The cutting edge

Leave your turning center alone: This is automatic tool change

When your machine stops waiting for you and production keeps moving even while you step away, something fundamental shifts on the shop floor. This is the turning point in turning automation. If you walk through the Sandvik Coromant factory in Gimo (Sweden), you quickly learn to stay alert. The floor is busy, the machines are focused on their work, and the small automated guided vehicles (AGVs) can appear at your side without a sound. Each one is named after a Lord of the Rings character, so it’s not unusual to see the mythical Gandalf or steadfast Frodo rolling past on their way to pick up the next batch of materials. We were there to watch automatic tool change (ATC) in action, running steadily in the middle of all this activity. It fits naturally into the pace of the place: consistent, predictable, and designed to keep production moving without adding stress to the team. Step behind the scenes with Bo Hammarberg and Niklas Larsson, Product Manager and Manufacturing Engineer at Sandvik Coromant, and see automatic tool change in action as they talk about the challenges it solves and the shift it brings to turning. In turning centers, efficiency evolves by spotting patterns and acting on them with the right combination of knowledge and tools — but one of the most significant barriers to productivity has always been the moment everything must stop. When the tool wears out, the operator steps in, the machine goes idle, and valuable minutes slip away. Across the industry, this pattern repeats thousands of times a day: small interruptions that accumulate into major losses. For years, this has been the accepted compromise in turning and for many manufacturers, it has become a critical bottleneck, one that the industry no longer has the workforce to absorb. When skilled labour becomes scarce, downtime becomes expensive In one case, a U.S. customer built a new production unit with 40 machines and needed 100 trained operators to run them. They could find just five.  This shortage reshapes how manufacturers think about time, utilization, and risk. Manual tool changes require skill, attention, and availability — three things in increasingly short supply. With every routine manual change or delayed swap, machine utilization drops and cost per part rises. “The skills gap is here and now.” — Bo Hammarberg This is the landscape Sandvik Coromant stepped into when developing automatic tool change for turning centers, closing the final gap in automation that has held turning back for decades. A simple idea with transformative impact “Turning machines have always struggled with the number of tools,” Niklas explains. “Since you only have twelve positions on a turret, you are often very limited.” ATC effectively solves this limitation by combining an external tool stand with robot-managed tool change. Turning centers can now access up to 40 additional tool positions, expanding capability without altering the machine footprint. Tools are monitored automatically, swapped autonomously, and prepared by technicians outside the machine while it keeps cutting. The system is built on machine-adapted clamping units with a Coromant Capto interface, ensuring stable tool changes and compatibility across setups. “The biggest technical advantage is machine uptime.” — Niklas Larsson “Now we can change cutting tools both on static turning tools as well as rotating tools, which no one else can do in the industry today on turning centers,” Bo says. While convenient, the true value lies in the ability to machine continuously, enabling unmanned or lights-out production. “With multiple sister tools, you can run the machine unmanned for long periods,” Niklas says. Using VERICUT, the entire automatic tool change sequence can be simulated and verified virtually before it ever reaches the shop floor, adding another layer of certainty to unmanned production. Automation that protects both performance and people The benefits extend beyond productivity. Turning centers are notoriously tight spaces — cramped, sharp, difficult to maneuver. Operators risk cuts and bruises during manual tool handling, especially when rushing between machines. “With ATC, that risk disappears,” Bo explains. “If you change the tools with the robot, you put safe distance between yourself and potential injury.” Safety is fundamental to Sandvik Coromant and reflects its commitment to manufacturing wellness, where resilient processes, sustainable operations, and healthier working environments form the foundation of progress. “We don’t make machines. We make them better.” — Bo Hammarberg For decades, turning has lagged behind milling and multitask machines in automation maturity. Even highly advanced systems relied on manual tool changes — a missing piece that prevented full lights-out manufacturing. “Automatic tool change is the next step in the machine development when it comes to turning centers,” Bo says. “And now we have come to a breakthrough, where you can have automatic tool change as you have on all other machine concepts today.” The dedication invested in this project is not to be underestimated. “When I started working here three years ago, I was handed this project,” Niklas recalls. “Here we are now, with machines fully up and running. I’m extremely proud.” Machines evolve and we make them better ATC marks a shift in how turning centers work. By taking over a task that once demanded time, focus, and experience, it frees skilled people to work where their judgment actually matters. The machine keeps cutting; the operator keeps creating value. Its impact also represents two habits that define a future-ready workshop: embracing new technology and automating for success. Both reduce the pressure on scarce expertise and create room for clearer thinking, smarter decisions, and steadier production. Remove the repetitive work, and consistency follows. Automate the tool change, and the machine finally runs the way it was built to without unplanned breaks and surprises. This is how reliability becomes part of daily progress, and how manufacturing wellness takes shape on the shop floor. “As a mechanical engineer, I love new technology… This is the future.” — Niklas Larsson With automatic tool change for turning centers, the future is constantly on the move: running, cutting, and producing with minimal downtime and maximum potential for productivity. Leave your turning center alone: This is automatic tool change Leave your turning center alone: This is automatic tool change Leave your turning center alone: This is automatic tool change When your machine stops waiting for you and production keeps moving even while you step away, something fundamental shifts on the shop floor. This is the turning point in turning automation. Automatic Tool Change The article explains how automatic tool change for turning centers increases tool capacity, enables unmanned machining, reduces downtime, and improves operator safety. Overview of Sandvik Coromant’s automatic tool change for turning centers, extending tool capacity, enabling unmanned production, and improving safety and utilization by automating tool changes with robot-handled tooling. chevron_right

