In many scenarios, the main focus of improving production efficiency lies in enhancing the cutting edge's performance. By optimizing the cutting ability of the tool, productivity can be significantly boosted. However, due to the varying characteristics of different workpieces, tool overhang has become a critical factor in machining. As a result, more attention is being paid to the cutting edge’s vibration resistance. A longer tool overhang often leads to vibration tendencies, but this issue can typically be minimized by using light cuts and gradually approaching the workpiece—though at the cost of reduced efficiency. When a tool must enter a hole or cavity, deflection forces are generated, increasing the risk of vibration. Sandvik Coromant’s latest innovations not only address this challenge but also dramatically enhance production efficiency.
**Damping Tools**
After years of development, damping tools have seen remarkable improvements. Compared to the technology introduced by Sandvik Coromant in the 1970s, today’s advancements are far more sophisticated. The original designs made previously impossible operations feasible, such as tool overhangs up to ten times the tool diameter in some cases. Silent Tools damping tools now represent the most advanced level of vibration control in the industry. With extensive application experience and continuous R&D, these tools have become increasingly mature, addressing modern machining challenges and boosting productivity. They are widely used in applications requiring long tool overhangs, delivering improved efficiency, tight tolerances, and enhanced process safety.
In today’s machining environment, operations like bore turning, boring, grooving, and milling increasingly require extended tool overhangs. In some cases, multiple workpieces may need to be machined on the same part. Unfortunately, many long overhang applications still suffer from low performance, barely meeting the basic requirement of avoiding vibrations. This lack of stability affects both safety and quality, leading to increased noise, shorter tool life, and even scrap. As a result, cutting parameters are often limited, raising costs and prolonging production time.
**Milling Process**
During milling, the intermittent nature of the cutting action makes vibration a common issue. When long overhang tools are used, the tendency for vibration becomes even more pronounced. While several methods—such as selecting the right cutter and optimizing the tool path—can help reduce vibration, they are not always sufficient. If the tool overhang exceeds three times the shank diameter, additional measures are necessary to meet standard machining requirements.
With the growing demand for tool diameters that allow overhangs four times or more, overcoming vibration has become essential. Vibration limits efficiency, forcing operators to use lower axial depths and feeds, which reduces metal removal rates. In many cases, long overhang tools are required for both milling and boring, especially on multitasking machines where the B-axis spindle restricts tool access. This necessitates the use of long overhang tools.
To combat vibration, advanced damping technology is now used to manufacture damping shanks that effectively minimize vibration amplitude. These tools can precisely detect and counteract specific vibration patterns. Recent R&D efforts have integrated various techniques and expertise in vibration damping, enabling smoother, faster cutting. Although complete vibration elimination is not possible, modern systems now reduce it to a level that does not interfere with the machining process.
Advanced simulation, measurement systems, and a deep understanding of structural dynamics have helped eliminate the negative impact of forces on the tool. This innovation not only provides effective damping but also allows for precise tuning of the tool’s overhang length.
For milling, the new standard adapter ensures optimal performance even with long tool overhangs. It minimizes typical vibration amplitudes across two overhang ranges. There are currently two types of damping shanks: one for 4–5x the shank diameter and another for 6–7x. Custom adapters allow for even longer extensions. These adapters are ideal for the most common long overhang applications in milling. The system boosts efficiency and shortens the return on investment.
This milling adapter enables higher axial depth and feed rates, significantly increasing productivity. It opens up high-efficiency milling possibilities, such as machining pockets beyond the normal range, especially when using larger face mills. The new product extends tool overhang capabilities while maintaining or even increasing productivity.
**Inner Hole Turning**
Inner hole turning involves a broader range of tool overhangs. Many parts feature deep holes with strict overhang requirements, ranging from 4x to 14x the mast diameter. The correct selection and application of the tool play a crucial role in the success of the operation, as hole turning is highly sensitive to vibration. One advantage of the Silent Tools damping mast is its design, which places the damper mechanism as close to the cutting edge as possible. This setup quickly responds to any vibration tendency.
Standard steel masts are suitable for 4x overhangs, while solid carbide masts are ideal for 6x. For longer overhangs, damping masts are essential. Steel damping boring bars are used for 10x overhangs, and reinforced hard alloy masts for 14x. Grooving and threading usually involve shorter overhangs. Additionally, each machine tool has unique vibration characteristics, meaning the same process may vibrate at different frequencies depending on the machine. Therefore, developing a standardized damping tool that can operate across a wide frequency range is vital for consistent performance.
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