Optimising machine tool investment through cooperation: Manufacturers that purchase the right machines and cutting tools from the start save valuable time and maximise their return on investment.
There are many factors to consider when making a decision to purchase a new CNC machine tool or another large capital equipment investment to process metal shapes or sheet into a component or product.
“The recent challenges of load shedding in South Africa have put the industry under a spotlight, prompting a focused discussion on energy-efficient equipment. Naturally, with the energy crisis battering South Africa, energy efficiency, reducing usage, and alternative or uninterrupted power supplies are a critical talking point at the moment. It’s become clear that the financial returns from investing in such equipment are considerable, especially when you compare the expenses of running inefficient systems on generators and alternative power sources. Practical solutions to combat the effects of load shedding and reduce operational costs are a high priority.”
Sandvik Coromant’s Hein Nel
“Worldwide the need to reduce carbon emissions and evolve more sustainable, environmentally friendly commercial solutions continues to grow more urgently in all manufacturing environments. Driven by energy transition and climate change, industry is undergoing a deep restructuring. Renewable energy and technologies for decarbonisation are gaining more and more attention. But the paths towards decarbonisation and sustainability are just as varied as industry itself.”
“However, adopting new technologies, along with engaging the relevant industry experts, is vital for this transformation. As manufacturers, we are in one of the most capital-intensive industries, and it can seem like we are always investing in our businesses without a pause. Technology is constantly advancing, and it can be a struggle to keep up. This is why you need to consult with all your relevant suppliers, which you should be regarding as your partners, making an equipment purchase because it could become a costly headache.”
“Obviously we all want to purchase the right machine for the right job. There are many factors to consider first, though. Ask yourself, ‘Will this purchase allow me to deliver faster and with higher quality?’ Customers love it when you can deliver faster. More importantly though ask yourself: ‘Am I purchasing the right machine for my machine shop setup, the customers I serve, the processes required to machine these customers’ components and of course can I afford it?’”
In 2017 Sandvik Coromant introduced the PrimeTurning methodology and tools for external turning operations. Revolutionary in concept – it might even be called radical – the PrimeTurning methodology has turned turning on its head. The PrimeTurning process allows turning and facing in all directions
“For example, 5-axis machining is enabling machine shops to take on more complex work and helping it produce less complex jobs more efficiently. You are also able to take on more of the complex work that other companies shy away from. A 5-axis machine can move the cutting tool along the X, Y, Z, A, and B axes, whereas a 3-axis CNC machine is capable of moving its cutting tool along the X, Y and Z axes. The 5-axis machine immediately gives you an advantage as it can machine a component on five different sides and no extra machining or setups are required, which, as we all know take time and can reduce the required precision.”
“The capabilities of a machine are just one aspect of the equation. Generally, companies won’t get the machine size requirements wrong but how many times do we see a customer that has purchased a machine without a high-speed spindle or high-pressure pump yet they are planning to do deep hole drilling on aluminium?”
“In view of the ever-increasing competitive pressure, manufacturing companies face the challenge of improving productivity, shortening time-to-market and maximising return on investment (ROI). Developing and implementing new systems that meet these specific requirements and generate sustainable competitive gain are crucial in today’s manufacturing environment. However, this course of action requires significant investment in time and resources, making it essential to achieve ROI in the shortest possible time.”
In 2008 Sandvik Coromant introduced a range of Coromant Capto machine-adapted clamping units (MACU)
“Therefore, the planning of the purchase of a machine tool requires careful consideration. For instance, as we said, will a 3, 4 or 5-axis machining center be required? Will a conventional 2-axis turning machine suffice, or will a multi-axis turning center with driven tools be necessary? Perhaps a combination of both, in the form of a multitasking or mill-turn machine, will provide the solution?”
“Support is often necessary for a new investment to be a success, in the form of defining current needs, identifying new opportunities or exploring promising paths. Consequently, when buying a machine, all parties (suppliers and staff) should be involved in the process, right from the start.”
“It is vital that manufacturers use both the right machine and the right tools from the very beginning. Around 70% of all machines are still sold without tools. Because the entire production process, including any special tool requirements, is rarely taken into account when the machine is purchased, developing a productive and efficient machining process can become more difficult.”
“The Sandivk Coromant concept follows a new and innovative approach that focuses on the entire process from the very start. As a matter of course, the cutting tool and tooling system specialist relies on intensive exchange and strives to understand the customer’s business down to the last detail. In all cases, the goal is to develop individual solutions that are specifically tailored to the respective requirements, regardless of whether the customer is a multinational corporation or a small company with a handful of employees.”
“We as an OEM supplier can advise with our project teams that have maybe come across similar machines for similar jobs. Why not get their input?”