This is how you turn productivity insight into sustainability impact

The data is clear: sustainability is now a business mandate. Fictiv’s 2025 State of Manufacturing report shows that 91% of manufacturers have sustainability governance in place, and 95% say sustainable practices are essential. Energy costs, regulations, and customer expectations are driving a fundamental shift in how workshops operate. Yet even with these commitments, most factories still lack one crucial capability: the ability to see their true energy consumption and CO footprint component by component, operation by operation. The Sustainability Analyzer changes that. Developed as an extension to the long-established Productivity Analyzer, it brings energy, emissions, and cost data directly into everyday machining analysis. Instead of guessing where inefficiencies are hidden, manufacturers can now see the full picture right down to the component. Why energy visibility is crucial Today’s CNC machines consume more power than ever. Idle energy, spindle load, cooling systems, and toolpath choices all contribute to a workshop’s environmental footprint. Even small inefficiencies compound into significant cost and emissions over a year, yet many manufacturers still have no system to measure them. That gap in visibility is exactly where the Sustainability Analyzer creates value. By combining spindle energy data, idle power consumption, local electricity pricing, and regional CO intensity, it turns complex production data into clear, actionable insights. What the Sustainability Analyzer brings to your shop floor The white paper breaks down how the tool creates a unified view of both productivity and sustainability, enabling manufacturers to: Understand energy usage per component Track annual CO emissions linked to machining Identify where savings can be unlocked Validate tooling or process changes with real numbers Support decisions that align productivity, cost, and climate targets In other words, it helps manufacturers transform sustainability from a broad ambition into something measurable, manageable, and tied directly to performance. Why it matters now From the EU’s Carbon Border Adjustment Mechanism (CBAM) rollout to increasing investor pressure, environmental performance is becoming a competitive differentiator. Manufacturers who cannot quantify their impact will struggle to meet new expectations, while those with the right data can move faster, invest smarter, and demonstrate real progress. Tools like the Sustainability Analyzer offer exactly that advantage. Want the full picture? The Sustainability Analyzer white paper focuses on minimizing manufacturing’s environmental impact with data-driven insights and explores: The industry pressures reshaping sustainability in machining Why energy data is becoming a core business metric How the Sustainability Analyzer works and what it reveals How manufacturers can use it to accelerate both productivity and emissions performance Read the full white paper to see how data-driven insights can reshape your approach to sustainability. Highlights Minimizing emissions and climate impact based on data with Sustainability Analyzer The analyzing tool that helps customers reduce their energy consumption and carbon emissions based on data This is how you turn productivity insight into sustainability impact This is how you turn productivity insight into sustainability impact This is how you turn productivity insight into sustainability impact The data is clear: sustainability is now a business mandate. Fictiv’s 2025 State of Manufacturing report shows that 91% of manufacturers have sustainability governance in place, and 95% say sustainable practices are essential. Energy costs, regulations, and customer expectations are driving a fun... Sustainability Analyzer Overview This article describes how the Sustainability Analyzer uses machining data to quantify energy use, emissions, and costs so manufacturers can align productivity improvements with sustainability goals. Explains how the Sustainability Analyzer links machining productivity data with energy use, emissions, and costs to make environmental performance measurable and manageable. Describes its role in visualizing energy per component, validating process changes, and supporting decisions that balance productivity, cost, and climate targets. Outlines regulatory and market drivers that make quantified sustainability a competitive factor for manufacturers. Summarizes what the white paper covers about using data to reduce machining-related CO2 footprint. chevron_right

Technology serves people. Always.

In every factory, the numbers matter — but behind every number, there’s a person. An operator who trusts the machine, an engineer who chases ideas, a partner who listens and responds. That’s the real drive of manufacturing wellness: technology shaped by people, for people. “We needed trust, not just a tool.” At Hägglunds, a Bosch Rexroth brand, cam ring drilling in bearing steel had long been a battle. The material is unforgiving, and the stakes are high — one bad hole can jeopardize a whole component. For Andreas Branthsson, Production Engineering Manager, the real problem wasn’t speed. It was trust. “Our old tool just wasn’t durable or reliable enough. We didn’t trust it to deliver and couldn’t leave the machine unattended like we wanted to,” he recalls. The solution came through collaboration. Working side by side with Mikael Carlsson, Product Application Specialist at Sandvik Coromant, Hägglunds adopted the CoroDrill DE10, an exchangeable-tip drill designed not just for toughness but for consistency. After extensive testing, the drill proved itself. Operators could walk away from the machine knowing the next part would match the last.  “What makes this drill stand out is the repeatable hole quality,” says Carlsson. “We drilled thousands of holes in testing, and the consistency was there, hole after hole.” Productivity rose 18 percent — but more importantly, confidence returned to the shop floor. Production engineers on the shop floor at Häggunds. “Fractions of a hair aren’t good enough.” That same pursuit of trust shapes the way Sandvik Coromant develops tools. As Nils Wik, R&D Engineer, and Senior R&D Professionals André Svensson and Fritz Alum Yah put it during the CoroDrill DE10 project: “Even fractions of a hair that could be wrong is not good enough. This idea is what’s going to define the future.” For CoroDrill DE10, the development team ran thousands of simulations before cutting the first chip, using digital twins to tweak the design virtually and refine it until only the most durable design concept remained. The result was a patented clamping interface and a geometry that delivers repeatable, reliable holes every single time. Technology, yes. But more than that, it’s the mindset of people who push themselves to build a product that can be relied on. From left to right: André Svensson, Fritz Alum Yah, and Nils Wik at the Sandvik Coromant Center in Sandviken, Sweden. Milling without doubt The same principle drives the CoroMill MS20 shoulder milling cutter, created to make shoulder milling less of a gamble. True 90-degree shoulders, predictable wear, and fewer tool changes — it all adds up to one thing: less uncertainty for the operator. Instead of juggling multiple cutters or worrying about sudden insert failure, teams can focus on the work itself. CoroMill MS20 simplifies the workflow, reduces inventory headaches, and gives machinists the stability to plan, not just react. People first, technology second The tools matter. But they matter most when they free people (operators, engineers, managers) to do their best work. That’s what embracing new technology really means in manufacturing wellness. Not chasing the latest release for its own sake, but adopting solutions that make life simpler, safer, and more rewarding for the people behind the machines. Because in the end, the greatest outcome isn’t just thousands of perfect holes or flawless shoulders. It’s the human certainty that tomorrow’s shift will be just as good as today’s. Explore Embrace new technology for more real stories of progress in action. Technology serves people. Always. Technology serves people. Always. Technology serves people. Always. In every factory, the numbers matter — but behind every number, there’s a person. An operator who trusts the machine, an engineer who chases ideas, a partner who listens and responds. That’s the real drive of manufacturing wellness: technology shaped by people, for people. People-Focused Technology This article explains how drilling and milling tools are developed and applied to improve reliability, repeatability, and confidence for people working in metal cutting production. Article showing how drilling and milling solutions like CoroDrill DE10 and CoroMill MS20 are developed and applied to increase process reliability, repeatability, and operator confidence in metal cutting production. chevron_right

