3D printing cutting tools

Sandvik Coromant introduces new 3D printed metal cutting tool to improve productivity

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Swedish tooling systems manufacturer Sandvik Coromant has introduced a new milling cutter with a metal 3D printed head. A first for the company, the component marks a move toward the company’s involvement in 3D printing for end-use production.

An overarching trend for the 3D printing industry,end use production has become a key aim for many stakeholders. Not only does its successful completion demonstrate 3D printing’s transformation from a prototyping technology to a real competitor with traditional manufacturing, it also speaks to the scalability of the process.

At the end of April this year HP announced the integration of its own 3D printed parts into new system hardware. As seen in initiatives like the NextGenAM project from EOS, Daimler and Premium AEROTEC, automation is also a key part of this. A few months earlier Carbon, the Silicon Valley-based company behind Digital Light Synthesis(DLS) 3D printing technology, partnered with Ford to to deliver 3D printed end-use car parts with comparable or even superior properties to injection molded parts.

As part of the wider Sandvik engineering group, Sandvik Coromant’s new 3D printed tool is just one part of a range of undertakings made to strengthen its position in additive manufacturing.

The Lightweight CoroMill 390 additive manufactured milling head and Silent Tools milling adaptor. Image via Sandvik Coromant

Investing in AM innovation

Founded in 1862, the Sandvik AB group works within mining and rock excavation, metal-cutting and materials technology. Its AM related products & services include a consultancy for customers experimenting with, or hoping to develop, additive manufactured parts. As well as a rapid prototyping and serial production service, which it provides using its in house powder bed fusion (PBF) and binder jetting technology. It also offers testing and quality assurance, which includes access to northern Europe’s largest R&D Center for advanced stainless steels, powder-based alloys and special alloys, with sophisticated testing facilities and equipment.

Investing heavily in material development, in 2018 the company allocated $25 million to establish a specialist additive metal powder production plant in Sweden, which is officially set to open in 2020. The investment will accelerate the production of fine metal powders made from titanium and nickel, contributing to Sandvik’s existing Osprey brand of powders.

SEM images of Sandvik’s Osprey gas-atomized metal powders. Top – Stainless steel powder for MIM. Bottom – refined, more uniform stainless steel for additive manufacturing. Images via Sandvik Osprey

More recently Sandvik announced a further collaboration with Renishaw, a UK-based engineering firm and 3D printer provider, to increase its capacity for metal additive manufacturing. As part of the partnership, Sandvik invested in several RenAM 500Q systems, intended for installation in its specialist additive manufacturing plant.

Within the industrial Sandvik AB group, Sandvik Coromant is the company’s tooling supplier which was founded in 1942 and currently operates in 130 countries and employs over 8,000 people.

The Lightweight CoroMill 390

The new Lightweight CoroMill 390 produced by Sandvik Cormorant, is a metal milling head based on the CoroMill 390 design.

Thomas Wikgren, Manager Product Application Management at Sandvik Coromant, explains, “When designing our new lightweight CoroMill 390, material has been tactically removed to create the optimal cutter design for minimizing mass. This is called topological optimization and it makes the cutter more compact and significantly lighter than a conventional version, thus helping machine shops to boost the productivity of their long-overhang milling operations.”

The tool, produced using Sandvik’s trademark titanium alloy Osprey powder, has been specifically developed to overcome vibration issues during metal milling with long overhangs. Such features are a common requirement of components used in the aerospace and oil & gas sectors. Deep cavities in a CNC milled part can be compromised by vibration, leading to slower production, shorter tool life and poor surface finish. When used in combination with the company’s Silent Tools milling adaptors the company reports that the tool can increase productivity by 50%.

Wikgren adds, “a shorter distance between the damper in the adaptor and the cutting edge improves performance and process security.”

The Lightweight CoroMill 390 can perform long-reach face milling, deep shoulder and side milling, cavity milling, and slot milling. The tool is available in 40 mm and 50 mm diameter variants.

You can now cast your vote for the 3D printing innovation of the year in the annual 3D Printing Industry Awards. Help decide this year’s winners now.

Subscribe to the 3D Printing Industry newsletter for the latest news in additive manufacturing. You can also keep connected by following us on Twitter and liking us on Facebook. Looking for a career in additive manufacturing? Visit 3D Printing Jobs for a selection of roles in the industry.

Featured image shows the Lightweight CoroMill 390 additive manufactured milling head. Image via Sandvik Coromant

Tags CoroMill 390 Lightweight CoroMill 390 Renishaw Sandvik Sandvik Coromant Thomas Wikgren

Jack Colyer

Jack holds a MA in International Journalism and has experience writing for The Guardian,The Hackney Gazette, The Islington Gazette and The Conversation.

