NUMROTOplus. NUMROTOplus Software that makes the difference

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Page 2 NUMROTOplus Tools catered for Modern programming environment NUMROTOplus Page 3 Tapered milling cutters Resharpening Production Page 4 3-D Simulation Up/Down Milling Cutter Page 5 Cylindrical

1 Page 2 NUMROTOplus Tools catered for Modern programming environment NUMROTOplus Page 3 Tapered milling cutters Resharpening Production Page 4 3-D Simulation Up/Down Milling Cutter Page 5 Cylindrical end mill cutters Template database Measurement of tools Saving tools in the database Page 6 Drills and step drills Machining of points Production of drills and step drills Page 7 Step drill Straight step drill Form cutters DXF Contour Page 8 Radial sharpened form cutter Page 9 Gundrills Burrs Page 10 Profile inserts Wheel profile determination Page 11 NUMROTOplus Technical Specifications NUMROTOplus Software that makes the difference Manufacturers of tool-grinding machines and tool manufacturers and resharpeners rely on the tried and tested programming system for tool grinding NUMROTOplus. This makes NUMROTOplus the best solution for customers, since the software has been fulfilling the needs of the industry ever since it was first developed at the end of the 80's. NUMRO- TOplus will continue to satisfy the industry's needs in the future. The NUMROTO team possesses inter-disciplinary knowledge in all areas of tool grinding on CNC controlled machines. Updates and enhancements result from the ongoing dialogue with users worldwide. It is important to note that NUM offers a customized training program for newcomers and advanced users. NUMROTO experts not only offer training courses at the company headquarters in Teufen, but also at the machine manufacturers' facilities or directly at the tool manufacturing and resharpening sites. This technical information will give you a first impression of the capabilities of NUMROTOplus. If you have further questions, please get in touch with our information center in Teufen (CH) we look forward to a continuing positive relationship.

2 NUMROTOplus NUMROTOplus is a software package for producing and resharpening a whole range of tools. It allows you to program your grinding machine directly at a PC and provides you with programming support in the form of graphical help screens and well-designed user interfaces. When working on complex machining tasks, the programmed tool may be examined and optimized before grinding starts by using the high-precision simulation facility. Tools catered for NUMROTOplus has been devised in such a way that it can be expanded with virtually any tool form. A selection of tools which could be produced is described in detail on the following pages. Of course, what you see here represents only a fraction of the tools that can actually be made. Depending on the way that the machining options are combined, the tools described below can be ground in many different ways. Furthermore, NUM- ROTOplus is being expanded all the time so that even the most exotic combination tools can be quickly programmed, produced or resharpened. Modern programming environment NUMROTOplus uses leading edge technology to exploit all the capabilities of modern PCs and operating systems. NUMROTOplus is completely compatible with Windows 95/98 and Windows It can be easily networked and also used with your in-house software. The operating interface (see illustration below) conforms to the Windows standard so that users don't have to reorient themselves after working with other Windows programs. NUMROTOplus operator interface 2

Tapered milling cutters The resharpening and production of tapered milling cutters with a ball nose or corner radius are standard tasks for today's grinding machine.

Resharpening: Measurement of the entire length of the helix twist with a probe so that virtually any tapered cutter can be resharpened.

3 Tapered milling cutters The resharpening and production of tapered milling cutters with a ball nose or corner radius are standard tasks for today's grinding machine. All the same, results can vary enormously. NUMROTOplus offers several advantages with this kind of tool. Some of them are listed here. Resharpening: Measurement of the entire length of the helix twist with a probe so that virtually any tapered cutter can be resharpened. Calculation of a compensating curve which smoothes out the sampled helix and conforms to the preprogrammed lead type. Choice between constant or variable front infeed (circular infeed). This allows the resharpening of cutters with a form contour (e.g. «Christmas tree cutters») Multi pass grinding with different roughing and finishing cuts. Production: Individual flute geometry which can be optimized using the simulation facility. Operations can be machined in any order. So, for example, the relief angle can be premachined with a peripheral wheel. The reliefs can be machined in the direction of your choice. Reverse finishing of flutes optimizes the overall finish. Body clearance to allow a constant land width to be ground around the periphery. This ensures sufficient rake volume when milling shallow flutes. Simulation of tapered cutter with constant lead. Body clearance ensures constant width of land. 3

3-D Simulation In spite of a polished calculation algorithm and a very efficient 2-D simulation, a 3-D simulation of the entire tool is desirable for complex tools before grinding.