Trajectory Optimization in Face Milling Operations

Face milling is a fundamental machining operation used to generate flat surfaces with high precision. Traditionally, it has been optimized based on parameters such as cutting speed, feed rate, and depth of cut. However, the trajectory followed by the tool also plays a crucial role in the overall efficiency of the process, both in terms of energy consumption and the usual effects on tool life, productivity, and surface quality. Types of trajectories in Face Milling Thanks to the development of CAM systems, we now have a wide range of options for machining trajectories for roughing and finishing surfaces. Among all these options, there is a main difference: some operations keep the tool always in contact with the workpiece, while others include idle (non-cutting) movements. We can classify them into four basic categories: Unidirectional : The most basic and easiest operation to program. The tool works with linear trajectories in the same direction and returns without cutting. Acceptable surface finishes are obtained, but if direct entry is used, it can affect tool life and increase the total cycle time. Zig-zag (bidirectional) : Linear movements with the tool moving in both directions, reducing idle times, but with negative effects on the resulting surface quality. Managing the changes in direction can affect tool life. Spiral: Either towards or from the inside of the workpiece, it allows for continuous cutting with controlled engagement, offering good surface finishes and good control of tool life while reducing machining times. Adaptive and trochoidal : Trajectories that optimize tool-material contact by maintaining controlled radial engagement, improving surface quality. They usually include small idle movements in hard-to-reach areas but aim to keep the tool in contact as much as possible. They are highly recommended for difficult-to-machine materials. Each of these trajectories has different implications in terms of machining time, workload, energy consumption, and heat generation. CO Emissions In this article, we will mainly address the energy effect of trajectories by comparing those that maintain constant contact between the tool and the workpiece with those that, due to their configuration and different orientation, involve idle (non-cutting) movements. To illustrate this comparison, we will use, an alternative unidirectional trajectory and a spiral trajectory from the outside, both under the same cutting conditions, and compare the energy consumption of both options. Subsequently, we will compare both trajectories with improved cutting conditions. We can calculate the power consumed on different materials, selected from a wide data base, and using specific combination of tools and inserts geometries, during a milling operation using “ToolGuide,” available at this link. ToolGuide For a face milling operation with the CM345 ref 345-050Q22-13H Z6, with inserts 345R-1305M-PM 1230, on a 32CrMoV12-28 P3.0.Z.AN steel workpiece with 230 Hb, we will start from these two cutting conditions, which will give us two different cutting power consumptions. During rapid movement at speeds of 5,000 to 10,000 mm/min (without cutting load) on a conventional 5-axis CNC machine with a maximum power of 40 kW, typical energy consumption ranges between 4 and 7 kW. For our example, we will use 5.5 kW as the calculation value. The components that make up this basic machine consumption are: Software and electronic equipment of the machine. Machine movement, plus the rotation of the cutting spindle itself. The higher the feed rate, the greater the energy demand. Machine movement, plus the rotation of the cutting spindle itself. The higher the feed rate, the greater the energy demand. This range is useful for estimating energy consumption during rapid positioning phases or movements between operations, especially in intensive machining cycles. Case Studies Case 1: Unidirectional vs. Spiral trajectories. In a face milling operation on a 250x250 mm steel plate, two trajectories were compared: unidirectional and spiral. The spiral trajectory has a total cutting length of 1,250 mm, which is equivalent to 38.26 seconds of cutting time. In the unidirectional trajectory, there are 5 paths of 300 mm each, and we must add 4 return paths with a table feed of 7,500 mm/min. This allows the total machining to be completed in 45.918 9.6 55.51 seconds, an increase due to the non-cutting return time. The cutting power is 16.7 kW, and the power consumed during idle movements is 5.5 kW. Therefore, the total energy consumption during the cutting time is 0.2276 kWh for the unidirectional trajectory and 0.1774 kWh for the spiral trajectory. The graph provides a clearer view of the kWh savings. Comparison between unidirectional and Spiral trajectories Case 2: Comparison between original and higher Fz0,4 cutting conditions. We have already seen how idle movements of the machine affect energy use. Now, if we take our second set of cutting conditions, with a feed per tooth of 0.4 mm, we can observe the effect of increased cutting parameters on both energy consumptions. The working power will increase to 18.1 kW, but the cutting time for the spiral trajectory will decrease to 33.48 seconds. In the unidirectional operation, the cutting time will be 40.17 9.6 50.07 seconds. Therefore, the new total energy consumption during cutting time is 0.2166 kWh for the unidirectional trajectory and 0.1683 kWh for the spiral trajectory. This is a counterintuitive result, cause with higher cutting power, we obtain lower energetic total consumption thanks to cycle time reduction. Increase feed on unidirectional trajectories effect Increase feed on unidirectional trajectories effect Energy and CNC Machine Cost Analysis by Region The following table presents a comparative analysis of energy costs, CNC machine hourly rates, and average CO emissions per kilowatt-hour (kWh) across different regions. This data is useful for evaluating the environmental and economic impact of CNC operations globally. And here are the data for all the cases studied. kwh y CO2 emissions and cost based on average data for all regions. Conclusion The choice of trajectory in face milling operations not only affects quality and productivity but also has a direct impact on process sustainability—energy costs, direct machine costs, and CO emissions into the atmosphere. Adopting optimized trajectories through advanced CAM software allows you to: Improve energy efficiency. Reduce tool wear. Decrease CO emissions. Lower direct machining cost and increase productive capacity. For CO consumption, the reduction is 26% when comparing the unidirectional trajectory with Fz0.35 to the spiral trajectory with Fz0.4. This also results in a 40% economic reduction . In an industrial environment increasingly focused on sustainability, these technical decisions can make a significant difference. Selecting tools that allow us to work at the highest cutting conditions will achieve both direct economic savings and reductions in CO emissions. Alvaro Ruiz Global product solution specialist Milling Trajectory Optimization in Face Milling Operations Face milling is a fundamental machining operation used to generate flat surfaces with high precision. Traditionally, it has been optimized based on parameters such as cutting speed, feed rate, and depth of cut. However, the trajectory followed by the tool also plays a crucial role in the overall ... Face Milling Trajectories This article analyzes how different face milling trajectories affect machining time, energy consumption, CO emissions, and overall process cost. Overview of face milling toolpath strategies, their impact on cutting time, energy use, CO emissions, and cost, with case studies comparing unidirectional and spiral paths under different cutting conditions. chevron_right

