Covers Protect Tooling, Provide Safety For Operators

What is a machine tool show in Moscow like? What is Moscow like thesedays? MASHEX, the Industrial & Technologies For Russia show, hasbeen held every year since 1988. This year, the show moved to theCrocus Center Expo site about 15 miles from the Red Square, which isliterally and figuratively the heart of Moscow. (Red Square, by theway, is still properly called such because that color was consideredsynonymous with beauty when the Kremlin and its cathedrals and palaceswere built centuries ago. Their beauty remains, although politicalrevolutions have come and gone.)

The Crocus Center is a modern complex with several large exhibithalls that rival any trade show venue in Europe or North America. Thebuildings are spacious, clean, functional and tastefully decorated.MASHEX ran for four days (May 29-June 1) during a rare heat wave thatdrove outside temperatures into the 90s, although the exhibit hallswere comfortably air-conditioned. The show can be summed up in thestatistics reported by show sponsors: 50,000 square meters of exhibitspace; 500 exhibitors; 15,000 attendees. These numbers, however, do notreveal the nature or significance of the show.

It isRussia’s main machine tool show, the place where machine tool sellersand buyers from all over the country convene. What the exhibitorsshowed and what interested Russians tell much about the metalworkingindustry there. In general, exhibitors brought their latest and mostadvanced equipment. To offer anything less, apparently, would be tounderestimate the Russian metalworking market. Buyers are as interestedin all of the leading technologies and advanced processes as buyersanywhere around world.

On display were five-axis VMCs;multitasking machine tools; lathes for hard turning; wire and ramelectrical discharge units; robotic welders; carbide inserts with thenewest coatings and geometries; and other recently developed technology.

Althoughparts of Russia’s economy and social infrastructure are still incatch-up mode, the country is experiencing booms in many industrialsectors. The energy industry is expanding rapidly; a growing middleclass is hungry for consumer goods; and the construction industry is atfull tilt—tall cranes salute the future on every horizon in the Moscowvicinity, it seems.

To keep up, Russian manufacturers generally want machines capable ofhandling complex work to close tolerances. They seem to be lessinterested in automation such as gantry loaders, robotic part transferor flexible machining systems, although pallet changers that keepmachine downtime low are popular. Salaries and benefits are relativelylow in Russia, so there is no great pressure to reduce head count infactories.

Withthe largest market share in Russia, European machine tool builders arethe best represented at the show. DMG, Danobat and Index were there, aswell as numerous smaller companies serving the industry. SandvikCoromant, Walter AG and Iscar were among the cutting tool exhibitors.Delcam and Siemens were among the software and CNC suppliers. Buildersfrom Japan were not far behind. Yamazaki Mazak, Mori Seiki, Okuma,Makino and a number of other companies had a strong presence. Don’tbother consulting the show directory for a complete listing of SNMG Insert “Who’sWhere With What.” Not every dealer or distributor lists all of thelines they carry.

A number of U.S. companies were conspicuous. Haas Automation, Hurco,Hardinge, Gleason, and MAG Industrial (representing Fadal, CincinnatiMachine, Giddings & Lewis, and other brands now in that family)were present, to name a few.

Machine tool building in Russia is not what it used to be, a factapparent at this show. The Soviet government once supported a thrivinggroup of builders, but many of them had factories in other Soviet-bloccountries. When the USSR disintegrated in the early 1990s, these“machine tool enterprises” lost access to these manufacturingfacilities. They also lost captive markets in the trading bloc and lostheavily subsidized production orders from the Soviet government, atriple whammy. Yet several of these companies Carbide Drilling Inserts have managed to regroupand re-establish themselves as key players in the Russian andinternational markets. These companies had large booths at MASHEX.

Two other Russian machine tool builders, Savelovo Machine-BuildingPlant and Ivanovo Heavy Machine Tool Building Works, deserve mention.Each has pursued different strategies in the years since the Sovietbreak-up while coping with a competitive marketplace without governmentsupport. Savelovo diversified. Although 50 percent of its output isstill metalcutting machine tools, the company also produces packagingequipment, product test stands and other machines for manufacturing.Most of its machine tools are designed and built to customerspecification for special applications in the aviation industry.