A push of a button generates all the grinding paths for a tool, so that the tool can be directly simulated by the Vericut 3-D simulation software.

In the process, the grinding wheel geometry is taken into account 100 percent, that is, including corner radius and angles.

All the 3-D pictures shown in this pamphlet have been calculated with NUMROTO and then simulated using Vericut.

4 3-D Simulation In spite of a polished calculation algorithm and a very efficient 2-D simulation, a 3-D simulation of the entire tool is desirable for complex tools before grinding. To fulfill this need, NUMROTOplus offers an interface to a well-proven 3-D simulation software. A push of a button generates all the grinding paths for a tool, so that the tool can be directly simulated by the Vericut 3-D simulation software. The generated model exactly corresponds to the actual grinding process. In the process, the grinding wheel geometry is taken into account 100 percent, that is, including corner radius and angles. During the simulation run, the grinding wheel is shown transparently. In addition, the collet can be optionally faded in. All the 3-D pictures shown in this pamphlet have been calculated with NUMROTO and then simulated using Vericut. Up/Down Milling Cutter Up/Down Milling Cutter The above picture shows a special milling cutter for the wood industry. Out of the total of four teeth, two are sharpened with a right-handed twist and two with a left-handed twist. Naturally with NUMROTOplus, all necessary operations can be programmed in one workpiece. The readied grinding program can be verified again at the push of a button with 2-D or 3-D simulation. 3-D simulation of the tapered cutter of the previous page Simulation sequence of the up/down milling cutter Overall view of machining sequence with all operations required for the production of an up/down milling cutter 4

Cylindrical end mill cutters The sophisticated options available for grinding tapered tools can also be used for regular cylindrical end mill cutters.

This makes for more efficient use of the measurement machine and means that grinders are used for grinding alone.

The data is loaded from tool templates in the database. The unique feature is that the operator can modify or extend the data or match it to his or her requirements.

5 Cylindrical end mill cutters The sophisticated options available for grinding tapered tools can also be used for regular cylindrical end mill cutters. Of course this isn't necessary for resharpening and grinding standard milling cutters. It is also possible to use one measurement machine together with several grinding machines. This makes for more efficient use of the measurement machine and means that grinders are used for grinding alone. Template database NUMROTOplus automatically selects the appropriate grinding parameters so that the optimal settings exist for all cutters from the start of the job. The data is loaded from tool templates in the database. The unique feature is that the operator can modify or extend the data or match it to his or her requirements. This guarantees that the basic data used for a new tool stays the same even in large workshops with many grinding machines. Example of result page after completion of automatic measurement with the probe Part of a tool template list Saving tools in the database To allow all programmed tools to be saved for future use, NUMROTOplus includes an ingenious data management system. Tools can be saved under meaningful names and also divided into categories. Furthermore, a filter is available which can be used to reduce the number of tools which appear in the list. All this means you will quickly find the tool you are looking for. Measurement of tools When resharpening tools it is important that as many dimensions as possible are automatically measured by the probe or another measuring device. This saves time and avoids input mistakes. Using a measurement probe NUMROTOplus incorporates ingenious measurement cycles which allow a single probe to measure many dimensions. Measuring machine interface NUMROTOplus is also able to import data from a measurement machine. Additional values can be generated and directly imported as with the probe. Tool database with category list opened 5

Drills and step drills NUMROTOplus makes easy work of resharpening step drills with its optimized computation routines and sophisticated auxiliary functions at the same time it improves results.

Illustration of flute form compensation measured with probe One of the many special features is the grinding of a separate step clearance during step transition.

Even if minimal recess depth is involved, a longer area can be ground free above the step without having to use a grinding wheel with a chamfer that matches to the face angle.