Mastering high-volume hole making

Overcoming common drilling pain points with CoroDrill DE10 High-volume drilling requires precision, efficiency and reliability to meet demanding production schedules and maintain cost-effectiveness. For manufacturers, these requirements often pose challenges, such as ensuring tool longevity, achieving consistent hole quality and minimizing downtime. So, what’s required to achieve more efficient hole drilling in an increasingly competitive environment? Here, Mikael Carlsson, Global Product Specialist for Indexable Rotating Tools at Sandvik Coromant, explains how a new drilling innovation could reinvent high volume hole making. Several shifts in manufacturing trends are increasing the demand for high volume drilling. Producing electric vehicles (EVs), for example, requires drilling thousands of precise holes in battery enclosures and thermal management systems, intensifying the need for reliable, scalable solutions. Similarly, renewable energy sectors, such as wind and solar power, rely on high-volume drilling for producing key components like wind turbine shafts and solar mounting systems, where accuracy and durability are paramount. In industries where efficiency and reliability are non-negotiable, finding solutions that balance these demands is critical. Drilling down the challenges High-volume hole making often reveals challenges that can be underestimated, even by experienced manufacturers. Many already recognize the critical importance of tool wear and cycle times, but it is the hidden complexities of high-speed and high-penetration operations that can profoundly impact productivity and operational efficiency. Take, for example, thermal and mechanical stresses encountered during the drilling of thousands of holes — especially in typically more challenging materials like hard steels and heat resistant super alloys. These forces can lead to accelerated tool fatigue, burr formation or even deformation of the workpiece. Such challenges go beyond tool durability. They involve understanding the interplay between the tool's geometry, coatings and material composition with the specific characteristics of the workpiece. Effective heat dissipation, resistance to microfractures and the ability to maintain edge sharpness over prolonged use are all crucial factors for ensuring consistent quality across extended production runs. Another consideration is the cost impact of seemingly minor inefficiencies, such as setup or tip changes. In large-scale operations, for instance, even a small amount of downtime per shift — whether due to recalibrating machines for a new tool or replacing worn-out tips — can accumulate into substantial productivity losses. These inefficiencies highlight the importance of streamlined solutions, such as systems designed for quick setup, precise alignment and easy tool changes. Additionally, eliminating unnecessary steps in the drilling process can drive significant time and cost savings. For example, tools that remove the need for pilot holes or pre-setting equipment can drastically reduce cycle times and minimize the reliance on operator intervention, thereby increasing overall process stability and throughput. Addressing these pain points with thoughtful planning and optimized tooling strategies is essential for manufacturers striving to meet the demands of high-volume production without compromising on quality or efficiency. A streamlined approach Introduced by Sandvik Coromant in March 2025, CoroDrill DE10, an advanced exchangeable-tip drill designed for high-volume hole drilling, aims to address these drilling challenges. CoroDrill DE10 is shown to boost productivity while streamlining operations, due to its advanced -M5 tip geometry. This innovative design achieves an ideal balance between high feed rates and precise penetration, enabling the tool to deliver exceptional performance across diverse materials. From steel alloys to stainless materials, CoroDrill DE10 can ensure consistent hole quality while also minimizing the risks of burr formation or workpiece deformation. A crucial feature of CoroDrill DE10 is a patented pre-tension clamping interface, which combines familiar design with enhanced security. The interface enables fast and easy tip changes without spare parts, ensures reliable drilling at high feeds and speeds, delivers superior clamping strength and achieves straighter holes with tighter tolerances. It also extends drill body life, making CoroDrill DE10 the most robust exchangeable-tip drill of its kind. Furthermore, CoroDrill DE10 also eliminates the need for pilot holes to further streamline workflows and reduce cycle times and inventory complexity. Its robust design supports extended tool life, with more tips per tool body, which ultimately drives down the cost per hole. As a plug-and-play solution, CoroDrill DE10 integrates effortlessly into existing setups, making it a practical upgrade for manufacturers looking to enhance productivity without overhauling their systems. It also integrates seamlessly with digital machining systems through Sandvik Coromant's CoroPlus platform. This compatibility provides operators with precise cutting data and real-time performance insights, so parameter settings can be optimized and tailored to specific materials and applications. Operational and cost-saving benefits Several success cases have highlighted how CoroDrill DE10 drastically improves productivity in high volume drilling. In testing conducted in Italy, CoroDrill DE10 demonstrated significant performance advantages over a competing tool while drilling AISI316L stainless steel. The case involved 52 mm through and blind holes, using emulsion coolant at 70 bar. CoroDrill DE10 achieved a remarkable 57% increase in productivity and 43% longer tool life compared to its competitor. The tool also delivered excellent hole surface quality, consistent chip control and sound-level performance aligned with expectations. The tool’s robust design and advanced -M5 tip geometry ensured reliability and repeatability — and both were key factors for the high-value components in this application. With a higher feed rate, extended tool life and reduced need for downtime, CoroDrill DE10 proved to be a cost-effective, efficient and sustainable solution for high-volume drilling in challenging materials. In another case, an automotive manufacturer faced issues with high cutting forces deforming its drill bodies, specifically while machining gearbox housing components from 47CrMo4 alloyed steel. This issue led to tool failures and increased costs. Instead, switching to CoroDrill DE10 resolved these challenges. Using a feed rate of 0.35 mm/rev at a depth of cut of 2.5 times the drill diameter, the tool delivered a 17% productivity boost. As in other applications, CoroDrill DE10's robust design and patented pre-tension clamping interface ensured exceptional accuracy, extended tool life and minimized downtime. These examples demonstrate how CoroDrill DE10 meets industry needs while offering significant operational and cost-saving benefits. High-volume hole-making demands precision, durability and efficiency, making it essential for manufacturers to overcome its challenges to achieve greater productivity and remain competitive. With its advanced features, tools such as CoroDrill DE10 offer a new perspective on drilling, and a strategic solution for the future of manufacturing. Learn more about CoroDrill DE10 Sandvik Coromant info.coromant@sandvik.com Mastering high-volume hole making Mastering high-volume hole making High-Volume Drilling This article examines high-volume drilling challenges and introduces CoroDrill DE10. Explore methods to tackle challenges of high-volume hole making with the CoroDrill DE10. Special features enhance productivity and tool life while reducing inefficiencies. chevron_right