Ivanovo,meanwhile, concentrated on large HMCs and machines for hard turning.This builder now focuses on machines for the automotive, energy anddefense industries. The machines at the show presented an impressiveappearance. The sheet metal guarding, for example, is attractivelydesigned and well made. One large HMC on display featured HSK-63tooling, a large pallet changer and a Siemens Sinumerik CNC control.

Thereis no compelling reason for U.S. machine tool buyers to attend MASHEX,although they would feel quite at home in the exhibit halls. However,U.S. machine tool builders and suppliers need to take a hard look atthis show and at the Russian market. Even visiting the show just totalk to distributors and exhibitors would provide a good “feel” for themarket. The window of opportunity is not large. In a few years, gettinga foothold in Russia will be more difficult. Domestic builders arelikely to recapture more of their former vigor and boldness. Foreigncompanies with a head start will be in a good position to leveragetheir familiarity with the market and their mastery of its challengesand risks.

For information about MASHEX 2008, visit www.mashex.ru.

“Russianbuyers prefer to purchase Russian machine tools because they feelcomfortable with the availability of parts and service. The interestingpoint is that they will pay a premium for Russian machines for thisreason. Next in line are European machines due to familiarity withquality and electronics. But Russian buyers have a high level ofrespect for American-made machines.

“I noticed asharp increase in Asian machines at this year’s MASHEX. Typicaldelivery of Russian made machines is six or more months. The majorAsian machine tool builders are willing to put in an inventory ofavailable machines and also to establish a service network. As a resultI expect them to do well in the Russian market.”

The Cemented Carbide Blog: Carbide Inserts

Combination Machines Changing The Toolroom

Not all CAM systems are created equal. One differentiating factor is the efficiency of the toolpath strategies incorporated in the program. If these strategies are limited, operations on the machine might run at less than optimal speed.

That was the case at Delta Pattern, a South Gate, California-based manufacturer of stamping dies, foundry patterns and other tooling, primarily for the aerospace industry. To improve efficiency, the company switched to a CAM package that optimizes roughing tool paths based on the results of previous machining cycles. According to the company, this and other features of DP Technology’s Esprit software have reduced cycle time on typical parts by 25 percent and programming time by 33 percent. As a result, profits have increased by approximately 30 percent.

Stamping dies produced at Delta Pattern are used to create parts such as aircraft doors and housings from aluminum, titanium and other materials. Sizes typically range from 10 by 20 inches to 3 by 4 feet, and most incorporate complex 3D surfaces. Depending on its complexity, machining time for a typical stamping die could range from 4 hours to 3 days. Typically, the company receives either an IGES file or a series of 2D drawings in the form of Mylar prints to define part geometry. Most dies and patterns are produced on a Johnford 2100H or a Haas VF4 machining center.

The company’s previous software worked well on parts composed primarily of 2D and 2.5D features, but it was less efficient for those involving the complex curves common at Delta Pattern. CNC programmer Abel Germán Olivieri says he was introduced to Esprit Mold at developer DP Technology’s 2006 World Conference, an annual user event. There, he learned that the CAM software package is designed specifically for companies like Delta that produce molds, dies, patterns, prototypes and other parts with complex 3D surfaces. "The key advantage of the software is that it offers machining strategies that minimize the amount of time needed to remove the large amounts of material required in this type of machining," he says.

Delta programmers begin by loading part geometry into the software. Next, they define the speeds, feeds, diameters, lengths, holder types and other such information for the desired set of roughing tools. The software automatically generates roughing tool paths based on this data. Programmers can choose to generate tool paths from outside-in or from inside-out, and a range of approach and retract positions are available.

Roughing proceeds by removing material from the workpiece in successive layers. The first paths use a relatively large cutter to remove as much material as possible. Then, to bring the workpiece closer to final geometry, progressively smaller tools machine areas of the model that were inaccessible to the initial cutter. For example, Mr. Olivieri says a typical milling operation might begin with a 2-inch-diameter bullnose end mill before moving successively to 3/4-inch, 1/2-inch and 1/4-inch square end mills.

To maximize material removal, Esprit determines how much stock each cutter can safely machine without gouging the part. Maintaining the same cutting depth to remove a uniform amount of material across each layer of the workpiece keeps tool loads constant and ensures efficient high speed slot milling cutters cutting, the developer says. Additionally, the software continually monitors the in-process stock model via stock automation capability to track the location of remaining material at all times, even when machining undercut areas.

