Sandvik Coromant launches a new product line of optimized solid carbide end mills specifically for profile milling with the CoroMill Plura Barrel. The new solution offers high process reliability, significant productivity increases, and cycle time reductions of up to 90 percent, making it particularly suitable for the aerospace industry and other sectors with high demands.
The CoroMill Plura Barrel is an extension of the comprehensive end mill program for ISO S profile milling, which includes the CoroMill Plura ball nose end mill, the CoroMill Plura lollipop mill, and the CoroMill Plura end mill with conical ball shank. The new tool offers a new machining principle for profile mills – key features include the unique shank shape with a barrel radius and up to six optimized cutting edges, making the tool an ideal complement to the product range.
Compared to conventional machining strategies with ball nose end mills, the CoroMill Plura Barrel is particularly advantageous as it operates with a larger contact radius. This design allows for a reduction in cycle time of up to 90 percent through increased feed rates, which not only improves machining efficiency through a significant increase in the SRR (Surface Removal Rate) but also ensures excellent surface quality.
The optimized barrel design leads to a lower peak height between passes, resulting in better surface qualities and lower surface roughness. The stability and process reliability of the barrel mills make them the ideal choice for precise surfaces in demanding profile milling applications, even under higher forces.
"The CoroMill Plura Barrel is ideal for applications where precision and high surface quality are essential," says Liam Haglington, product manager for solid carbide cutting tools at Sandvik Coromant. "Its large cutting edge radius allows for greater feed rates and shorter cycle times, increasing productivity when removing large amounts of material. The large barrel radius makes it ideal for machining large, complex contours and 3D shapes while minimizing roughness at low cutting depths."
The tool is particularly suitable for demanding applications such as in aerospace, where components like engine blisks feature complex geometries and challenging materials. However, it also improves profile milling in other challenging areas such as medical technology, the oil and gas industry, and energy production.
Sandvik Coromant has developed a range of material-specific grades, including T2CH for titanium alloys and R2AH for heat-resistant superalloys (HRSA), both equipped with Sandvik Coromant's Zertivo 2.0 PVD coating for improved durability and wear resistance. For customers with specific size and diameter requirements, the tool can be customized through Sandvik Coromant's Tailor Made Service, while the CoroPlus Tool Guide platform further supports application requirements with expert tool advice.
"The previous results demonstrate the reliability and productivity of the tool," says Haglington. "In one case, a customer machining an Inconel motor blisk achieved a cycle time reduction of more than 40 percent using the CoroMill Plura Barrel machining strategy. With a machining time of 88 minutes, a 50 percent longer tool life was achieved compared to the customer's existing solution. In another case, this time machining a titanium blisk, the customer saved more than 90 minutes of machining time by using the new tool compared to a competitor's conical ball nose solution."
As part of its commitment to sustainability, Sandvik Coromant also offers a comprehensive recycling program for used carbide tools, including the CoroMill Plura Barrel and other high-performance end mills. This service allows customers to return used tools for responsible recycling, reducing industrial waste and conserving key materials such as tungsten and cobalt. By participating in the program, manufacturing companies not only contribute to ecological sustainability but also benefit from a more resource-efficient and cost-effective production process.
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