Silent Tools TM

Productivity with slender tools

Reducing vibration
in focus
Vibration-prone operations pose a constant threat to productive
and secure machining, especially when dealing with long
overhangs or deep cavities. Reducing process parameters such
as depth of cut, speed or feed is one aspect to consider, but it will
most likely have a negative impact on productivity.
A more productive solution is to use Silent Tools™. Silent Tools
is a unique range of long-reach cutting tools and adaptors for
turning, milling and boring, designed with a damping system
inside the tool body to minimize vibration.
For components requiring slender tool assemblies, Silent Tools
can be your one and only choice for productive machining.
However, Silent Tools is not only a problem-solver, it can also
be used as a powerful productivity booster when working with
shorter overhangs.

Enjoy the silence!

 Silent ToolsTM benefits
• Improved process security
• Improved surface finish
• Productivity gains
• Reduced cost per component
Difference in vibration between undamped
and damped tool.

Inside the tool is a pre-tuned damping system that consists of a heavy

mass, supported by rubber spring elements. If vibration arise, the kinetic
energy will be absorbed by the damping system. This leads to minimized
vibration and greatly improved productivity.

Internal turning
CoroTurn® SL with Silent
of mandrel.
Tools turning adaptor.

Maximum reach with Silent Tools Shoulder milling with CoroMill® 490. Titanium milling of aerospace landing
elliptical adaptors. gear beam with CoroMill® 390.
Silent ToolsTM for turning
Secure and productive
turning
Silent Tools turning adaptors
Internal turning is very sensitive to vibration. It is essential to select
the largest possible tool size and to minimize the overhang
in order to obtain the best stability and accuracy. Choosing
the right turning adaptor has a big impact on production
economy. The Silent Tools turning adaptors are ideal for
successful turning operations at overhangs reaching from
4 up to 14 times bar diameter, and are available from diameter
16–250 mm (0.630–9.84 inch) as standard solutions.
The easily replaceable cutting head and the stable,
robust interface make the CoroTurn® SL modular system
a standardized interface for all Silent Tools damped bar
adaptors. The combination offers great flexibility with a large
number of cutting heads suitable for a wide range of applications.

Stable threading for every need

Ultra-rigid CoroThread® 266 covers just about all types of internal and external thread
turning applications possible. It is designed with an iLock™ interface to handle the extreme
forces placed upon the insert in threading operations. The tool ensures exceptional insert
stability for ultimate accuracy, surface finish and product consistency.
CoroThread 266 provides great stability in long overhangs. Damped Silent Tools boring
adaptors dedicated for threading can withstand the increased radial cutting forces of
internal machining and maintain precision even in the most difficult machining conditions.
 Exact reach with elliptical bars
The Silent Tools™ elliptical adaptors are designed for maximum reach
into deep seats. Combined with CoroTurn® SL cutting heads with a
lightweight design and stretched radial length, you have a tool tailored
for machining challenging features such as the valve seat pocket.
The optimized tool helps overcome challenges like narrow entries and
long overhangs in order to achieve a highly stable machining process.

Performance: Machining a flanged bearing

Customer case

The customer was struggling with vibration and productivity

loss when machining a flanged bearing case. The existing process
featured a steel bar, and the remainder of the bore had to be finished in
a secondary operation.

When changing to Silent Tools, the outcome showed a huge increase in productivity. Vibration was diminished and
surface finish improved, while saving valuable time when completing roughing and finishing in one operation. In
addition, it saved a lot of ear plugs.

