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Small part machining brochure - .PDF file.

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Coromill 790 brochure - .PDF file.

The Coromill Century indexable insert cutter and other technologies from Sandvik Coromant are being utilised by dragster specialist Don Schumacher Racing (DSR) to optimise the production of cylinder heads and connecting rods for its cars.

Tooling supplier Sandvik Coromant joined forces with DSR in late 2010 to help expand its shop-floor capabilities. The partnership addresses some of the most pressing manufacturing challenges that the racing teams face. Shortly before partnering with Sandvik Coromant, DSR added nine Fadal CNC machines to the two Okuma machines it had originally. With the arrival of the new machines, DSR decided to further increase its process improvement efforts in order to maximise return on investment.

The companies decided to focus initially on optimising the machining process for two main components: cylinder heads and connecting rods. Each cylinder head has 90 holes measuring 115mm in depth, along with complex geometries and stringent surface quality standards. Starting with a solid aluminium billet, the production process is lengthy and involves a number of tools and operations.

Initial analysis focused on face-milling operations. For rough and finish face milling, DSR was using 150mm cutters that required hand loading because they filled three positions in the tool magazine. DSR was concerned about the long setup times with its existing face-milling tooling. As a result, a 100mm Coromill 590 Century indexable insert cutter that only needed one spot in the chain was suggested.

DSR also wanted to eliminate a blend line on the cylinder head combustion surface. Machinists were able to increase the speed and feed rates by 335 per cent using a roll-in, roll-out technique recommended by the Sandvik Coromant team. In order to combat issues with component quality and chip clearance, Sandvik Coromant recommended that DSR switch from its 25mm-diameter solid-carbide endmill to a 50mm Coromill 790 indexable insert cutter.

Specialists also fixed the problematic hole-drilling process. Before the optimisation project, conventional solid-carbide twist drills were deployed. As some of the tools did not have through-tool coolant, DSR had to use peck drilling techniques, which added significant time to the process. By switching to Corodrill Delta-C R840, the pecking cycles could be eliminated.

Clink on the links above to download brochures for some of the Sandvik Coromant technologies utilised in this application.

Key benefits of product application

  • The Coromill 590 Century indexable insert cutter does not require hand loading.
  • The roll-in, roll-out technique has reduced production time and increased tool life while helping DSR to improve surface quality by 58 per cent.
  • Taken as a whole, the face-milling process changes recommended have allowed DSR to eliminate manual tool changes completely, which has helped to optimise spindle utilisation.
  • The original 25mm-diameter solid-carbide endmill had long overhang that caused vibration problems. A Coromant Capto C5 shank has improved rigidity, while modifications to the CNC program using circular interpolation techniques have reduced the radial and axial depth of cut while increasing cutting speeds and feeds.
  • Spindle load has been reduced and vibration problems diminished. In addition, tool life has improved and tool changes are much simpler.
  • Corodrill Delta-C R840 has provided the additional benefits of improved chip evacuation and hole quality and reduced cycle times (by 75 per cent).
  • The productivity improvements free up time that DSR’s teams can devote to engineering precision car parts.

Sandvik Coromant

Part of global industrial engineering group Sandvik, Sandvik Coromant is at the forefront of manufacturing tools, machining solutions and knowledge that drive industry standards and innovations demanded by the metalworking industry now and into the next industrial era.

Part of global industrial engineering group Sandvik, Sandvik Coromant is at the forefront of manufacturing tools, machining solutions and knowledge that drive industry standards and innovations demanded by the metalworking industry now and into the next industrial era.

Educational support, extensive R&D investment and strong customer partnerships ensure the development of machining technologies that change, lead and drive the future of manufacturing. Sandvik Coromant owns over 3100 patents worldwide, employs over 8,500 staff, and is represented in 150 countries.

For more information visit www.sandvik.coromant.com or join the conversation on social media.

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