Archive for the ‘CNC Tooling’ Category

Last week, the focus of this column was on developments in machining centres, as well as drilling, milling and turning machines. In this second contribution of emerging machine-tool industry trends I home in on some of the opinions expressed by those experts who compiled the ‘closing report’ for VDW (the Association of the German Machine Tool Manufacturers) for at the EMO Hannover 2007 concerning grinders, as well as metal-forming machines and sheet-metal machining centres.

GRINDERS
In years past, machine tool manufacturers focussed on optimising the actual machining process, namely on reducing peak times. For this reason, there are not expected to be great leaps forward expected, unless, that is, significant progress is made by component manufacturers.

Therefore, in order to minimise this dependency and achieve a competitive edge, a few machine-tool manufacturers have developed methods for specifically reducing nonproductive time.

In fact, one grinder manufacturer has implemented the objectives mentioned in a new CNC grinding centre by integrating a grinding disk changer and a pick-up loading unit into the working area, thus achieving a high degree of automation, which, in turn, raised both productivity and repeat accuracy.

A particularly efficient solution for reducing nonproductive time unveiled at EMO Hannover 2007 was the incorporation of nozzle elements for injection pumps, used by motor-vehicle manufacturers, into a new grinding machine. The machine has been so constructed that the required cooling jet does not just fulfil its actual function, but is also used for transporting the work pieces. In this way, the time taken for changing work pieces has been reduced by over 50%, to 0,9 s. Since the grinding process for these nozzle elements only takes a few seconds, the whole machining process duration was considerably reduced.

METAL-FORMING AND SHEET-METAL MACHINING
For metal forming machines and sheet-metal machining centres, too, the trend towards shortening nonproductive time is a major theme, with technical challenges arising in this area being solved by EMO Hannover 2007 exhibitors in very different ways.

A further and very important topic for manufacturers and users of metal-forming machines and sheet-metal machining centres is the reduction of manufacturing costs.

In order to meet both requirements, manufacturers showed the results of their optimisation attempts and of their machines that had been improved in terms of construction details.

In sheet-metal machining, the requirement for laser-welding equipment is increasing, since the demand for accuracy, particularly for tailored blanks and profile sections, is increasing. In previous years, great progress had been made in this area, and these tasks had in the meantime been converted into standard procedures in the machining units.

In order now to reduce costs, it appears that laser machining and machining centres will now become more compact and flexible. Over and above this, they will be offered with integrated automation. For example, a directly-linked loading and unloading unit, making the hitherto employed pallet-changer superfluous. This should reduce the footprint, which in turn will be able to be used to best advantage for tasks to be carried out.

The operating speed for the latest laser-machining devices is limited by the mass of the work piece to be moved. Here, the so-called flying optic (laser head) is the optimisation device, which is moved using highly dynamic motion sequences at speeds of up to 200 m/min and acceleration of up to 20 m/s. In order to achieve this mass reduction by lighter and more stable structures, various types of lightweight construction are employed in these machines.

Cold massive forming was likewise exhibited at the trade fair and focussed on shorter processing times. Through innovation, high-tensile materials can be rolled, using optimised thread rolling machines, economically and with maximum precision, even for short runs.

Along with thread making, gear cogs, worm gears and other profile sections are also cold-rolled. For instance, a machine concept was presented, which is able to complete gear cogs within 46 s.
 

Extending its manufacturing facility at Ruebig/Nabburg, Germany, as the competence centre for fine machining, Kennametal now offers precision reaming tools and tools for fine-boring operations

Kennametal now offers precision reaming tools with guide pads, tools for fine-boring operations with precision adjustment. The company said that its product development offers innovative high-speed tools for machining centres, combining several operations in one tool. These high precision tools can be used with traditional coolants as well as with minimum-quantity lubrication..

As far as pre-adjustments, Kennametal offers its systems RIQ and Romicron tooling requiring only a fraction of the adjustment times compared to some other tool designs, said Michael Grimm, director of Advanced Engineering, Europe.

Grimm told manufacturingtalk.com: ‘The requirements of the market for fine finishing tools can not be fully fulfilled with ready-made off the shelf products due to the ultra fine tolerances demanded.

Ruebig have many years design and manufacturing experience in delivering individual custom solution tools ensuring that our customer gain a competitive edge in a challenging market place’. In Nabburg/Upper Palatinate there are 300 employees designing and manufacturing symmetrical drilling, countersinking, reaming and milling tools.

At present, 4,000 tools (70% customized to suit customers individual needs) are produced per day.

* Fine machining – fine machining will be one of the highlights of the new drilling catalogue, which will be published in spring 2008.

The precision tools from Nabburg and the know-how enable Kennametal to supply tooling to most industries.

In cooperation with the Advanced Engineering division, Grimm said that Kennametal customers all over the world are offered complete solutions and services from one source.

* About Kennametal – Kennametal Incorporated (NYSE: KMT) is a leading global supplier of tooling, engineered components and advanced materials consumed in production processes.

The company improves customers’ competitiveness by providing superior economic returns through the delivery of application knowledge and advanced technology to master the toughest of materials application demands.

Companies producing everything from airframes to coal, from medical implants to oil wells and from turbochargers to motorcycle parts recognize Kennametal for extraordinary contributions to their value chains.

Customers buy over US$2.4 billion annually of Kennametal products and services – delivered by its 14,000 talented employees in over 60 countries – with almost 50% of these revenues coming from outside the United States.

