Case: Design the unseen - optimize performance

The additive version of CoroMill® 390 milling cutter has resulted in optimized design, 80% lower weight and up to 200% increased productivity.

CoroMill® 390 is a versatile industrial system with cutter versions for shoulder milling and long edge milling. The development of the additive version of CoroMill® 390 has been like an evolution.

New design versions have continuously evolved and developed into something quite different from what the customer and Sandvik’s additive project team expected when the project started.

Significant productivity improvement

To reduce weight, the product was topologically optimized – and as a next step the material was also changed into a titanium alloy, using powder bed fusion laser as the printing technology.

With the new light-weight version of CoroMill® 390, produced with additive manufacturing, the weight of the cutter body is reduced by >80%.

As a consequence, the mill cutter body weight was reduced by more than 80%, without compromising strength. Bringing down the weight at the end of the milling assembly significantly reduces vibration in the system. In the case with CoroMill® 390, the precision light-weight design limits vibration and smooths cutting performance – increasing customer productivity by 50–200%.

Facts

Outcome
Optimized design, 80% lower weight and up to 200% increased productivity.

Designers
Per Viklund, Johan Lindström, Einar Leo Ottesen and Anna Nordstrand

Material
Titanium alloy, Ti6Al4V

Additive technology
Powder Bed Fusion Laser

Post processing
Heat treatment and machining

"With the new light-weight version of CoroMill® 390, produced with additive manufacturing, the weight of the cutter body is reduced by >80%. Combined with new Silent Tools™ milling adaptors, this is an exceptional tooling combination for slender tooling. The solution limits the vibration tendencies and enables high productivity and good process security in demanding applications," says Thomas Wikgren Product Manager Shoulder Milling, Sandvik Coromant.

Re-invented product

CoroMill® 390 is a great example of how we work closely with our customers to develop the most optimal additive solutions. In this case – thanks to Sandvik Coromant’s leading expertise in metal cutting and our expertise in additive manufacturing, we step-by-step, tweaked, tested, and truly re-invented this product with radically increased end customer value.