The square shank tool holder is one of Sandvik Coromants most common products. The tool holder has been manufactured the same way for 25 years without changing tolerances. However, it is predicted that tighter tolerances will be required in the future to maintain competitiveness.   The purpose of the thesis was to study how today's square shank tool holders can be made straighter and to what price it can be done. The tolerances allow too much convexity and concavity which might lead to unstable products. To find where in the current production flow the greatest impact occurs, the production flow was studied and then a common square shank tool holder with high production volume was followed through the production flow.   The tool holders were measured with a CMM after each station and analysis showed that the hardening station has the largest impact on the tolerances. This lead to six experiments using different manufacturing methods and the results were compared to see what production flow that allowed the best tolerances and lowest cost.   The results lead to two optional ways of manufacturing since they showed better results with a production economic perspective. Option 1 includes manufacturing in hardened material and Option 2 includes a grinding process.   The production flow for Option 1 is to first harden the blank followed by the manufacturing processes. By moving the hardening processes to the beginning of the production flow, the shape changing is prevented and the final product becomes straighter and obtains a smooth and aesthetic surface since the hardening process creates a rough surface. The production time is increased by CON% and the production cost is increased by CON%. The bottom side flatness tolerance of the final product is reduced by CON%.   The production flow for Option 2 is to first manufacture the shank followed by hardening. After the hardening process the tools get surface grounded on the bottom side and the outside. By grinding the tool holder, it becomes straight and the surface flatness obtains a tolerance of CON mm. The production time is increased by CON% and the production cost is increased by CON%. The bottom surface flatness tolerance of the final product is reduced by CON%.   The advantages of Option 1 are that the final product becomes better and it is easy to apply in the current production flow. The advantages of Option 2 the surface becomes very flat and the tool holder is more competitive.   By choosing any of these two options, Sandvik Coromant will achieve a straighter and more competitive final product.

<p>Large improvements in cutting tool design and technology, including the application of advanced surface engineering treatments on the cemented carbide insert, have been achieved in the last decades to enhance tool performance. However, the problem of improving the tool body material is not adequately studied.</p><p>Fatigue is the most common failure mechanism in cutting tool bodies. Rotating tools, tool going in and out of cutting engagement, impose dynamic stresses and require adequate fatigue strength of the tool. Working temperatures of milling cutter bodies in the insert pocket can reach up to 600°C depending on the cutting conditions and material of the workpiece. As a result, steel for this application shall have good hot properties such as high temper resistance and high hot hardness values to avoid plastic deformation in the insert pocket of the cutting tool. Machinability of the steel is also essential, as machining of steel represents a large fraction of the production cost of a milling cutter.</p><p>This thesis focus on the improvement of the cutting tool performance by the use of steel grades for tool bodies with optimized combination of fatigue strength, machinability and properties at elevated temperatures.</p><p>The first step was to indentify the certain limit of the sulphur addition for improved machinability which is allowable without reducing the fatigue strength of the milling cutter body below an acceptable level. The combined effect of inclusions, surface condition and geometrical stress concentrator on the fatigue life of the tool steel in smooth specimens and in tool components were studied in bending fatigue.</p><p>As the fatigue performance of the tools to a large extent depends on the stress relaxation resistance at elevated temperature use, the second step in this research was to investigate the stress relaxation of the commonly used milling cutter body materials and a newly steel developed within the project. Compressive residual stresses were induced by shot peening and their response to mechanical and thermal loading as well as the material substructures and their dislocation characteristics were studied using X-ray diffraction.</p><p>Softening resistance of two hot work tool steels and a newly developed steel was investigated during high temperature hold times and isothermal fatigue and discussed of with respect to their microstructure. Carbide morphology and precipitation as well as dislocation structure were determined using transmission electron microscopy and X-ray line broadening analysis.</p>