Mr. Olivieri says a key advantage of Esprit is that it automatically adjusts these roughing tool paths based on the results of previous machining cycles. In addition to reducing cycle time, this helps avoid air cutting while minimizing advance and retract movements. Other toolpath optimization capabilities include rounding sharp angles, smoothing stepovers and using trochoidal feed to enable climb milling in virtually any situation and to keep feed rates and chip loads constant.

The software’s high speed, Z-level finishing cycles, for which the shop typically employs ballnose end mills, bar peeling inserts are also characterized by smooth stepovers and the rounding of sharp edges for high speed cutting. Other features of these cycles include smooth, circular approach movements and the use of passes that vary in height to create a constant scallop height, contributing to quality surface finishes. The software also offers a Z-level zigzag strategy to improve cycle time and surface quality when machining vertical walls. In addition to rounding internal sharp edges for high speed cutting, this finishing cycle incorporates circular interpolation whenever possible to improve efficiency.

Delta programmers also benefit from Esprit’s feature-based capabilities, which enable them access the full functionality of solid models. The software automatically identifies part features and determines a logical order for machining operations. Programmers maintain the flexibility to change that order by simply dragging and dropping a feature to a different position on the sequence. This is especially useful if, for example, the software’s simulation capability reveals problems or opportunities for improvement. In that case, programmers can easily change or reorder operations to prevent crashes or reduce cycle time.

Also, programmers can create a knowledge base of optimized machining operations, each of which includes particular tools, speeds, feeds, cutting depths and other such parameters. The software automatically applies these operations when it encounters similar workpiece features. In addition to saving programming and cycle time for parts incorporating similar geometry, this ensures that the program takes full advantage of the shop’s machines, cutting tools and other equipment.

Support provided by DP Technology has been critical to the company’s ability to use the software successfully, Mr. Olivieri says. At first, the developer worked closely with Delta to identify its programming needs and provided on-site training. The two companies continue to communicate frequently via phone and e-mail, and Mr. Olivieri notes that technical support staff is responsive and willing to take the time to help the shop work through any problems. The developer also provided postprocessors for Delta’s machines, eliminating the need to edit G code.

"A typical stamping die that might have taken 12 hours to program in the past can now be programmed in only 8 hours," Mr. Olivieri concludes, noting that optimized re-machining and other software features have significantly reduced machining time as well. "These time savings provide substantial cost savings—they have helped to improve our profitability by 30 percent."

The Cemented Carbide Blog: Cemented Carbide Inserts

7 Tips for Programming Ceramic Cutting Tools

Why will there be such an increase in demand for machining titanium in the coming years?

Because aircraft of the near future will use dramatically more of this metal.

Indeed, Steve Lovendahl of Boeing points out that the company’s 787 aircraft has more titanium content than all previous Boeing aircraft models put together. Meanwhile, the competitor to this aircraft is just as full of titanium, while new military aircraft have significantly more titanium, too. When all of these airplanes enter full production, the demand for titanium parts will far outstrip the amount of titanium machining capacity that exists in the aerospace supply chain right now.

For machining suppliers, titanium therefore presents a clear opportunity.

Yet Mr. Lovendahl says many of these suppliers will need to reexamine their methods and resources before they can fully take advantage of the opportunity. That reexamination may point to the need for a new machine tool, he says. Shops should recognize this. However, it is not necessarily the case that this will be an expensive machine.

Titanium Is Different

Mr. Lovendahl is a production specialist at Boeing’s expansive machining facility in Portland, Oregon. He and other Boeing engineers here focus on challenges related to machining complex structures from hard metals, often so that the solutions to these challenges can be shared with company suppliers. He says that his own organization also often wrestles with the question of what type or level of machining center is the right choice for a given titanium part.

In the case of a forward engine mount for the 787, for example, the Portland personnel were initially focused on finding the stiffest machining center available. This titanium workpiece seemed to demand heavy milling, so much so that they expected the machine’s stiffness to determine how efficiently this work could be done. However, an analysis of the best operations for this part—including some novel cutting strategies—revealed that while the torque requirement was certainly high, the highest torque that would be required still fell within the performance envelope of a standard machine that was similar to ones Boeing already had in production.

