Modular solutions

Modular tooling systems provides the ability to build an optimized and tailored assembly for a specific application using standard items. A relatively small inventory can build a huge number of combinations allowing common tooling systems to be used throughout the factory regardless of the machine interface.

A modular system interface is an intermediate interface sitting between the machine interface and a shank or insert. Applications and machines place different requirements on a modular system interface.

Modularity using Coromant Capto®

Using Coromant Capto® as an interface allows for a huge and flexible combination of assemblies for turning, milling, drilling, boring and tapping. This allows for a common tooling assortment with a relatively small inventory to cover all machine interfaces.

Coromant Capto® is used to build assemblies for:

• Machining centres – milling, drilling, boring and tapping
• Multi-task machines – turning, milling, drilling, boring and tapping
• Vertical lathes – turning

Modular tooling systems opens up many flexible combinations of tool assemblies.

Machining centre spindle interfaces can be divided into small/medium and large/extra large.

Small and medium machine spindle interfaces are selected for smaller tool diameter and shorter gauge length allowing high rpms. For the best and most stable result, use the shortest assembly possible – preferably solid adaptors.

Large and extra large machine spindle interfaces are selected due to the requirement for stability for larger cutter diameters and longer assembly length.

The ability to tailor assembly lengths using extension and reduction adaptors ensures maximum stability and at the same time eliminates the need for special adaptors. All items are stocked standard with next day delivery ensuring that the inventory is kept low.

The machine interface adaptors are available in all machine interfaces in two designs to be able to optimize the assembly length in combination with different lengths of extension/reduction adaptors.

• Short/long length: Steep taper/BIG-PLUS®
• Slender/Heavy duty: HSK

The centre bolt assembly is easily carried out either at the machine or tool room with use of the fixture block.

Use a quick change adaptor to reduce the time spent on set-up and tool change dramatically.

Modular solutions for turning applications

Modular solutions for turning, such as CoroTurn® SL, provide very big benefits for two main reasons, the ability for different tool combinations and cost reduction.

Tool combinations: A large range of combinations can be built up with a relatively small number of adaptors and heads. This eliminates the need for most engineered tools ensuring that standard tools are always available even for some special applications.

Cost reduction: Quick change holders are more expensive than a shank tool or boring bar. By using modular solutions for turning on some of the higher risk applications helps to keep the tool cost at the same level as for shank tools in the long run.

Modular solutions are available for both internal and external turning, parting, grooving and threading applications.

With modular tooling systems you can build many combinations with a small number of adaptors and heads.

There are also modular options for multi-task machining which is beneficial when there is a need to reduce tool change time and at the same time rationalize the number of magazine pockets by using multiple cutting heads on one adaptor.

Typical situations when modular solutions are beneficial:

• Profiling and grooving on large diameter components. Clearance is applied to the cutting heads as well as internal machining so each cutting head can be used in any configuration. CoroTurn SL oval coupling SL70 is a robust solution that gives the rigidity and accessibility needed
• External turning applications where Coromant Capto® cutting units are not available, such as when there is need for extra clearance on RAM:s for vertical lathes and when using internal clamping units

Modular solutions for small/medium sized machines

Milling and boring assemblies require the flexibility to optimize the gauge length to the feature being machined to minimize the risk for vibration. Critical gauge length, stick-out length and clearance/overhang are the main assembly categories requiring consideration.

Critical gauge length

When machining over 3 × the spindle contact diameter, vibration will become a problem with higher cutting forces limiting the metal cutting efficiency. A spindle interface with flange contact (BIG-PLUS® and HSK), provides increased stability and productivity. The gauge length is a limiting factor on small, but even medium-sized, interfaces for end mills.

Stick-out length

The stick-out length from the chuck has an impact on the stability and therefore tendency to vibrate. 4×D is the absolute limit for steel shank tools. Over 4×D solid carbide or heavy metal shanks are required to be able to run without vibration.

Clearance/overhang

Even in small/medium sized machines it could be of interest to use a longer tool assembly to reach the area to be machined. In this case it is important to think about clearance for the whole assembly. Use either an oversized cutter with a straight adaptor (a) or an undersized shank with nominal cutter (b). For more details see long overhangs – considerations

a

b

Learn about Coromant EH, a modular solution for small diameters that provides a broad range of heads and adaptors.