Large improvements in cutting tool design and technology, including the application of advanced surface engineering treatments on the cemented carbide insert, have been achieved in the last decades to enhance tool performance. However, the problem of improving the tool body material is not adequately studied. Fatigue is the most common failure mechanism in cutting tool bodies. Rotating tools, tool going in and out of cutting engagement, impose dynamic stresses and require adequate fatigue strength of the tool. Working temperatures of milling cutter bodies in the insert pocket can reach up to 600°C depending on the cutting conditions and material of the workpiece. As a result, steel for this application shall have good hot properties such as high temper resistance and high hot hardness values to avoid plastic deformation in the insert pocket of the cutting tool. Machinability of the steel is also essential, as machining of steel represents a large fraction of the production cost of a milling cutter. This thesis focus on the improvement of the cutting tool performance by the use of steel grades for tool bodies with optimized combination of fatigue strength, machinability and properties at elevated temperatures. The first step was to indentify the certain limit of the sulphur addition for improved machinability which is allowable without reducing the fatigue strength of the milling cutter body below an acceptable level. The combined effect of inclusions, surface condition and geometrical stress concentrator on the fatigue life of the tool steel in smooth specimens and in tool components were studied in bending fatigue. As the fatigue performance of the tools to a large extent depends on the stress relaxation resistance at elevated temperature use, the second step in this research was to investigate the stress relaxation of the commonly used milling cutter body materials and a newly steel developed within the project. Compressive residual stresses were induced by shot peening and their response to mechanical and thermal loading as well as the material substructures and their dislocation characteristics were studied using X-ray diffraction. Softening resistance of two hot work tool steels and a newly developed steel was investigated during high temperature hold times and isothermal fatigue and discussed of with respect to their microstructure. Carbide morphology and precipitation as well as dislocation structure were determined using transmission electron microscopy and X-ray line broadening analysis.

The aim of this thesis is to design different variants, choose an optimal one and the constructional solution of a tool manipulator for vertical lathe from SKG line by TOS HULÍN a.s. This thesis also includes technical and economical report. There is a solution of a basic conception, main dimensions, functional calculations and calculations of rigidity of chosen parts of this manipulator. All computations and methods are in accord with valid standards.

Neudert Pavel Goal of this work is preparing different variants of manipulator for changing the tool holder. The report contains choose of optimal solution and specific design solution of manipulator, including technical report and economical conclusions.

The thesis is focused on making the most efficient actuator shaft, using machinery company. Using Fanuc's control system on all machines with examples of their use in practice. Production and integration of a special holder for the drill stage.

Le perçage vibratoire auto entretenu propose la rupture technologique nécessaire à une augmentation de la performance du perçage profond. Un porte outil spécifique a été conçu pour permettre les vibrations axiales, et se présente sous la forme d'un système masse ressort, dont les caractéristiques sont identifiés par l'utilisation de la théorie des lobes de stabilité. L'identification des caractéristiques géométriques d'un outil optimal passe par la caractérisation des aspects tribologiques, des caractéristiques mécaniques du matériau usiné, ainsi que la définition d'une préparation d'arête adéquate. Enfin, ce procédé étant piloté par l'énergie de la coupe, deux modèles d'effort ont été identifiés. La méthode CAM repose sur la discrétisation de l'effort de perçage lors de la phase de pénétration, alors que l'approche analytique permet de prédire l'effort à partir d'un modèle de coupe analytique identifié à partir d'essais de coupe oblique. / Self-sustained vibration drilling offers the technological breakthrough needed to increase the performance of deep drilling. A special tool holder is designed to allow axial vibration, and comes as a spring mass system, whose characteristics are identified by the use of the theory of stability lobes. Identification of the geometric characteristics of an optimal tool requires the characterization of tribological aspects, mechanical properties of the machined material, and the definition of a proper edge preparation. Finally, this process is driven by the energy of the cut, and two types of effort have been identified. The Edge-Material-Pair Method is based on the discretization of the drilling thrust force during penetration phase, while the analytical approach can predict forces from a cut pattern identified from oblique cutting tests.