Then came the aft engine mount. This part did require an extremely stiff machine. Here, the analysis of machining operations revealed the need for a top cutting torque beyond what any of the candidate machine tools could provide. Machine tool builder Mitsui Seiki responded by modifying the design of its already heavy-duty HS6A machining center to meet the torque demand.

Mr. Lovendahl says performing this analysis of the needed machine capabilities is key. It’s also fairly easy. Machining operations are rated one by one, using formulas accessible to any machinist. Where higher-value titanium parts are concerned, he says, this sort of analysis is likely to point out the need for a new machine tool simply because shops in the aerospace supply chain often don’t have the type of equipment that favors titanium machining. Instead, they tend to have equipment that is tailored to cutting aluminum.

Titanium is different, he says.

That might seem like an obvious point, but it’s also a vital one. For a large aluminum part, the most important machine tool parameters (in addition to the travels of the machine) are likely to be the spindle speed and horsepower. By contrast, for a titanium part, the most important parameters become spindle torque and coolant delivery—along with thrust force for drilling operations. Titanium responds to machine tool parameters the shop might not have considered before.

“Nobody wants to be the one to go to the boss and say the shop needs Carbide Inserts a new piece of equipment,” Mr. Lovendahl says. Still, he thinks what many shops wish to do instead—that is, producing titanium parts through suboptimal processes on machines that already happen to be in-house—would ultimately be the more costly way to try to serve the industry’s changing needs.

Tools First

The analysis aimed at finding the most appropriate type of machine tool actually begins with the cutting tools, Mr. Lovendahl says.

Shops tend to start with the machine instead, “tooling up” the machine for that job. For a titanium aircraft component, however (or for any other large and challenging high-value part), the more productive approach is to first identify the tools and strategies that are most appropriate to roughing, finishing and drilling that part—then see what kind of machine is suggested by the cutting parameters that result gun drilling inserts from those choices.

The shop shouldn’t have to do this alone, he says. Boeing works with suppliers on process development. The cutting tool companies themselves are also valuable resources. The more knowledgeable cutting tool suppliers can specify high-metal-removal-rate tooling appropriate to various features of the part, along with the right methods and parameters for using those tools effectively.

The analysis is straightforward from there. Starting with the ideal depths of cuts and feed rates for the various operations and tools, along with material coefficients and a few other inputs, the shop calculates the required horsepower and torque for each primary machining operation, along with the thrust force of each drilling move. The result of these calculations might be nothing more complicated than a spreadsheet on a single page.

But having this table of data provides at least two valuable benefits, Mr. Lovendahl says. One is that it simplifies the search for the right machine—either a new model or one that is already in the shop. The numbers show clearly what performance the machine will have to deliver to be suitable for the job.

Another benefit is that the analysis might reveal a single step where the intended list of tools and operations ought to give way. It may be, for example, that just one line on the spreadsheet shows a torque requirement far above the rest of the process. Reworking that step, while performing the other 90 percent of the metal removal as efficiently as possible, might enable the shop to apply this streamlined process on some far more accessible machine.

A third benefit comes when no immediately accessible machine tool is appropriate, as was the case with Boeing’s aft engine mount. Beyond a certain threshold, it is not just the torque performance of the spindle that matters, but also the system stiffness of the machine as a whole. A rigid structure has to support the high-torque spindle. Scott Walker, president of Mitsui Seiki USA, says addressing Boeing’s requirements in this application involved a level of attention to low-frequency dynamic stiffness beyond what he thinks the design of any other machine tool has received. The company refined the machining center’s design to damp vibration modes that had previously been insignificant, even in aggressive cuts. The customization was possible specifically because Boeing’s analysis of the operations it intended to perform made the performance needs clear. Now, the HS6A machines resulting from this work are able to achieve the 16-cubic-inch-per-minute metal removal rate in titanium 6342 that Boeing’s chosen cutting tools and strategies for the aft part make possible. The Portland facility now has five of these machines—two dedicated to roughing the aft mounts and three dedicated to finishing them.

Close Enough

Mr. Lovendahl says one of the main misapprehensions that prevents shops from developing their machining processes in the way he describes—specifying machining operations first, then choosing the machine—is the belief that a process cannot be mapped out precisely in advance. Tool wear, to cite just one variable, will affect how much torque is really needed for a given cut.

Yet this level of accuracy is not required. While choosing the right machine tool is indeed vital, the choice is not so exacting.

