Cutting-tool and tooling-system specialist Sandvik Coromant has unveiled a “revolutionary new turning concept” that offers improved machining flexibility and the potential for significant productivity gains.

The company’s PrimeTurning methodology and supporting tools offer manufacturers — particularly in the aerospace and automotive sectors — the industry’s first true ‘all directional turning’ solution.

PrimeTurning allows machine shops to complete longitudinal (forward and back), facing and profiling operations with a single tool.

The methodology is based on the tool entering the component at the chuck and removing material as it travels towards the end of the component; this allows the use of a small entering angle, a higher lead angle and the possibility of machining with higher cutting parameters.

Furthermore, conventional turning (from the end of the part to the chuck) can be performed using the same tools.
Sandvik Coromant believes that some applications could see productivity increases in excess of 50% through the use of PrimeTurning rather than conventional techniques.

This level of improvement is due to the small entering angle and higher lead angle, as these create thinner and wider chips that spread the load and minimise heat at the nose radius, allowing the use of increased cutting data while at the same time extending tool life.

Furthermore, Sandvik says that because cutting is performed in the direction moving away from the shoulder, there is no danger of chip jamming (a common and unwanted effect of conventional longitudinal turning).

Higher machine utilisation — due to reduced set-up time and fewer production stops for tool changes — also enhances overall productivity.

Håkan Ericksson, global product specialist at Sandvik Coromant, says: “Experienced operators know that a small entering angle allows for increased feed rates.

However, they are restricted in conventional turning to using entering angles of around 90deg to reach the shoulder and avoid the long, curved chips that a small entering angle characteristically delivers.

“PrimeTurning solves these problems by combining a perfect reach at the shoulder and the application of 25-30deg entering angles with excellent chip control and maintained tolerances. This is not just a new tool, but a totally new way of turning.”

PrimeTurning is initially supported by the introduction of two dedicated CoroTurn Prime turning tools and the PrimeTurning code generator, which supplies optimised programming codes and techniques.

CoroTurn Prime inserts have three edges/corners: one for longitudinal turning, one for facing and one for profiling, thus ensuring efficient edge utilisation and longer tool life.

Two inserts are available: CoroTurn Prime A-type features three 35deg corners and is designed for light roughing, finishing and profiling, while CoroTurn Prime B-type features ultra-strong corners and is designed specifically for rough machining.

Suitable for ISO P (steel), S (heat-resistant super-alloys and titanium) and M (stainless steel) category materials, nine CoroTurn Prime A-type and six CoroTurn Prime B-type inserts are currently available.

Inserts for other materials will be introduced in the future. The inserts are supported by 52 variants of tool-holder, including Coromant Capto, CoroTurn QS and shanks.

The PrimeTurning code generator ensures not only maximum output but also process security, with suitably adjusted feed rate and entry radius parameters. It creates ISO codes that are compatible with various CNC systems.

More information can be found at the Web site (www.sandvik.coromant.com/primeturning).