Operation: Rough and finish deep boring

Workpiece material: CMC 02.1, MC P2.2.Z.AN – Alloy steel forging +160%

Tool: A570-3C D32-27 40 Finishing productivity

Insert: TNMG 332-QM, grade GC4215

Sandvik Coromant Competitor

vc m/min (ft/min) Roughing: 99 (325), finishing: 152 (500) Roughing: 67 (220)
fn mm/rev (in/rev) Roughing: 0.406 (0.016), finishing: 0.559 (0.022) Roughing: 0.356 (0.014)
ap mm (inch) 3.18 (0.125) 3.18 (0.125)
Results
Time saved 15 min per part
Productivity increase, roughing
Productivity increase, finishing
132%
160%
+132%
Roughing productivity
Silent ToolsTM for milling
Maximize your milling cutter
productivity
Working with rotating tools differ from turning, where you have a boring bar in a rigid tool post.
Most considerations for successful operations are however the same, such as workpiece
set-up and machine stability. Make the most out of your milling operation with Silent Tools.

CoroMill® 390 with integrated damping

By integrating Silent Tools technology into the extra-long,
extremely versatile CoroMill 390 end mills, you can easily
stabilize your machining process while maintaining required
surface finish and high-quality components.
The combination offers unrivalled productivity with small-
diameter milling cutters on slender, undersized shanks.
Available for insert sizes 07 and 11 for minimized vibration
and increased output.

CoroMill 390 covers many applications, including

shoulder milling and pocketing. The cutters are
ideal for ramping and helical interpolation.

Vibration-free groove milling

CoroMill® QD with Silent Tools provide you the
required reach and vibration can be kept at bay up to
six times bar diameter. Add a cutter with light-cutting
insert geometries for an ideal solution for reducing
vibration when milling grooves with long overhangs.
Apply CoroMill QD with Silent Tools for long-reach,
internal or external groove milling or for slitting of
tubes, casings and sleeves.
 Silent Tools™ arbor milling adaptors
The Silent Tools arbor milling adaptors are available for a large
number of cutting concepts and for a wide range of applications,
including long reach face milling, deep shoulder and side milling,
cavity milling, slot milling and profiling.
Undersized adaptors with nominal diameter cutters are first choice
for greatest productivity in deep cavities, while nominal diameter
adaptors are available for maximum stiffness and capacity for
oversized diameter cutters.

Productivity gains:
At least 50% for the shortest adaptor
lengths and up to 300% for longer
adaptors, compared to same length
without Silent Tools

Tool assembly lengths:

4 to 8×body diameter

High reliability in large machining centres with Coromant EH

Silent Tools adaptors are suitable for cavity and profile milling in deep molds,
Pelton wheels, Francis blades and impellers. Choose betweeen CoroMill® 216
and CoroMill® 316 ball nose, CoroMill® 300 with round inserts or CoroMill® 415
high feed cutters with Coromant EH machine side interface.
Silent ToolsTM for boring
Flexible boring at long
overhangs
Internal boring of large-diameter holes and deep holes is a particu-
larly vibration-prone operation, especially when machining with long
overhangs. To avoid vibration-related issues such as bad surface
texture, insufficient accuracy and increased insert and machine tool
wear, a stable tooling solution is a necessity.
Sandvik Coromant offers Silent Tools for rough and finish boring. The
tools are designed with a strong dedicated interface between bridge
and damped adaptor, and the same adaptors and bridges can be used
for both rough and fine boring. This gives you unique flexibility and
modularity to build desired tool assemblies.

Vibration-free rough and finish boring

Silent Tools finish and rough boring tools give increased productivity and close tolerances
from lengths of 3–10 × body diameter. When using Silent Tools, you have the opportunity to
double the depth of cut, while maintaining productive boring at long overhangs.
CoroBore® BR20 with Silent Tools™ technology is part of the new generation rough boring
tools. This flexible solution holds features such as differential pitch, coolant nozzles with
high precision capability and step boring functionality, and is to be combined with dedicated,
four-edged CoroBore® 111 inserts. Together with CoroBore® 825 and CoroBore® 826 for
finishing, these are ideal solutions for close hole tolerances and excellent surface finish in
small diameters.
For large-diameter roughing and finishing, up to 1275 mm (50.197 inch) in standard
assortment, the versatile CoroBore® XL system provides the optimal solution, giving great
stability and vibration-free boring.