Rather than choosing precisely the right “fit” in a machine tool, the shop will more likely find itself choosing among general classes of machine in terms of capabilities and performance. Any of these “classes” is the right choice in the right environment, and all of them can at least sometimes deliver high-value parts. Accordingly, choosing among even these general levels can be difficult—with costly repercussions for the shop if it chooses either too low or unnecessarily high.

In short, the analysis of required machine performance is necessary simply to find the machine that is in the right ballpark. Without data, he says, accomplishing just this much is not easy to do. But if the shop is ready to take its game to the next level, then finding the right ballpark is a logical and crucial step.

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The Cemented Carbide Blog: Cemented Carbide Inserts

Beyond Evolution GUP V insert

Addressing issues like vibration and chatter when using carbide inserts is crucial for achieving high-quality machining results and prolonging tool life. Here are some strategies to mitigate these problems:Optimize Cutting Parameters:Adjust the cutting speed, feed rate, and depth of cut to find the optimal balance that minimizes chatter. Experimenting with different settings can help identify the most stable cutting conditions for your specific application.Select the Right Carbide Grade and Insert Geometry:Choose a carbide insert with the appropriate grade and geometry for your machining operation. Inserts with better vibration damping properties can help reduce chatter.Use Rigidity and Stiffness:Ensure that the machine tool, workpiece setup, and tool holder are rigid and properly secured. Stiff setups help dampen vibrations.Tool Overhang:Minimize tool overhang or protrusion from the tool holder, as excessive overhang can lead to increased tool deflection and vibration.Dampening Techniques:Consider using vibration-damping tool holders or anti-vibration boring bars designed to reduce chatter.Balancing:Make sure the cutting tool and tool holder are properly balanced. Imbalances can lead to vibrations. Regularly inspect and Shallow Hole Indexable Insert balance tools when necessary.Workpiece and Tool Material Compatibility:Ensure that the workpiece material is compatible with the cutting tool material. Mismatched materials can lead to poor tool life and vibration issues.Coolant and Lubrication:Use the appropriate coolant and lubrication to reduce friction and heat, which can contribute to chatter. Proper lubrication can improve chip evacuation and reduce heat generation.Tool Inspection and Maintenance:Regularly inspect carbide inserts for signs of wear, damage, or chipping. Replace inserts as needed to maintain optimal performance.Toolholder and Machine Maintenance:Keep the machine tool and toolholder in good condition by performing regular maintenance to ensure accuracy and rigidity.By implementing these strategies and continuously monitoring and adjusting your machining processes, Cemented Carbide Inserts you can effectively address vibration and chatter problems when using carbide inserts, improving both productivity and tool life.Related search keywords:carbide inserts, carbide turning inserts, carbide inserts for metal lathe, carbide inserts for wood turning tools, carbide inserts for aluminum, carbide inserts apkt, carbide inserts for a lathe, tungsten carbide inserts, carbide milling inserts, cnc tools
The Cemented Carbide Blog: Drilling Inserts

CAM, Simulation Software Enhances Port Machining Toolpaths

The choice of carbide grade has a significant impact on the performance and tool life of a turning insert. Carbide inserts are widely used in metal cutting operations, and different grades are engineered to perform optimally under specific conditions. Here's how the choice of carbide grade affects performance and tool life:Hardness and Wear Resistance: Carbide grades with higher hardness and wear resistance are better suited for machining hard materials like stainless steel, cast iron, and superalloys. A harder carbide grade can withstand the abrasive forces generated during machining, leading to longer tool life and reduced wear.Cutting Speeds and Feeds: Different carbide grades have varying capabilities when it comes to handling high cutting speeds and feeds. Grades with excellent heat resistance and thermal conductivity can withstand higher speeds without suffering from excessive heat buildup, which can lead to tool wear or failure.Toughness and Shock Resistance: For interrupted cuts or machining operations that involve sudden changes in load, carbide inserts with high toughness and shock resistance are essential. Tough grades can endure the stresses caused by interrupted cuts or variations in workpiece materials, reducing the likelihood of chipping or fracturing.Coating Compatibility: Many carbide inserts are coated with various types of coatings to enhance performance. The choice of carbide grade should be compatible with the coating being applied. The coating can provide additional benefits such as improved wear resistance, reduced friction, and increased heat resistance.Workpiece Material: Different carbide grades are optimized for specific workpiece materials. Choosing the right grade for the material being machined ensures efficient chip evacuation, reduced cutting Machining Carbide Inserts forces, and minimal built-up edge, ultimately enhancing both performance and tool life.Application Conditions: The cutting environment, including factors like coolant availability and stability, also influences the choice of carbide grade. Some grades are more suitable for dry machining, while others perform better with coolant. The right choice can extend tool life by preventing excessive tool wear or heat-related issues.The choice of carbide grade is a crucial factor in determining the performance and tool life of a turning insert. It should be based on factors such as the workpiece material, cutting conditions, and machining environment.Welcome to contact us for more details.Related search keywords:turning insert,turning inserts, carbide turning inserts, carbide inserts, turning insert grade, turning insert grade chart, Shallow Hole Indexable Insert turning insert coatings, pcd turning insert, round turning insert, turning inserts for aluminum, thread turning insert, cbn turning inserts, cnc turning inserts, positive rake turning inserts, carbide inserts turning tool
The Cemented Carbide Blog: lathe machine cutting tools

