Full speed

The driving force for improved machining of modern,

high-performance engine components
Cut component costs and increase
flexibility in engine manufacture
Engines that deliver more power, use less fuel,
generate less noise and meet ever-tougher environ-
mental demands have a bright future – as long as
they can be built to the high levels of quality, cost-
efficiency and reliability needed to satisfy the
paying motorist.

Greater flexibility is also a ‘must’ for latest cutting tool strategies and inno-
the automotive industry today. More vations from Sandvik Coromant.
frequent model launches plus greater It’s the driving force for increased
opportunities to tailor engine com- productivity, quality and flexibility in
binations signal a move away from engine manufacture – all at a lower
traditional transfer-line manufacture to cost per component.
more adaptable solutions.
To meet these challenges, you can
call upon new tools designed for com-
pacted graphite iron (CGI), now making
its breakthrough into large-volume
engine manufacture, plus the very

More for less in mass production cast iron milling

Cast iron milling is central to engine component manu-
facture and opportunities to save costs and increase
flexibility are many. Faster and predictable machining
is one obvious example. A greater focus on machining
centres another. We offer more for less in both areas.

Cost-efficient, large-volume removal

New CoroMill® 365 roughs and semi-
finishes cylinder blocks and heads
where large volumes need to be
removed in a short time. Maximum
cost-efficiency is its major attribute.
Comparative tests on cast iron diesel
engine blocks confirm that CoroMill®
365 brings real productivity gains
within easy reach.

Fitting CoroMill 365 with unique eight-edged left-hand or right-hand inserts

improves production economy. Large support surfaces distribute cutting forces to
ensure secure and reliable operation.
 High-quality, high-speed finishing
With its light cutting action, CoroMill® possible, leaving a high-quality flat sur-
Century with cubic boron nitride (CBN) face free from burrs and frittering.
inserts finishes the machining job in
the shortest time

Inserts optimized for motor manufacture

The cast iron used in motor manu-
facture puts special requirements on
insert design. Only specially optimized
geometries and grades will live up
to today’s productivity demands. For
CoroMill® 365 and well-proven
Sandvik AUTO-R, KM optimized-
geometry inserts give unique wear
resistance and greater edge-line
toughness. K-family examples include
K20D (dry milling) and K20W (wet). New
GC1020 inserts feature an optimized
PVD coating for longer operation at
higher speeds. For CoroMill® Century,
CB50 CBN grade means long tool life
plus an outstanding surface finish.

New K20W insert KM geometries are optimized KM geometry inserts in grades K20D and K20W CoroMill Century with CB50 CBN inserts gives
for block and head machining in cast iron. add new life to the Sandvik AUTO-R cutter. high-quality finished surfaces in record times.

Pioneering solutions for CGI machining

Compacted graphite iron (CGI) is making big inroads into
engine manufacture. With 75% higher tensile strength
and around 45% greater stiffness than grey cast iron, CGI
means stronger, lighter engine blocks and cylinder heads.
Exactly what you want – as long as you can machine them
quickly and efficiently. Sandvik Coromant understands
CGI intimately, and how best to machine it! New CGI-optimized KX insert geometries and
Sandvik Auto-R face mills make light work
of machining this novel material in engine
manufacture.

New solutions plus in-depth know-how

Machining CGI is a demanding task if
you don’t know the factors for success.
We do. Thanks to many years R&D
plus active cooperation with the devel-
opers of the material and with engine
manufacturers, we can supply you with
the tools and expertise to extract the
most from CGI’s enormous potential.
For mass production transfer lines,
we have no hesitation in recommend-
ing an Sandvik Auto-R large-diameter in machining centres or multi-task
machining solution. These well-proven, machines is undoubtedly new
extra close pitch face mills can now be CoroMill® 365. The high levels of
operated with new K20D and K20W productivity it achieves in cast iron
inserts featuring new KX geometries milling are equally evident in CGI.
specially optimized for CGI. They mini-
mise burr formation and let you raise
cutting parameters to give greater
productivity.
The face mill best for CGI milling
Overcome bottlenecks in bi-metal milling
Machining aluminium cylinder blocks with grey cast iron
liners poses a dilemma. Aluminium permits high cutting
speeds and requires very sharp cutting edges. In contrast,
grey cast iron demands lower speeds and a stronger
edge. Not surprisingly, bi-metal machining risks becoming
a manufacturing bottleneck. The potential for specialised
tooling solutions to overcome such a hinder is clear.

Our Sandvik Auto-AF 245 face mill-

ing solution combines high bi-metal
removal rates with mirror-like surfaces
that often dispense with the need for
further treatment. This flexible cas-
sette-based concept allows high-preci-
sion axial cutting adjustment for that
extra fine surface finish.

Sandvik Auto-AF 245 for high bi-metal removal rates plus mirror-like finishing of
deck faces. Exchangeable insert cassettes add extra security.

Know-how vital for fast and secure cubing

As more and more auto manufacturers now view aluminium
cylinder blocks and heads as outsourced semi-finished or
even finished products, choosing the right combination of
face mill, insert grade and geometry is more important
than ever. Even foundries and sub-contractors with con-
siderable cubing experience will welcome our expertise
in this field.

Cubing is a demanding technique

where optimized tooling solutions and
support are essential. Whether you
‘cube’ in transfer lines or machining
centres, our expertise means faster
working at lower costs. Three CoroMill®
face mills justify their place at the
forefront of trouble-free cubing.
CoroMill® 790 is particularly use-
ful for removing gates and raisers.
CoroMill® Century and CoroMill® 390
offer secure, high-speed machining.
CoroMill 790 is a fast and deep ‘super-remover’ when cubing
aluminium cylinder blocks.
Head office:
AB Sandvik Coromant
SE-811 81 Sandviken, Sweden
www.coromant.sandvik.com
E-mail: info.coromant@sandvik.com

C-1040:073 ENG/01 Printed on recyclable paper. Printed in Sweden, AB Sandvikens Tryckeri. © AB Sandvik Coromant 2006.06 Your Productivity Partner

www.coromant.sandvik.com