3D Printing at the Cutting Edge: What AM Brings to Cutting Tools - 3DPrint.com

According to the “Market Opportunities for Additive Manufacturing in the General Industry and Tooling Sector 2020-2029” report from SmarTech Analysis, 3D printing for industrial manufacturing is expected to generate $5.48 billion in total revenue by 2029. One application that is continuing to gain traction is the additive manufacturing (AM) of cutting tools. So, why is 3D printing shaking up the world of cutting tools?

3D Printing Makes Large Cutting Tools More Manageable

One of the downsides of manufacturing large components, such as those for the automotive and aerospace industries, is that bigger parts require bigger cutting tools. However, since the tools are also heavier, there’s a risk of spindle damage or that the tool may fall out of the machine during use.

At least one company has found a workaround for that issue by relying on 3D printing. Star SU Neher uses 3D printing to make the cutting tools weigh less, perform better and last longer than their non-3D-printed counterparts.

By designing in lattice structures, the weight of the tool can be cut by as much as 30 percent. Image courtesy of Star SU Neher.

One of the company’s tool designers mentioned that adding internal lattice structures cuts their products weight by 30% without adversely affecting torsional strength. Plus, company representatives custom-make most of their cutting tools to meet individual components’ needs. 3D printing enables that flexibility.

One of the reasons why the company’s 3D-printed cutting tools last longer is through the incorporation of a cooling channel, a technique that is increasingly used in 3D printing cutting tools. Typically, such channels are created via drilling, a method with limited effectiveness. With AM, channels can be designed directly into the part, improving the tool’s overall effectiveness. The increased flow of coolant can raise metal removal rates by as much as 30%.

3D printing makes it possible to reduce the weight of large cutting tool heads to limit the changes of damage or slippage in a machine tool part. Image courtesy of Star SU Neher.

The 3D printing of large cutting tools is not necessarily faster than creating them through more conventional methods. It can still take up to 24 hours to produce a component that takes up the whole print bed with its size. However, given the other advantages, it can often make good business sense to pursue 3D printing.

3D Printing Can Promote Better Wear-Resistance

Cutting tool manufacturers working with clients in certain industries, such as oil and gas and defense, often need to satisfy the need for wear-resistant tools. Cutting tool maker Kennametal specializes in products made from tungsten carbide. The company has an in-house line of products crafted from that material. Similar to Star SU’s application, the printing process allows for the formation of fluid cooling channels within the tools. Due to the design freedom of AM, 3D those pathways can be curved or branched in ways that other manufacturing methods could not accomplish.

Kennametal is able to 3D print drill bodies with interior cooling channels. Image courtesy of Kennametal.

While Kennametal relies on both metal binder jetting and powder bed fusion (PBF), some of the cutting tools are 10 millimeters or smaller in diameter and require PBF. Representatives say it gives them an economical way to produce tools and meet client needs. Weight reduction is also a possibility. In one instance, a 3D printed boring device used for electric vehicle parts production was 15 to 20 pounds lighter than those made with conventional methods.

3D printing made it possible to cut the weight of this boring tool for manufacturing electric vehicle parts by 15 to 20 pounds. Image courtesy of Kennametal.

3D Printing Helps Revolutionize Cutting Tools

Cutting tools featuring 3D printed components is not yet a widespread practice, but it’s a technology worth exploring. As of now, 3D printing is often less expensive and sometimes faster than conventional methods, depending on the application.

AM won’t replace common methods for producing most cutting tools anytime soon. Many ongoing efforts are still in the early stages and manufacturers will almost certainly find instances where 3D printing is not an appropriate way of producing specific cutting tool types.

The technology is a particular good candidate for tools that have complex shapes. However, when the pieces are large parts with comparably regular geometries, it may make more sense to buy those off the shelf than to use 3D printers to produce them.

Another thing to remember is that, since 3D printing as a tool-manufacturing method is relatively new, decision-makers may want to see how it has paid off for similar companies before giving the go-ahead to invest in it. Once they see the results, they may be more willing to gradually scale up the process.

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Tagged with: 3D printed cutting tools • cutting tools • general industry • industrial 3d printing • Kennametal • Star SU

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3D printing tools.

What you need to have on hand.

If you have a 3D printer, then you will have to master the intricacies of 3D printing. And to facilitate this process, you need to acquire some tools (Tools for 3D printing).

Today we will talk about what kits and tools you may need.