CoroBore BR20 with Silent Tools technology and CoroBore 825 CoroBore XL for large diameters, including dedicated lightweight
for small diameters up to 167 mm (6.57 inch). bridges that fit together with existing slides and cartridges for
both rough and fine boring.
 CoroBore® XL with damped Silent Tools adaptor
boring a landing gear.

Performance: Finishing of a chamber

Customer case

The customer produces 200–250 components per year, but had problems obtaining the desired surface finish without
encountering vibration. Prior to the finishing operation, two roughing operations were performed which gave a concen-
tricity error of 0.02.

By changing to Silent Tools, the customer benefited from time savings of up to 12.3 minutes per machined part. No
vibration, a good finishing surface and no conical dimension of the hole were all welcomed results. The radius 0.8 mm
gave better results than previous 0.4 mm due to the possibility to increase feed and further the stability.

Component: Chamber with interrupted cut

+400%
Workpiece material: 6082 aluminium, CMC 30.21

Operation: Finishing
Time savings per part
Machine: Biglia Smart Turn B1200 L, HSK 63

Coolant: Emulsion

Sandvik Coromant Competitor

Machine interface adaptor C6-390.419-63 100
Tool C6-R825C-FAG 307A, R825-AF23STUC1103 Modular assembly HSK 63
Diameter, mm 100 103
Tool length, mm 440 440
Insert TCGX 110308-AL H10
vc m/min (ft/min) 323–388 (1060–1273) 100 (328)
n, rpm 1000–1200 240
fn mm/rev (in/rev) 0.15 (0.006) 0.15 (0.006)
ap mm (inch) 0.15 (0.006) 0.15 (0.006)
Results
Minutes per part 3–2.73 15
Time saved Approx. 12 minutes per part
Engineered tools
for specialized machining
The standard off-the-shelf Silent Tools™ offer represents a good
platform for optimized solutions and high productivity, but if you
need a tailored tool our engineered solutions are the answer.
Together, we can carefully examine your application and develop the
best solution for your process. The engineered damped boring bars
are often tapered, elliptical and/or curved, with the mounting adapted
to the machine. Bars with overhangs of up to 14 x bar diameter (BD)
are available.
Ask your yellow coat representative to help you order your
engineered solution.

Engineered tool with Silent Tools

technology optimized for internal turning.

Silent Tools™ + sensor-based anti-vibration technology

Connected Silent Tools + cutting tools allow you to remotely monitor the tool
and machining in order to optimize your metal cutting process. The tools are
equipped with sensors embedded in the adaptor and Bluetooth data distri-
bution capacity, and are designed to increase process control and security in
internal turning with long overhang.
 Machine-adapted advanced Silent Tools™ boring bars
Sandvik Coromant offer machine-adapted boring bars with bar diameter
ranging from 100–300 mm, suitable for overhangs up to 14×BD. The bars are
equipped with ATC in the front to fit many tool configurations and to minimize
downtime. They have through coolant capability with pressure up to 350 bar
(5076 psi).

Machining of jet engine shaft with an engineered Silent Tools + 120 mm BD boring bar, working with
a 16×BD overhang.
Calculated success
Sandvik Coromant offers several helpful applications to guide you towards
maximum return of your investment. Use CoroPlus® ToolGuide to receive
quick and accurate tool recommendations and apply the productivity calcu-
lators to monitor your savings and maximize your earnings.
A Silent ToolsTM investment almost always has a short pay-back time, thanks
to increased productivity and less scrap. Use the dedicated Silent Tools
calculators to help you calculate return of investment (ROI) of your Silent
Tools. With limited input, you will instantly see the outcome and payback time
for a Silent Tools investment, compared to undamped tools.
Enter your measurements and you are on your way to calculated success!

Find the calculators and other useful info such as a comprehensive appli-
cation guide at www.sandvik.coromant.com/silenttools

Head office:
AB Sandvik Coromant
SE-811 81 Sandviken, Sweden
E-mail: [email protected]
www.sandvik.coromant.com

C-1040:166 en-GB © AB Sandvik Coromant 2016