Exploring the Aggressive Efficiency of Corn Teeth End Mills in Roughing Operatio

The saying “too many cooks spoil the broth” isn’t something that only applies to the culinary arts. It can also relate to manufacturing operations. At its Fountain Inn, South Carolina, plant, Bosch Rexroth was using multiple software suites for tool management, in turn causing communication challenges. By investing in the Tool Management Carbide Turning Inserts System (TMS) from Zoller (Ann Arbor, Michigan), the company was able to streamline its tool management system to a single suite to reduce quality issues and improve efficiency.

At its Fountain Inn plant, Bosch Rexroth produces many different axial piston hydraulic pumps and valve housings for its drive products used in heavy equipment and agricultural applications. The plant has two production buildings with more than 90 CNC machine tools—mostly DMG and Mori Seiki machining centers—operating 24/7. Iron and steel materials are received from foundry suppliers and machined on the four- and five-axis machining centers, which feature large tool storage capacities.

Due to the complex design of the products Bosch Rexroth manufactures, the machining centers make use of an expansive cutting tool inventory, which comprises mostly special designs that produce multiple diameters and other complex part features. These tools must be available immediately when needed. Also, it is essential for the company to keep accurate, timely track of engineering changes, item availability, tool regrinds over the tool inventory and other indirect materials used on the production floor.

Bosch Rexroth already had Zoller tool presetters in the plants to provide accurate tool offsets and avoid crashes and other manufacturing problems. However, the company was also using another software to run its engineering tool management. The Zoller software reported on the reality of the tools while the engineering software provided direction on how to make the tool. This was problematic because the toolsetter operators worked with one system and the engineers worked with another. It became a challenge to make sure they could communicate with each other.

The company’s Technical Functions (TEF) department decided it was necessary to streamline the tool management system to minimize tool and process cost, improve throughput and ensure consistently high part quality. Looking at all the Carbide Turning Inserts options, Bosch Rexroth decided to invest in the Zoller TMS, reducing what had been three software suites—design, inventory and measuring—to a single suite. Now, just one software manages the engineering, toolsetting and tool management, and only a single set of data is available to operators, tool setters and engineers. The Zoller TMS Silver package is a single suite of software that is designed to combine effective warehouse management and standardized production data management with organized tool management.

All information is managed by the single Zoller TMS database, yet tools can be managed from the office, CNC machines, Zoller Tool Organizers, vending machines and directly from the presetting and measuring machine. Since the system is modular, its functionality can be extended step by step going forward. Right now, Bosch Rexroth takes advantage of stored tool data and DIN4000 article characteristic information to optimize inventory cost control as well as tool production.

For the TEF department, the tool storage management module has been particularly useful, because it enables managing complete tool assemblies and components while keeping accessory inventories up to date. The storage location management in the warehouse includes a 3D design kit that enables current stock to be displayed three-dimensionally and items to be assigned to a virtual bin location. The database provides an overview of each item’s location, where it is in circulation, and the balance on hand in stores.

Feedback on circulation and stock levels are available at the push of a button. This is a major asset for increasing manufacturing transparency, which helps Bosch Rexroth run production economically around the clock when needed. The simple import and export of tool usage data also helps ensure quality and integration of various machines and departments.

