Choose digital, choose the right drill
Fewer than 30% of manufacturers have extensively adopted Industry 4.0 technologies, according to responses to a new report. But, manufacturers’ reluctance to go digital might have to change if they are to adapt to an unpredictable future. Here, James Thorpe, global product manager at Sandvik Coromant, the global leader in metal-cutting tools, explains how, by combining advanced software with the correct machine tools, manufacturers can digitalise profitably, and on their own terms.
The Industry 4.0 & Smart Manufacturing Adoption Report by IoT Analytics suggests that the Industry 4.0 technology uptake is still low among manufacturers. Given that the advantages of Industry 4.0 are now so well-understood, why aren’t more manufacturers digitalising their processes?
One perception is that applying Industry 4.0 to existing production setups is expensive when, actually, it doesn’t have to be. Another reason for the slow uptake is that manufacturers see no reason to upgrade their existing tooling set-up and processes. If it isn’t broken, why replace it? Manufacturers in this category may be unsure of how Industry 4.0 fits into their established way of doing things.
The truth is, automated Industry 4.0 technologies can greatly benefit manufacturers’ bottom lines. For instance, Sandvik Coromant has found that a 20% increase in machine utilisation can provide a 10% higher gross profit margin and automated systems can massively increase machine uptime.
Automated equipment can also support the growing trend for machining with limited, or no, human supervision — particularly amid the pandemic. As stated in a recent Pricewaterhouse Coopers (PwC) report, COVID-19: What it means for industrial manufacturers, “For companies vulnerable to a viral outbreak within their ranks, this would be a critical time to explore a proactive deployment of automation technologies.”
Today’s Industry 4.0 technologies, including sensors and machine learning can also be beneficial in minimising the number of production stops. Again, increasing profit. This includes stops needed to replace worn tooling, like drills.
Previously, operators had to rely on manual monitoring to detect wear in machine tools. PwC’s report points towards the Industrial Internet of Things (IIoT) as an alternative. An example of this is Sandvik Coromant’s latest CoroPlus® Machining Insights platform, an expansion of the company’s CoroPlus suite of connectivity software.
Using Machining Insights, CNC machines can connect through Ethernet and transmit information at higher volume than they can currently. This includes manufacturing data to improve workshop efficiency and overall equipment effectiveness (OEE). And this isn’t limited to new machinery. Most machines are connectible to the network, and there are adapters for older machines to make them compatible. In other words, Industry 4.0 can be integrated easily, even with legacy hardware.
Tool technology in practice As manufacturing becomes increasingly automated, unpredictable tool life is more of an issue. In Korea, an automotive manufacturer experienced this exact issue and worked with Sandvik Coromant to improve tool life.
The CoroDrill 860-GM is suitable for all applications where hole quality is critical. This includes aerospace, general engineering, oil and gas, nuclear and renewable power. Its optimised reliability is also proven in automotive production, including the drilling of engine blocks, casings, flanges and manifolds.
The application used the CoroDrill 860-GM to drill through holes for automotive transmission connectors. Overall, eight 8.2 mm (0.32”) diameter through holes were drilled into each component that measured a depth of 10 mm (0.39”). The previous tool produced 200 components, 1600 holes in total, with a cutting speed (Vc) of 80m/min (3102 RPM) and cutting feed (Vf) of 381 mm/min. In comparison, the CoroDrill 860-GM produced 2300 components (18400 holes) with a Vc of 100m/min (3878 RPM) and Vf of 814 mm/min.
The result was a significantly improved tool life of 1150%, and a productivity increase that lowered the overall costs-per-part.
As well as facilitating longer tool life, these tools can deliver increased cutting data and therefore enable faster cutting rates. In fact, an engineering company in Lancaster, Ohio, US, was able to achieve a 57% faster cutting rate when using the CoroDrill 860-GM versus a competitors drill. The application used the tool to drill sensor housing components made from 304 stainless steel — 11 holes in each, 6.6 mm (0.260”) in diameter.
Predictable wear
Machining Insights is designed to give manufacturers greater visibility of machining processes and provide information to identify and eliminate downtime and inefficiency. This includes during periods of largely or fully-automated processes.
Let’s face it, one of the biggest threats to production is unpredictable tool life. For a tool to properly support automated production, limiting continuous, controllable wear and eliminating discontinuous, uncontrollable wear are the keys to success.
Sandvik Coromant’s specialists had this in mind when developing the CoroDrill® 860 with enhanced -GM geometry, a new design solid carbide drill that’s optimised for a wide range of materials and applications, across all industry sectors.
Unique approach to design
For Sandvik Coromant’s specialists, the key to longer tool life is not limited to the amount of time a tool spends in use, but the drill design itself.
The CoroDrill 860-GM has an innovative, polished flute design. The ground-breaking design improves the evacuation of chips and yields greater hole quality, while also helping to reduce heat build-up and cutting forces while drilling. Other key features of the drill’s design include a reinforced core and corner chamfers, edge preparation to remove cutting micro defects and a double margin to enhance drilling stability. The drill’s point is also designed with refined clearance angles and improved surface quality.
Go online
To increase tool life, manufacturers must invest in Industry 4.0 technologies, like Machining Insights, to monitor wear. That said, they must not overlook investing in strong tooling to begin with. Sandvik Coromant’s CoroPlus® Tool Guide simplifies tool selection. By accessing the online application via a web browser and the entering workpiece material and application, users can find the best solid round tool and cutting data for their requirements.
Meanwhile, along with Machining Insights, Sandvik Coromant’s digital machining portfolio includes CoroPlus® Process Control, a process control solution comprising both hardware and software. The solution monitors machines in real-time and automatically acts according to defined rules, rather than just providing an alert. Actions can include stopping the machine in case of a collision, or replacing a worn tool.
There are countless productivity, profit and maintenance advantages available to machine shops that are willing to overcome their reluctance to embrace Industry 4.0. Through the correct use of these technologies, manufacturers can go digital on their own terms — and be within the 30% of manufacturers, cited in IoT Analytics report, that are prepared for an unpredictable future.
