Hyundai Motor Company, a leading South Korean automotive manufacturer, established its largest overseas production facility in Chennai, India. The plant started operations in the spring of 1998 and has since grown to become the second-largest and fastest-growing automobile manufacturer in the country, setting technical standards for the domestic industry. It produces a wide range of models such as Santro, Accent, and Sonata, covering everything from compact sedans to luxury vehicles, with engine capacities ranging from 100cc to 2000cc. The Chennai plant is a full-scale manufacturing hub, featuring production lines, an aluminum foundry, paint shop, pressure lines, plastic parts manufacturing, and assembly facilities. Among these, the flexible production line can process multiple models with an annual capacity of 120,000 cars, ensuring quality inspection and high automation levels. Sandvik Coromant, a division of the Sandvik Group and one of the world’s leading manufacturers of metal cutting tools, has maintained a long-term partnership with Hyundai Motor (India) Co. since the establishment of the Chennai plant. This collaboration has significantly enhanced production efficiency, improved product consistency, and reduced processing costs through the use of high-quality tools and tailored solutions provided by Sandvik Coromant. One notable example of this partnership is the improvement in the production of engine linkages for the Santro and Accent models. Previously, the connecting rod production line faced challenges with chip control, causing tool jams and downtime that affected output. To address this, engineers set a goal of achieving "trouble-free" production. Sandvik Coromant introduced Coromant Delta drills, specifically designed for drilling steel connecting rods made of CMC02.2 material with a hardness of 245–300 HB. These drills feature internal cooling and a unique top groove design, allowing efficient drilling of small-diameter holes (9.5–30.4mm) with a standard depth of 3.5 times the drill diameter. Customized tools were used to optimize various processes, especially for coated holes requiring a high surface finish. With a cutting speed of 100 m/min, feed rate of 300 mm/min, and a feed per revolution of 0.15 mm, the Coromant Delta drill achieved a tool life of 1,250 holes. After implementation, chip-breaking performance improved significantly, and tool life increased by 166%, from 11 meters to 30.4 meters. Further improvements led to a tool life of up to 32.3 meters after remanufacturing, with consistent quality even after regrinding. As a result, the cost per part dropped from 5.26 to 2.44, saving approximately 230,000 yuan annually when machining 120,000 connecting rods. Additionally, chip interference issues were completely eliminated. Another significant application involved the boring of cylinder bores in the Santro model’s engine block. Previously, there were inconsistencies in bore size, uneven cutting forces, and high noise levels. Sandvik Coromant introduced custom cylinder boring tools with a 65.80mm diameter, using the TM260.20 tool to machine 100mm-deep holes. With a cutting speed of 67 m/min, feed rate of 225 mm/min, and a feed per revolution of 0.72 mm, the tool achieved a predictable 40m tool life while maintaining precise dimensional tolerances of +30 microns. This ensured smooth and consistent machining, improving both safety and productivity. In Shanghai, the Automobile Gearbox Factory IV relies heavily on Sandvik tools to produce over 50 different shafts and gears, shipping more than 150,000 units annually to Shanghai Volkswagen. Approximately 70% of the cutting operations in the fourth workshop are performed using Sandvik products, including P-Lline inserts, Corocut, and Q-Cut knives. For machining small shaft parts, the GC4125 grade Corocut groove insert extended tool life from 75 to 160 parts, maintaining high-quality output without any loss of performance. Ningbo Yuejin Automobile Front Car Co., Ltd. produces around 60,000 steering knuckles for Toyota each year, which occupy five processing centers. By using Coromant Delta drills and following recommended cutting parameters, the company achieved high-precision drilling in a single operation, previously requiring multiple steps. This improved accuracy and boosted production efficiency. Currently, Ningbo Yuejin is developing a computer-controlled manufacturing facility, integrating advanced CAM functions with existing CAD systems. It also leverages global research bases in the U.S., Germany, Italy, and Japan to adopt innovative technologies. The company plans to further integrate Coromant products into its system, making Sandvik tools a key component of its future growth.

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