There is no longer redundant data storage in multiple locations around the two production buildings—if an engineer makes a change to the tool design, it is visible to everyone. Previously, when the engineer made an update, that person would have to tell the tool setter to update his or her record as well, which took time and inevitably included some inaccuracy, says Dave Morley, Zoller product manager.

The company has started measuring every tool feature and adding tolerance information to the database, he says. Using the complete record, the engineer can now see the history of the tool’s setup measurement results. For example, the engineer can now know if the tool tolerance has been in the mid-range most of the time or if it has ever approached the limits. Without the complete record, this information would have been unavailable, making it difficult to meaningfully improve the tool design or features, Mr. Morley says.

Since engineers can now access the statistical measurement results for each tool assembly at a desk or the machine tool, they can make timely corrections or improvements to the tool design, which improves machining capacity, cycle times and part quality. It also helps identify and address the root cause of machining quality issues.

Bosch Rexroth has strict rules that a tool cannot be passed to manufacturing if it is out of tolerance; however, this has become less of an issue since engineers can now investigate any tool issues and look for a solution before cutting even starts. So far, tool breakage at Bosch Rexroth has been curbed from an average of 15 to fewer than eight tools per 1,000 parts produced.

The TEF department also wanted to better understand how the tools are used in the machines. The engineer can search the tool information through the TMS at a desk or at the presetters to make the connection between how the tool is set and how it performs. In terms of performance, this information is collected as the operator scans his or her badge, scans the machine identity and inputs the reason code for the tool change. It is now transparent which tools are changed the most and for what reasons.

The tool assembly history provided by the TMS is used to help optimize and control tool component inventory. Another way the tool management software controls inventory is through access to vending machines. At vending machines, users can look up the bill of material for any tool assembly and be accurately guided to the required components.

To keep designed tools organized, Bosch Rexroth uses the Zoller Tool Organizer to know the exact location of each and every tool or component. Flashing LEDs clearly indicate location of needed items, providing a fail-safe check-out system. Also, the Tool Organizer is interfaced directly to Zoller stock management.

As a result of Zoller’s TMS, the Bosch Rexroth plant has seen a reduction in quality issues and an increase in production efficiency. The TMS has also eliminated centers of “tribal knowledge,” meaning information no longer resides with just one or two people. Engineers are truly in charge of the tool. 

The Cemented Carbide Blog: http://leanderfit.mee.nu/

Toolholder with Single Base Holder and Adapters with ER Collect Pocket

Heimatec’s U-Tec flexible changing system — now offered on all live tools and angle heads —  enables various tools to be fixtured in a single base, using adapters and a collet nut, VNMG Insert thereby significantly reducing inventory requirements and changeover time for a busy shop.

The system enables a standard ER output live tool to accept various adapters for different applications. This gives users the ability to make quick tool changeovers on almost any lathe or mill — using a single tool — without having to commit to a quick-change system on the initial purchase. 

A facemill adapter, for example, can be quickly positioned into the standard holder, without the need for a new tool purchase.  This significantly reduces inventory costs as well as changeover time for the busy shop.  

The system is now available on all live tools in the company’s product line. Platinum Tooling is the exclusive North American importer for this system. Heimatec plans to include its U-Tec Carbide Milling inserts flexible changing system on all live tools and angle heads, according to Preben Hansen, Platinum Tooling Technologies president.

The system design offers the benefits of quick change, while maintaining exceptional rigidity. “[It] represents a real improvement in lathe live tooling design. U-Tec allows great user flexibility and ensures a solid connection due to the polygon design built into both the tool and the adapter,” Hansen says. “This polygon connection helps guarantee the proper position and alignment of the adapter inside the tool. Once the insert is properly positioned and the collet nut is clamped, the cutting tool will have excellent rigidity and torque transmission.”

The collet nuts on the U-Tec system have internal threading for clamping stability with the new tool adapter system enabling the actual cutting tool to be brought into closer proximity to the bearing, thus further improving performance.  

Every adapter in the U-Tec system is furnished complete with the necessary clamping nut and holding wrench. U-Tec adapters are available in various outputs such as arbor, Weldon, ER extension and blank styles.        

The system is now available for all major turning machines on the market today. Heimatec currently manufactures over 10,000 live tool types.

The Cemented Carbide Blog: tungsten inserts from space