Unlocking the benefits of multi-material drills

Versatile drilling offers a key to more productive manufacturing In January 2025, the World Economic Forum reported that facilities identified as part of its Global Lighthouse Network are achieving remarkable productivity gains of 70%, while simultaneously reducing energy costs by 40% and time to market by 40%. Lighthouses aside, how can all manufacturers raise their productivity, without increasing costs? Here, James Thorpe, Global Product Manager for Hole Making and Composite Machining at Sandvik Coromant, explains how a new drilling tool can enhance manufacturing production goals for multi-material applications. Beyond the Lighthouse facilities, manufacturers across the globe are increasingly tasked with producing parts from a diverse array of materials — from hardened steels and composites to softer metals and plastics — all while striving for uncompromising precision and efficiency. Addressing these challenges head-on requires tooling solutions that not only push the boundaries of traditional drilling capabilities but also streamline operations in an increasingly competitive market.  Overcoming pain points   Drilling is a fundamental yet technically demanding operation in modern manufacturing. One of the most persistent challenges involves material variability. Manufacturers often work with a wide range of materials, from tough hardened steels to lightweight but ductile metals. Each material presents unique difficulties —hardened steels can cause excessive tool wear, while softer metals may deform under drilling forces.  Heat generation and tool wear are also significant concerns in drilling operations. High cutting speeds, prolonged machining cycles and demanding material compositions contribute to excessive heat buildup. This not only accelerates tool degradation but also impacts machining accuracy, leading to surface defects and deviations from required dimensions. Effective heat management solutions, both in tool design and machining strategies, are therefore critical for extending tool life and improving component quality.  Another key challenge is chip evacuation. In deep-hole drilling or high-feed applications, inefficient removal of chips can lead to clogging, increased heat generation and even tool failure. Drill flutes must be designed to facilitate smooth and consistent chip evacuation, preventing operational disruptions and maintaining stable machining conditions.  Process stability is equally essential for precision manufacturing. Accurate hole positioning and straightness are critical for high-quality components used in sectors such as aerospace and automotive. Any deviation can compromise the functionality of the final product, leading to costly rework or component rejection. Achieving and maintaining stability requires a combination of robust tool geometry and optimized machining parameters.  Lastly, manufacturers face growing pressures to adopt sustainable and cost-effective production practices. Reducing waste, extending tool life and minimizing energy consumption are priorities as companies strive to meet both economic and environmental goals. These factors drive the demand for drilling tools that deliver superior performance while lowering the total cost per part.  A drill for all materials    To boost productivity and maintain cost-efficiency, there’s a growing need for versatile drills that can handle multiple materials, eliminating the need for frequent tool changes while lowering tooling costs. Advances in coatings and tool design enable these multi-material drills to perform well without compromising quality, offering both cost savings and improved sustainability.  A prime example of this is CoroDrill Dura 462, which is specifically engineered to enhance performance across a wide range of materials. Featuring a fine-grained cemented carbide substrate, CoroDrill Dura 462 offers exceptional wear resistance and reliability with a well-controlled microstructure that ensures consistent results, even when working with challenging materials like hard metals or ductile alloys. This makes it an invaluable tool for manufacturers seeking uniform precision and stability, no matter the material composition of their components.  CoroDrill Dura 462’s geometry is designed with versatility in mind. The tool’s point design significantly reduces cutting forces, improving positional accuracy, especially in high-tolerance applications. The drill’s clearance angles reinforce point strength, while its single-margin configuration helps minimize heat buildup, further enhancing tool stability and overall performance.  Further enhancing its performance is Sandvik Coromant’s patented Zertivo 2.0 PVD coating, which, alongside the fine-grained carbide substrate, provides superior wear resistance and enables high-speed drilling while maintaining process stability.  Benchmarking results have shown the tool’s clear competitive advantage. In one customer case, CoroDrill Dura 462 increased productivity by 110% and extended tool life by 36%. Another case demonstrated an 85% productivity gain and a tool life that more than doubled compared to a low-cost competitor.  While WEF's Lighthouse facilities guide the industry toward more efficient manufacturing, manufacturers need the right tools to navigate the complexities of multi-material production. By adopting versatile solutions that tackle material variability, heat management and process stability, they can chart a course toward significant productivity breakthroughs and operational excellence.  Learn more about CoroDrill Dura 462 Sandvik Coromant info.coromant@sandvik.com Unlocking the benefits of multi-material drills chevron_right

Hands free tool changes for smarter machining

