Improved performance with smart tools

Sensors in tools Improved performance with smart tools

2023-06-18 Source: WFL Millturn Technologies 3 min Reading Time

Related Vendors

WFL Millturn Technologies GmbH & Co. KG

HASCO Hasenclever GmbH + Co KG

Renishaw plc

DIPROFIL Diamantprodukter AB

The Silent Tools Plus boring bar from Sandvik Coromant is designed to enhance productivity and flexibility in machining processes through the use of integrated sensors that monitor temperature, deflection, surface quality, and load. This offers several advantages for operators and the product quality.

The Silent Tools Plus boring bar creates an interface between the tool and the machine for automated, digital machining.(Source: WFL) — The Silent Tools Plus boring bar creates an interface between the tool and the machine for automated, digital machining.
(Source: WFL)

The geometry of workpieces and the materials used are becoming increasingly more complex. In addition, the market expects quick responsiveness and a high degree of flexibility, turning greater productivity from a mere topic for discussion into a firm customer requirement. These challenges have to be mastered and the customer's wishes fulfilled. The Silent Tools Plus boring bar from Sandvik Coromant is equipped with sensors to provide data on utilisation, temperature, deflection and the surface quality achieved, and intervenes adaptively in the machining process if the limit parameters are exceeded. The process transparency gained allows the machining process to be significantly optimised.

The integration of smart sensors enables detailed tool information and machining states to be called up on the machine control system, a tablet or a PC. Various sensors installed in the Silent Tools Plus boring bar provide data on load, temperature, deflection and more. Signals are transmitted via Bluetooth so that the machine can respond interactively to a defined trigger event. The process can be visualised and documented, making it fully transparent. Using an inductive coupling to power the sensors instead of an accumulator is a completely new feature.

Gallery

The screen shows precise data for load, surface, vibrations and temperature in the damping system as well as the cutting time.(Source: WFL)

The sensors are powered by an inductive coupling.(Source: WFL)

The ultimate protection for machines, workpieces and tools

The Silent Tools Plus boring bar has integrated sensors in different places. A vibration sensor fitted to the cutting head allows vibrations to be detected even at an early stage. The operator or machine control system can react in real time, preventing the problems commonly associated with vibrations and thus reducing scrap rates and rework. A temperature sensor built into the damping unit monitors the actual temperature, which is also displayed. This increases process reliability and ensures better maintainability of the boring bar. Sensors are also installed in the boring bar itself, which provide data on the force being exerted on the bar.

In combination with the iControl process monitoring system, the operator enjoys the ultimate level of protection for the machine, workpiece and tool to ensure reliable and economical production, especially in spare parts production or for small batch sizes. On the one hand, the machine and tools should be used with maximum productivity; on the other hand, the process should run as stably and reliably as possible. The up to 16 process signals to be monitored are configured by WFL at the factory according to the machine equipment and displayed live on the controller's screen. Important process signals are the forces or torques of the NC axes and spindles, but also the signals derived from the sensors integrated in the Silent Tools Plus boring bar.

The learning mode of WFL iControl offers an excellent strategy. The process signal of an entire machining sequence with the Silent Tools Plus boring bar can be recorded through a learning cut. The allocation of upper and lower process limits defines the tolerance band within which the process signal must remain during machining. If these limits are violated, the machine will stop. When using a new cutting insert, for example, a certain process limit can be set at the beginning of the machining process with the help of the load signal. Within just a few millimetres, the user receives information about the cutting force and can set a limit including an appropriate allowance. The machine will then automatically detect an overload situation at any point in the entire machining process.

Subscribe to the newsletter now

Don't Miss out on Our Best Content

Business E-mail

Please enter a valid mailadress.

By clicking on „Subscribe to Newsletter“ I agree to the processing and use of my data according to the consent form (please expand for details) and accept the Terms of Use. For more information, please see our Privacy Policy. The consent declaration relates, among other things, to the sending of editorial newsletters by email and to data matching for marketing purposes with selected advertising partners (e.g., LinkedIn, Google, Meta)

Date: 08.12.2025

Naturally, we always handle your personal data responsibly. Any personal data we receive from you is processed in accordance with applicable data protection legislation. For detailed information please see our privacy policy.

Consent to the use of data for promotional purposes

I hereby consent to Vogel Communications Group GmbH & Co. KG, Max-Planck-Str. 7-9, 97082 Würzburg including any affiliated companies according to §§ 15 et seq. AktG (hereafter: Vogel Communications Group) using my e-mail address to send editorial newsletters. A list of all affiliated companies can be found here

Newsletter content may include all products and services of any companies mentioned above, including for example specialist journals and books, events and fairs as well as event-related products and services, print and digital media offers and services such as additional (editorial) newsletters, raffles, lead campaigns, market research both online and offline, specialist webportals and e-learning offers. In case my personal telephone number has also been collected, it may be used for offers of aforementioned products, for services of the companies mentioned above, and market research purposes.

Additionally, my consent also includes the processing of my email address and telephone number for data matching for marketing purposes with select advertising partners such as LinkedIn, Google, and Meta. For this, Vogel Communications Group may transmit said data in hashed form to the advertising partners who then use said data to determine whether I am also a member of the mentioned advertising partner portals. Vogel Communications Group uses this feature for the purposes of re-targeting (up-selling, cross-selling, and customer loyalty), generating so-called look-alike audiences for acquisition of new customers, and as basis for exclusion for on-going advertising campaigns. Further information can be found in section “data matching for marketing purposes”.

In case I access protected data on Internet portals of Vogel Communications Group including any affiliated companies according to §§ 15 et seq. AktG, I need to provide further data in order to register for the access to such content. In return for this free access to editorial content, my data may be used in accordance with this consent for the purposes stated here. This does not apply to data matching for marketing purposes.

Right of revocation

I understand that I can revoke my consent at will. My revocation does not change the lawfulness of data processing that was conducted based on my consent leading up to my revocation. One option to declare my revocation is to use the contact form found at https://contact.vogel.de. In case I no longer wish to receive certain newsletters, I have subscribed to, I can also click on the unsubscribe link included at the end of a newsletter. Further information regarding my right of revocation and the implementation of it as well as the consequences of my revocation can be found in the data protection declaration, section editorial newsletter.

The ability to implement holistic solutions is important for complete machining. In the larger Millturn machines there is an additional compound slide to accommodate a large vibration-damped boring bar with a length-diameter ratio of up to 18 x D. The additional compound slide enables an automatic tool change at the front of the boring bar, a programmable projection length and Ultra High Pressure Coolant (UHPC).

(ID:49548759)