When producing large and expensive components, such as those used in the aerospace or oil and gas industries, manufacturing companies often slow down internal turning processes to protect the components being machined - as machining errors can be very costly. One way to both speed up machining and avoid scrap is to regularly check what is happening inside the machine tool. Knowing what is happening inside the component during internal turning can lead to significant increases in efficiency and reduced scrap, especially when machining long, slim components. In collaboration with users worldwide, Sandvik Coromant has developed the Silent Tools Plus boring bars, which can speed up the internal turning of high-quality components. This is possible because the integrated sensor technology can identify process anomalies, i.e. deviations from the specified machining parameters, and make them visible to the operator.

While the Silent Tools technology is around 50 years old, the current innovation is based on a new development that includes vibration and force sensors embedded in the boring bar. This technological advancement makes it possible to capture accurate information from the machining process and visualize it in real time via easy-to-understand and intuitive dashboards. Operators can see what is happening inside the component being worked on behind the closed doors of the machine tool.

Improve processing efficiency and decision-making

The vibration-damped boring bars have connectivity that provides information such as "in-cut" indication, vibrations, displacement of the cutting edge or the temperature within the damping system. With the help of such data, process reliability and machining efficiency can be optimized and damage to the machine and component, including surface damage, can be avoided. The result is less downtime due to tool breakage and the ability to machine expensive materials and complex components at higher cutting speeds.

The data displayed on a dashboard gives the operator an immediate picture of the machining process and a concrete idea of progress. If the machining process deviates from the specified parameters, for example in the form of excessive jolting or increased vibrations, the operator is immediately informed via the dashboard. In this way, he can react immediately and take appropriate measures to stop or adjust the machining process and thus avoid damage to the component and the machine.

To further improve decision-making at the machine door, the data also includes a history of the ongoing machining process. This is particularly important for manufacturing companies that realize projects for demanding sectors such as the aerospace or oil and gas industries.

Increase process reliability and machine utilization

The aim of making the machining process significantly more reliable and reducing the reject rate to a minimum is particularly important if the components to be machined are extremely expensive in terms of materials or if a high level of added value has already been achieved towards the end of the process chain. If, for example, digital technologies can prevent high-value components from having to be scrapped or reworked in the case of aircraft landing gear or underwater components, the investment pays for itself within a short period of time.

Better utilization can be achieved, among other things, by eliminating "air cuts" because it is always visible whether the cutting edge is engaged. Quick-change devices between the adapter and cutting head can also contribute to this through simple handling and precise changes.