Imagine a factory where the lights are off, not because no one is home, but because automated systems are working around the clock to keep production lines running with minimal human intervention. These futuristic setups are quickly becoming a reality, with touchless tool changes at the core of the automated machine cell. Here, Peter P Andersén, Manufacturing Engineer, and Lars Matiasson, Manager Global Manufacturing Equipment & Engineering, at leader in metal cutting tools and manufacturing solutions, Sandvik Coromant, unveils more about the company’s latest innovation in automatic tool changes. Unmanned machining represents a significant leap in manufacturing, where machines operate independently without the need for human supervision. Driven by CNC technology, robotics and automation software, these systems can run continuously — in some cases, 24/7 — performing tasks such as turning, cutting, milling and drilling with high accuracy. This approach enhances productivity, reduces errors and allows for efficient, around-the-clock operation. While many view unmanned machining as a futuristic approach to manufacturing production, Sandvik Coromant began reaping its benefits back in the 1980s. Going hands free Some 40 years ago, Sandvik Coromant’s production site in Gimo, Sweden, used a form of automatic tool change (ATC) that facilitated the changeover of machine tools without human input. The solution was offered as a product to customers, but it didn’t prove popular. Many could not grasp how ATC could save their machine shop time and enhance their productivity and the offering was dissolved. Fast forward a few decades and Sandvik Coromant continued to see value where others could not. This time around, the company worked with a machine builder to develop a second ATC solution. Again, it was implemented at the Gimo production facility and continues to run across several machine cells today. Using conventional tool management methods, a lathe could run without human input for around four-to-eight hours. After that, the tool would reach the end of its life and a human worker would need to stop what they’re doing to manually switch the tool with a new replacement. With the ATC solution, machines can run for up to 16 hours without an operator worrying about them. A new take on turning After using ATC technology for several years, Sandvik Coromant has now developed a solution for its customers that enables hands-free tool changes in turning operations. The new ATC system for machine-adapted clamping units (MACU) in turning centers fully automates the tool-changing process, eliminating the need for manual intervention. This leads to higher machine utilisation and improved productivity. So, why now? In the 1980s, the benefits of ATC were not as widely recognised. However, today, automating repetitive, time-consuming tasks is essential for creating more resilient and efficient production lines. The immediate benefit is the time it saves human workers. Running machines for up to 16 hours — four times longer than before — without the need for operator intervention  allows operators to focus on other tasks, rather than being occupied with constant tool wear inspections. ATC also helps optimise tool wear. When operators manually change tools while juggling multiple other tasks, they often replace tools prematurely, before they’ve reached their full potential. With ATC, tools are changed only when they're fully worn, maximising tool life and reducing waste. ATC also delivers significant sustainability benefits, including lower energy consumption, enhanced resource efficiency reduced waste and improved overall equipment efficiency. By keeping machines running at optimal levels, ATC minimises idle time and energy waste, increases output with fewer resources and reduces the frequency of breakdowns and downtime. Taking a holistic approach To create a future-proofed shop floor — whether the lights are on or off — ATC is a crucial piece of the puzzle. At the heart of Manufacturing Wellness , an initiative driven by Sandvik Coromant to promote healthy practices in future-ready manufacturing facilities, lies the importance of a holistic approach to production. In modern manufacturing, a comprehensive strategy boosts efficiency, productivity and sustainability. By optimising the entire process — from materials and equipment to environmental impact — companies can enhance operational performance. Advanced technologies and cross-department collaboration are key to achieving these goals. This all-encompassing strategy not only elevates quality but also secures long-term success in a competitive market. ATC forms a central part to this holistic take on machining, but Manufacturing Wellness is about more than just individual innovations; it’s about creating a seamless, resilient production ecosystem. ATC plays a key role in this broader vision, enabling factories to go beyond isolated efficiency gains to achieve true operational harmony. By automating routine tasks like tool changes, ATC frees up human operators for more strategic roles, while ensuring machines run at peak efficiency with minimal downtime. This integration of smart automation within a larger, wellness-driven framework positions manufacturers to thrive in an increasingly competitive, resource-conscious world. Sandvik Coromant’s ATC is applicable in turning centers and multi-task machines, requiring a MACU with a Coromant Capto interface. For turning centers, an ATC-enabled MACU turret is necessary, while multi-task machines with a lower turret can utilise ATC if the turret is ATC-prepared. Learn more by visiting the website. Sandvik Coromant Together with our customers and partners, Sandvik Coromant leads the way toward a sustainable future, supplying tooling solutions to the world’s engineering industries. Over eight decades of hands-on experience have given us a wealth of knowledge in metal-cutting and machining. This expertise transforms every challenge into an opportunity for innovation, collaboration, and progressive solutions. We aim to create positive change by promoting sustainability, efficiency, and growth to shape a future where innovation thrives. Part of global industrial engineering group Sandvik, Sandvik Coromant is shaping the future together. For more information visit www.sandvik.coromant.com or join the conversation on social media. Experience smarter machining with hands-free tool changes. Learn how Sandvik Coromant boosts productivity, reduces waste, and enhances efficiency. automatic tool change, hands-free machining, CNC automation, unmanned machining, Sandvik Coromant, manufacturing solutions, tool wear optimization, lights-out machining, smart machining, productivity in manufacturing, turning centers automation, sustainable machining, machine integration Hands free tool changes for smarter machining Hands free tool changes for smarter machining Experience smarter machining with hands-free tool changes. Learn how Sandvik Coromant boosts productivity, reduces waste, and enhances efficiency. Hands-Free Tool Changes This article explains Sandvik Coromant’s automatic tool change solution for turning and multi-task machines and how it supports unmanned, efficient, and sustainable machining. Overview of Sandvik Coromant’s automatic tool change system for turning and multi-task machines, enabling unmanned, lights-out machining, extended tool life, and higher equipment utilization within a holistic Manufacturing Wellness approach. chevron_right