Spatula, scraper…

You may need a spatula and scraper to get started. These can be painting or artistic devices that help to remove the finished model from the working platform. They are especially indispensable in cases where you print with difficult-to-separate plastic.

To remove the model with the blunt end of the spatula, try to pry the model from one side. Once you succeed, try to delete the model manually. If this does not work, then try to squeeze the spatula between the table and the model and slightly raise it.

It is important to be very careful not to scratch the surface of the table and injure yourself.

Deburring tool

This tool is the most indispensable tool of all. It really makes it easy to remove supports, clean up the model. At the same time, the tool is safe, and it is much more convenient to use it than to wield a knife. This tool will be especially useful when cleaning round holes.

Utility knife

This is a knife used for cutting appliqués, sometimes called a hobby knife. This tool is ideal for precise cutting of ABS, PLA and other popular plastics. It is important that this knife is very sharp. But it is also important to follow safety measures when working with the tool.

Pliers, round nose pliers

These tools are extremely useful when removing supports. At the same time, pliers are also useful for the 3D printer itself and for post-processing. Supports can be cut a little with a sharp knife and then with pliers it will be easy to remove them not one by one, but in blocks.

Wood carving set

This set is very useful for fine cleaning of models. The tips in this set have a variety of shapes, which allows for high-quality cleaning of models of any geometry and even in hard-to-reach places: corners, roundness, etc.

Super Glue

In fact, the choice of adhesives is now simply huge, and their possibilities are almost endless. Be sure to get superglue, as it is suitable not only for repairing or filling gaps, but also for gluing individual printed nodes. Be sure to focus on the viscosity of the composition, and also select the right tool. If you need to fill gaps, then we recommend choosing denser compositions than for assembling small parts. An important note - superglue works great with plastics such as ABS and PLA.

Files

A set of mini files will come in handy. Various forms of tools will allow grinding and smoothing of various surfaces.

Sanding (sanding) paper

With the help of grinding, surfaces can be significantly smoothed, achieving the ideal condition of the models. Especially grinding will be relevant if in the future the model will be stained. Sandpaper with a grit size of 120-200 will be the ideal solution for all types of plastics. Models made of ABS are particularly suitable for sanding.

Instead of a conclusion

All the 3D printing tools that we reviewed above will not gather dust on the shelf, waiting in the wings. If you are into 3D printing, then all of them will be in your favor. This is, in fact, the base that any 3D printer should have. Many manufacturers equip their 3D printers with a set of tools that can help with their work. If your equipment comes with a tool kit, take a close look at it so you don't waste money on what you already have.

90,000 characteristics, photos and reviews of buyers 182.91 - 283.99 ₽ to the store

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December 10, 2021

M***.

Color: Cyan, Size: 2PC, Shipping: Yanwen Economic Air Mail

Do not buy this item from this seller. I ordered 2 pliers from this store and the pliers were bentoned and they can't cut properly. Prior to this, I wait twice to receive my item because the pliers were returned to the store by his mail for no reason to me.

July 15, 2021

A***r

Color: Cyan, Size: 2PC, Shipping: AliExpress Saver Shipping

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November 16, 2020

L***y

Color: Cyan, Size: 1PC, Shipping: AliExpress Saver Shipping

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A***s

Color: Blue, Size: 1PC, Shipping: Yanwen Economic Air Mail

Sharp as a hick, perfect for what is described in the description.

August 08, 2021

M***s

Color: Blue, Size: 1PC, Delivery: Cainiao Super Economy Global

Very nice and high quality cutter. Thank you!

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I***r

Color: Cyan, Size: 1PC, Delivery: Cainiao Super Economy Global **h

Color: Blue, Size: 1PC, Shipping: AliExpress Saver Shipping

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A***r

Color: Blue, Size: 1PC, Delivery: Cainiao Super Economy Global

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E***a

Color: Blue, Size: 1PC, Shipping: AliExpress Saver Shipping *s

Color: Blue, Size: 2PC, Shipping: AliExpress Saver Shipping

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received as

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Nickel

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3D printing cutting tools

Sandvik Coromant introduces new 3D printed metal cutting tool to improve productivity

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Jack Colyer

3D Printing at the Cutting Edge: What AM Brings to Cutting Tools - 3DPrint.com

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3D printing tools.

Spatula, scraper…

Deburring tool

Utility knife

Pliers, round nose pliers

Wood carving set

Super Glue

Files

Sanding (sanding) paper

Instead of a conclusion

The price increased by 30.26 ₽

Reliable seller - 100%

tracked.

Prices from other sellers from 163.65 ₽

found 45 similar products

003

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