Hands Free Tool Changes For Smarter Machining

Imagine a factory where the lights are off, not because no one is home, but because automated systems are working around the clock to keep production lines running with minimal human intervention. These futuristic setups are quickly becoming a reality, with touchless tool changes at the core of the automated machine cell. Here, Peter P Andersén, Manufacturing Engineer, and Lars Matiasson, Manager Global Manufacturing Equipment & Engineering, at leader in metal cutting tools and manufacturing solutions, Sandvik Coromant, unveils more about the company’s latest innovation in automatic tool changes.

Unmanned machining represents a significant leap in manufacturing, where machines operate independently without the need for human supervision. Driven by CNC technology, robotics and automation software, these systems can run continuously — in some cases, 24/7 — performing tasks such as turning, cutting, milling and drilling with high accuracy. This approach enhances productivity, reduces errors and allows for efficient, around-the-clock operation.

While many view unmanned machining as a futuristic approach to manufacturing production, Sandvik Coromant began reaping its benefits back in the 1980s.

Going hands free
Some 40 years ago, Sandvik Coromant’s production site in Gimo, Sweden, used a form of automatic tool change (ATC) that facilitated the changeover of machine tools without human input. The solution was offered as a product to customers, but it didn’t prove popular. Many could not grasp how ATC could save their machine shop time and enhance their productivity and the offering was dissolved.

Fast forward a few decades and Sandvik Coromant continued to see value where others could not. This time around, the company worked with a machine builder to develop a second ATC solution. Again, it was implemented at the Gimo production facility and continues to run across several machine cells today.

Using conventional tool management methods, a lathe could run without human input for around four-to-eight hours. After that, the tool would reach the end of its life and a human worker would need to stop what they’re doing to manually switch the tool with a new replacement. With the ATC solution, machines can run for up to 16 hours without an operator worrying about them.

A new take on turning
After using ATC technology for several years, Sandvik Coromant has now developed a solution for its customers that enables hands-free tool changes in turning operations. The new ATC system for machine-adapted clamping units (MACU) in turning centers fully automates the tool-changing process, eliminating the need for manual intervention. This leads to higher machine utilisation and improved productivity.

So, why now? In the 1980s, the benefits of ATC were not as widely recognised. However, today, automating repetitive, time-consuming tasks is essential for creating more resilient and efficient production lines.

The immediate benefit is the time it saves human workers. Running machines for up to 16 hours — four times longer than before — without the need for operator intervention allows operators to focus on other tasks, rather than being occupied with constant tool wear inspections.

ATC also helps optimise tool wear. When operators manually change tools while juggling multiple other tasks, they often replace tools prematurely, before they’ve reached their full potential. With ATC, tools are changed only when they're fully worn, maximising tool life and reducing waste. ATC also delivers significant sustainability benefits, including lower energy consumption, enhanced resource efficiency reduced waste and improved overall equipment efficiency. By keeping machines running at optimal levels, ATC minimises idle time and energy waste, increases output with fewer resources and reduces the frequency of breakdowns and downtime.

Taking a holistic approach
To create a future-proofed shop floor — whether the lights are on or off — ATC is a crucial piece of the puzzle. At the heart of Manufacturing Wellness, an initiative driven by Sandvik Coromant to promote healthy practices in future-ready manufacturing facilities, lies the importance of a holistic approach to production.

In modern manufacturing, a comprehensive strategy boosts efficiency, productivity and sustainability. By optimising the entire process — from materials and equipment to environmental impact — companies can enhance operational performance. Advanced technologies and cross-department collaboration are key to achieving these goals. This all-encompassing strategy not only elevates quality but also secures long-term success in a competitive market.

ATC forms a central part to this holistic take on machining, but Manufacturing Wellness is about more than just individual innovations; it’s about creating a seamless, resilient production ecosystem. ATC plays a key role in this broader vision, enabling factories to go beyond isolated efficiency gains to achieve true operational harmony. By automating routine tasks like tool changes, ATC frees up human operators for more strategic roles, while ensuring machines run at peak efficiency with minimal downtime. This integration of smart automation within a larger, wellness-driven framework positions manufacturers to thrive in an increasingly competitive, resource-conscious world.

Sandvik Coromant’s ATC is applicable in turning centers and multi-task machines, requiring a MACU with a Coromant Capto interface. For turning centers, an ATC-enabled MACU turret is necessary, while multi-task machines with a lower turret can utilise ATC if the turret is ATC-prepared.