Master the unmachinable

Machining composite materials remains one of manufacturing’s toughest challenges. Abrasive fibers, layered structures and sensitivity to heat and vibration often result in unpredictable cutting behavior, delamination, and accelerated tool wear. Their poor thermal conductivity means composites are usually machined dry, making heat even harder to control. So what does it take to machine these materials more efficiently and with greater confidence?  Here, our experts in solid carbide end milling tools at Sandvik Coromant explain how. Composite materials, especially carbon and glass fiber reinforced plastics (CFRP/GFRP), impose unpredictable cutting forces that can vary dramatically depending on fiber direction, resin content and manufacturing method. Conventional tools can dull quickly on hard fibers, while excessive cutting forces or improper geometries often cause delamination or leave uncut fibers. The result is inconsistent performance and elevated scrap rates. The serrated router,  CoroMill Plura composite 2P350 , was developed to address these challenges directly, offering sharper, more durable edges and a geometry optimized for stable, low-defect machining. This is a significant step forward in stability, quality and process security when working in demanding composite applications. Patented dual cutting mechanism A crucial feature of CoroMill Plura Composite 2P350 is its patented serrated geometry, designed to deliver a balanced, scissor-like dual cutting action. This coordinated mechanism effectively clamps and shears the fibers, reducing cutting forces and countering the tendency of composite layers to split and delaminate or produce uncut fibers. The geometry balances cutting loads across all flutes, preventing any single tooth from taking excessive force. This results in lower and more consistent cutting forces compared to traditional routers, protecting both the tool and the workpiece. Reduced cutting forces also contribute to better surface finish and less risk of delamination or uncut fibers. By disrupting harmonic vibrations, the geometry also contributes to a more stable and quieter machining process. The controlled cutting action not only improves surface integrity but also enables reliable one-pass machining, supporting both process security and a more comfortable sound level in the workshop. A grade for abrasive composite environments The introduction of grade O2AD marks a significant breakthrough for tool life and long-term stability. Composite materials are extremely abrasive, and tools often lose sharpness quickly if not specifically engineered for these conditions. Grade O2AD is developed specifically to combat these challenges, featuring an optimized CVD diamond coating and a tailored substrate that enables strong adhesion between the two. The synergy between the coating and the substrate helps maintain excellent edge-line sharpness for optimal cutting action, ensuring excellent abrasive wear resistance, longer tool life, more predictable performance and less frequent tool changes. Internal tests and customer evaluations show that grade O2AD can double the tool life compared to the previous grade O12M, delivering clear gains in productivity and cost efficiency. Performance in aerospace and beyond CoroMill Plura composite 2P350 is particularly well-suited for the aerospace industry, where composite components must meet strict structural and dimensional requirements. The tool has shown strong performance when machining fuselage frames, wings, stabilizers, spars, ribs, floor beams and other critical structures. The tool’s reliable behavior across slotting, ramping and edging operations contributes to a more predictable machining process with less scrap and rework, which is especially valuable in high-value production environments. By enabling one-pass machining in these operations, it reduces the need for secondary operations. Simultaneously, the large flute volume enables efficient chip evacuation and high material removal rates, boosting productivity.  Beyond aerospace, industries such as automotive, defense, space and maritime benefit from the tool’s controlled cutting and consistent results, making this tool a versatile option for a broad range of applications.  Beyond aerospace, broader industries such as automotive benefit from the tool’s controlled cutting and consistent results, making this tool a suitable option for a broad range of industry segments and applications. The full portfolio CoroMill Plura composite 2P350 with grade O2AD represents a major advancement in composite machining tooling. Through its patented cutting geometry, optimized diamond coating and proven performance across demanding applications, it provides the process security and productivity needed to machine one of the industry's most challenging materials.  For even more specialized composite operations, CoroMill Plura composite 2P350 is supported by a wider portfolio. CoroMill Plura composite 2P460 compression router is ideal for components with woven glass layers on both sides, providing excellent vibration control in thicker materials through its overlapping flute design. For finishing operations, CoroMill Plura composite 2P050/2P051 low helix routers enable smooth, burr-free edges in composites and CFRPs, with right/left helix options for improved fixture stability and high-feed capability.  Together, these tools form a complete portfolio designed to help manufacturers achieve consistent, high-quality results across the full spectrum of composite machining challenges. Solid carbide end mill for composite machining CoroMill Plura composite Machining composite materials is a battle of unpredictable forces, heat sensitivity and rapid tool wear. For successful machining, sharp and controlled cutting is required to avoid delamination and vibration. Sandvik Coromant info.coromant@sandvik.com CoroMill Plura Composite Master the unmachinable Machining composite materials remains one of manufacturing’s toughest challenges. Abrasive fibers, layered structures and sensitivity to heat and vibration often result in unpredictable cutting behavior, delamination, and accelerated tool wear. Their poor thermal conducti... Composite Machining Tools This article explains how CoroMill Plura composite tools and the O2AD diamond-coated grade improve tool life, process stability, and surface quality when machining abrasive composite materials such as CFRP and GFRP. Overview of CoroMill Plura composite routers with serrated geometry and O2AD diamond-coated grade for stable, low-defect machining of abrasive CFRP/GFRP in aerospace and other industries. chevron_right

