard range because there is often a need to use tools with long overhangs combined with high cutting data. In this case, C8 couplings cannot meet the strength requirements for those operations where it is necessary to transmit more torque or where greater bending stiffness is required.

Also in the aerospace industry, the increased use of materials such as titanium and heat-resistant super-alloys (HRSA) to meet the demands of extreme applications has created a class of materials that are harder, tougher, less heat sensitive and/or more resistant to corrosion and fatigue. They are also more difficult to machine, and this puts demands on manufacturers to meet the challenge of workpieces that require high cutting data while raising productivity. The C10 is a stable, strong coupling that can handle power because of its inherent increased bending stiffness, and for this reason it can be used when very long tools and/or rigidity are necessary.

Like the other standard couplings in the range, the C10 is based on a face-contact coupling that locates tools via a self-centering tapered polygon. The coupling offers maximum stability, thanks to its two-face contact and interference fit. Despite the fact that it is designed for manufacturing large or heavy components such as, for example, railway wheels, the same benefits of quick change and modularity for tooling apply for drilling, milling and turning applications. Indeed, tool changing is five times faster than conventional tools, with the added advantage that there is limited need for time-wasting tool correction and measuring cuts.

Learn more about Tooling Solutions from Sandvik Coromant.

Case Study: Coromant Capto C10 is already being installed on vertical lathes, normally with automatic tool changing but also with manual clamping systems. In particular, the C10 is being used by a number of companies supplying components to the railway, power generation and aerospace industries. In one application for the production of railway wheel sets on Hegenscheidt machines, heavy machining with large indexable inserts was required. Though the modular tools cost more than with conventional equipment, the considerably improved economics, derived from higher output and improved utilization of production equipment, more than compensated for the larger initial investment.

Since the introduction of Coromant Capto, workpieces have been easier to machine without fluctuations in quality and with excellent repeatability. Interchangeable sets of tools are used, which avoids the need for repeated tool measurement, although the machines also permit this. The C10 coupling was chosen because even using 100 kilowatts of power, the system offers sufficiently large stability reserves to allow higher-than-average cutting forces to be generated.

Benefits:

• Stable

• Strong

• Better transmission of torque and bending forces

• Ability to handle increased cutting data

• Minimum run-out and guaranteed centre height

• Increased productivity.

Technical Facts:

• 100 millimeters in diameter

• Self-centering tapered polygon

• Two-face contact

• Press fit avoids play in coupling

• Automatic tool changing available.

Originally published in Metalworking World 1.2009, a business magazine published by Sandvik Coromant.