CNC Machining is the topic of choice for Video 6 in Ivan Irons CNC Ecourse video series. CNC Machining is the fifth and final step in the CNC Process and Ivan ensures to make a detailed depiction on the CNC Machining process. He covers topics such as the CNC Tooling you will need, the various types of professional and home CNC Machines, and CNC Machining safety.

Ivan spends a lot of time on taking the CNC student through the types of CNC Machines such as, CNC Plasma Cutter, CNC Mill, CNC Woodrouter, etc. He includes as many photo examples as possible and even shows CNC tooling and CNC Machines within his own shop.

CNC comes alive with Ivan’s account of what he calls “where the rubber meets the road” CNC Machining. All pertinent information on CNC Machining is included in Ivan’s CNC video tutorial with the added bonus of priceless personal tips from his own CNC Machining experience. All of the videos in Ivan’s CNC Ecourse can be found at: CNC Machine Tips

Ivan’s CNC Blog also has his latest video projects. Ivan continues to create more CNC projects, E-Video’s, and general CNC information that can be found on Ivan’s website at CNC Mill
 

To meet increasing demand for tooling regrinds from aerospace companies, a UK specialist tooling manufacturer has added on another CNC tool and cutter grinder for its consistency

Specialist tooling manufacturer and supplier, Industrial Tooling Corporation (ITC), has added another Helitronic 5-axis tool grinder. It complements seven other Walter CNC tool grinders and a Walter Heli Toolcheck tool measuring machine and represents a strategic investment by the company to meet increasing demand for tooling regrinds from aerospace OEMs such as Airbus and Rolls-Royce.

ITC has bought the Helitronic to extend its capacity for high-precision drill and reamer regrinds.

The machine, a Walter Helitronic Power, supplied by Korber Schleifring UK of Honiley near Kenilworth, is part of ITC’s ’substantial’ investment process during 2008.

Sales director at ITC, Roy Talbot, commenting on ITC’s continual programme, said: ‘is evidence of our commitment to the desire to always stay ahead of the competition through guaranteed high-quality output and responsive service.’ He added that the ITC-Walter machine association had extended over the past eight years and is based on good delivery and service back-up as much as it is on cost-effective machines that are fit for purpose.

ITC designs, manufacture and regrinds of a wide range of HSS and carbide tooling for customers in the aerospace, motor sport (Formula One) and die and mouldmaking sectors in the UK and overseas.

The company is also UK stockist of Hanita (Israel) and Metal Removal (USA) products.

As well as the speed and accuracy of the five-axis CNC Walter Helitronic tool grinders, the added consistency that the Walter Heli Toolcheck tool measuring machine has brought to quality control is proving the ideal complement to enable ITC to extend its successful supply relationship with customers like Airbus and Rolls-Royce, said Koerber Schleifring to manufacturingtalk.com.

A variety of power generation form tools, drills and reamers, for example, are supplied to these companies, and manufacturing certification and traceability are essential.

‘We know that the Helitronic Power effectively restores tooling back to original geometry, and the Toolcheck allows us to illustrate that,’ commented ITC technical director, Peter Graves.

He said how Walter’s ‘ancillary’ technologies play a particularly beneficial role at the company.

He gave the example of a previously-installed Helitronic Power tool grinder with a Production Loader accommodates and randomly processes 280 tools of up 32mm diameter and 220mm long.

ITC also uses five other auto loading systems on Walter machines and therefore extends the company’s commitment to ‘lights-out’, unmanned production.

This system complements the seven day shift operators who manage ITC’s total machine park of 17 tool grinders.

* Software saves time – the Walter Cyber grinding tool grinding software offers savings in cutting tool design and production by allowing non-standard new tools to be designed and ‘manufactured’ off-line.

Cyber Grinding eliminates time-consuming and costly prototypes, test batch work and interruptions to production, said ITC.

‘Customers increasingly want cost-effective, high-quality tooling delivered promptly and backed up by a high level of problem-solving technical engineering expertise in extremely short delivery times,’ concludesd Talbot.

‘We make sure we are in a position to respond, hence our continual investment in Walter technology.’

Kurt Introduces the 5C Angle Boss for Mounting in Kurt 6 Inch Vises

Minneapolis, Minnesota: Kurt announces the introduction of the 5C Angle Boss (Model No. K5CVMAB) for mounting in any Kurt 6 inch vise.

This manually clamped 5C fixture allows machining any custom angle desired or 24 precision indexes (+/-2 arc-min) using the mount’s special index pin.

Setup is fast and easy. Once the machining position is determined, simply clamp the 5C fixture using the massive 1-1/4 inch thick ground steel jaws. The vise will now hold the 5C fixture for most machining operations. Parts can be clamped and unclamped using the 5C clamp screw. Collets may also be changed from the top of the fixture without disturbing the original setup.

The 5C Model No. K5CVMAB Angle Boss accepts a 3-1/4 inch 3 jaw chuck (sold separately). This is a high quality, dead length 5C holder designed to save many hours of expensive setup time, giving Kurt vise users yet another option for improving machining center productivity.

In addition to standard vises and accessories, Kurt provides integrated custom engineered workholding systems and custom gaging systems for automated manufacturing. Both workholding and gaging are designed around a customer’s requirements with systems available for many industries including automotive, medical and aerospace applications.

Interested in more information? Call Kurt in USA and Canada, 1-877-226-7823. Outside USA and Canada, call 1-763-574-8309. Or see at: www.kurtworkholding.com. Email: workholding@kurt.com

Or write to Kurt Manufacturing Company, Industrial Products Division, 1325 Quincy Street NE, Minneapolis, Minnesota 55413. In USA, Fax 1-877-226-7828. Outside USA, Fax 1-612-623-3902.