Productivity meets sustainability

The Winning Combination with New CoroMill Face and Shoulder Milling Cutters In today’s competitive industrial landscape, performance, cost efficiency, and environmental responsibility are non-negotiable. That’s why CoroMill  milling solutions have become the gold standard for excellence—delivering superior results in the most demanding operations, from roughing to finishing, across all material types, especially ISO P, M, S, and K. Now, discover the latest innovations for face and shoulder milling: CoroMill MS20, CoroMill MS40, and CoroMill MS60. CoroMill  MS20 - Your go-to for perfect 90 shoulders Building on the legacy of our multi-optimized CoroMill  390,  CoroMill  MS20  is now the ultimate choice for flawless 90 shoulders. Engineered for exceptional dimensional accuracy – even in repeated passes – it ensures optimal chip control and unmatched reliability. Its versatility (face milling, pocketing, grooving, linear and helical ramping, plunging) simplifies tool management and reduces overall consumption. CoroMill  MS40 and CoroMill  MS60 - The perfect partners to CoroMill 490 Our flagship CoroMill  490 remains the universal solution for shoulder milling. But when your operations demand more, CoroMill  MS40 and CoroMill  MS60 step in: CoroMill  MS40 : Designed for repeated passes and wall machining, this tangential concept delivers rigidity, process security, and predictable tool life. With four cutting edges per insert, it maximizes chip removal and stability – even in high-intensity cycles. CoroMill  MS60 : The smart choice for roughing and semi-finishing. Featuring six cutting edges per insert and a unique reversible triangular design, it slashes cost per edge and optimizes carbide usage – helping you cut costs while reducing environmental impact. Choosing the right concept is easy with  CoroPlus  Tool Guide . This online service gives you more than cutting data – it delivers confidence. CoroPlus  Tool Guide — More than just cutting recommendations In just a few clicks, you’ll get an optimized, ready-to-use solution that combines technical performance, time savings, and a reduced carbon footprint.  CoroPlus  Tool Guide  offers: Smart selection of the best Coromant solutions for your material and operation.  Cutting conditions validated for each tool.  Environmental impact calculations: power consumption and CO emissions for responsible decision-making.  Take control of your milling operations today With  CoroMill  MS20 ,  CoroMill  MS40 , and  CoroMill  MS60  cutters, you’re not just choosing tools – you’re investing in  higher productivity, lower costs, and a smaller environmental footprint . Supported by  CoroPlus  Tool Guide , you’ll enjoy fast selection, optimized cutting parameters, and precise energy impact calculations. Sustainable performance starts now. Are you ready to make the switch? Sandvik Coromant info.coromant@sandvik.com Milling Productivity meets Sustainability Productivity meets sustainability The Winning Combination with New CoroMill Face and Shoulder Milling Cutters Milling Cutters Innovation Discover CoroMill cutters that offer sustainable, high-performance milling solutions. Explore CoroMill milling cutters, combining productivity and sustainability for efficient face and shoulder milling on varied materials. Learn about CoroMill MS20, MS40, and MS60, enhancing tool performance and minimizing environmental impact with CoroPlus Tool Guide. chevron_right