Sandvik are introducing new tools regularly
A holistic consulting approach for machine tool purchases
“A careful strategy that minimises amortisation time should include the purchase of the machine as well as a detailed evaluation of the most appropriate manufacturing processes and tools for the production process. In a common scenario, the areas of planning, investment and commissioning precede the actual machine set up and production. Getting it right is about defining and analysing every aspect of a new investment, both technically and economically. Ideally, all partners begin cooperating on topics such as capacity targets, costs per component, choice of machining method and possibilities for unmanned machining before the actual investment decisions are made. This strategy helps ensure that a new machine runs optimally, is equipped with the optimum tools and works efficiently right from the start.”
“Sandvik Coromant bases its holistic consulting approach on a combination of factors relevant for success, including tools and tooling solutions, service and support and its many years of industry knowledge. This enables the company to support customers in multiple areas: in the assessment and evaluation of components, processes and applications; in machining time and component cost studies; and in the creation of a tailor-made tool package for the respective machining requirements. Sandvik Coromant also provides online support for applications and customised training programmes for machine operators. The company’s global competence centers for productivity, application knowledge, machining technology and research enable its experts to interact and collaborate physically and digitally with customers and partners in a modern and inspiring environment.”
Sandvik are introducing new turning inserts and grades for steel – the new generation steel turning insert grades GC4425 and GC4415
Meeting the challenges of modern manufacturing
“In order to minimise the amortisation time of new investments, different challenges have to be mastered. To achieve optimal machine utilisation, for example, a quick-change tooling solution can accelerate the set-up process and increase the productivity time of a new machine. In the area of tool management, a modular system offers a large variety of tool assemblies featuring different characteristics, often decreasing the need for customized tools and the long delivery times they typically carry. When vibration causes problems, tools with damping mechanisms minimise the effect in long overhang applications and keep productivity and process reliability at a high level. In addition, digital machining solutions can help users realise a more efficient use of resources within the value chain and contribute to optimal, data-based decision making.”
“The combination of holistic consulting and the latest technologies can ensure that new machines produce parts and generate profits from day one. Many practical examples already prove this theory. In some cases, investment consulting from Sandvik Coromant has led to the amortisation period of a machine being shortened by a full year. In other instances, alternative tools and programming solutions enabled customers to significantly reduce the cost of component machining.”
Sandvik will assist you in your decision to purchase a new machine by evaluating parts, processes and application, assisting with time and cost per component studies, customising a tooling package that matches your machining requirements, providing onsite application support, customising a training programme for your operators using your new machine and tooling and offering research and testing facilities worldwide with a global network of experts
“In all cases, customers were pleased with an efficient and profitable machining process which, thanks to proposals made by Sandvik Coromant, could ultimately be implemented with a less capital-intensive machine investment.”
“In 2008 Sandvik Coromant introduced a range of Coromant Capto machine-adapted clamping units (MACU). Designed specifically for your machine MACU offers better performance and faster tool changes for turning, milling and drilling and are ready-equipped to channel high-pressure coolant to the latest in CoroTurn HP cutting heads.”
“In 2017 Sandvik Coromant introduced the PrimeTurning methodology and tools for external turning operations. Revolutionary in concept – it might even be called radical – the PrimeTurning methodology has turned turning on its head. The PrimeTurning process allows turning and facing in all directions, delivering dramatic increases in high volume production. Cycle time reductions of 50% or more can be achieved. Sandvik Coromant refers to PrimeTurning as an “all-directional” turning solution that allows a single tool to perform forward and backward cuts as well as facing and profiling operations.”
“These and other new products are regularly introduced by Sandvik Coromant.”
The CoroPlus Machining Insights platform gives better visibility to CNC machine tools and machining processes and provides the tools needed to analyse, identify, and eliminate common sources of downtime and inefficiency
“South African companies need to consult with us to learn how to adopt these and other technologies that will make them ‘smarter’ in their machining processors. Labour costs in South Africa are not competitive anymore and this is putting pressure on the manufacturing sector to work smarter. As a result, we will see an increase in automation as we try and compete globally. This will trigger a lot of new skill sets that will be needed and new types of machines and tooling will be needed in the coming years.”
“This is where industry 4.0 will really start making sense. Data information, machining knowledge and an open mind will help South Africa to eventually be more automated and become a serious global player in the machining world. This is why Sandvik Coromant has focused on leading this frontier in the manufacturing sector.”
“Investing in a machine is so critical to a machining business and every second that the machine stands and does not generate money, must be a concern.”
For further details contact Sandvik Coromant on TEL: 010 500 2295 or visit www.sandvik.coromant.com