Production of drills and step drills NUMROTOplus includes a wealth of special features and machining options which allow the tool maker plenty of scope for tailoring tool geometry.

Selectable cutting compensation for every step transition Double land on straight drills Integrated cylindrical grinding with various roughing and finishing cycles Manual grinding path = free

6 Drills and step drills NUMROTOplus makes easy work of resharpening step drills with its optimized computation routines and sophisticated auxiliary functions at the same time it improves results. So, for example, the current flute form is probed and the step relief matched to the outline of the flute as closely as possible. Illustration of flute form compensation measured with probe One of the many special features is the grinding of a separate step clearance during step transition. With this feature the area below the step can be quickly and optimally ground free with a flat angle. Even if minimal recess depth is involved, a longer area can be ground free above the step without having to use a grinding wheel with a chamfer that matches to the face angle. Many in-house point types can be developed from the preprogrammed geometry, or specialized commercially available bits may be resharpened. Production of drills and step drills NUMROTOplus includes a wealth of special features and machining options which allow the tool maker plenty of scope for tailoring tool geometry. Flute with selectable core profile Multifluting, even with a single land step-drill Flute with variable helix twist Optimized flute washout Use of wheel profile for flute (also during simulation) Selectable cutting compensation for every step transition Double land on straight drills Integrated cylindrical grinding with various roughing and finishing cycles Manual grinding path = free programming of wheel path but with use of the simulation It is also possible to grind step face angles of more than 180 using NUMROTOplus. The simulation below illustrates the grinding of a step with an angle of 220 using a cup wheel. For clarity, only the first relief is shown a second or third relief could obviously be ground as well. Furthermore, in each case, the last relief can be repeatedly ground, guaranteeing that the body has enough clearance. Diagrammatic view of a step clearance Machining of points There are of course a large number of preprogrammed shapes available for drill points. Furthermore, they can be modified and adapted using an array of simple parameters. Simulated machining of step with a step face angle of 220 S6 point Original Hertel SE point 6

Step drill The following step drill has five different step angles, all of which were face relief ground as was a special tip with two different point angles and a chamfer.

7 Step drill The following step drill has five different step angles, all of which were face relief ground as was a special tip with two different point angles and a chamfer. Further, two cutting flutes were programmed. Both cutting flutes were made using a variable core. The core is constant in the front area and is tapered only in the rear area. Form cutters It is also possible to grind complicated form cutters using NUMROTOplus.. The lead type of these profile tools can be helical, straight, or conform to a shear angle. The profile of these tools can be ground very precisely indeed because NUMROTOplus allows form cutters to be ground in a single clamp from start to finish. As the flute geometry is known, it can taken into account during grinding of the profile. Step drill with break point Naturally with the above examples, the limits of NUMROTOplus are far from being reached. A step drill can have up to nine step transitions. In addition, several cutting flutes can be sharpened per diameter, allowing the flute area to be individually configured. Straight step drill The following step drill with straight helix has, as a speciality, doubled land on both diameters. The machining, which produces the front and rear land, can be individually adjusted. DXF Contour The shape of a form cutter is defined by a DXF contour. The DXF files required can be created using a CAD program. Virtually any profile can be imported into NUMROTOplus. Axial relief angles along the whole length of the contour can be programmed in different ways. Moreover, it is also possible to grind a contour in a series of smaller steps and machine different sections with the wheel in different positions. Up to three relief angles may be machined and the last relief angle can be divided several times. It is then very easy to grind the body free. Of course every relief can be ground with a separate grinding wheel, allowing, for example, a very fine grade wheel to be used for the first relief angle. Step drill with 3 cutting edges and doubled land Simulation of relief angle grinding The point wheel is automatically swiveled to the required position in accordance with the programmed relief angle. 7

Radial sharpened form cutter Programming a form cutter, either a first, second and third relief angle can be sharpened or alternately a single radial relief.

Here the required infeed is automatically calculated so that a corresponding relief angle results.

Further features Reliefs can be machined from the front or back Cylindrical grinding along the whole contour Flute form compensation for tools with a helix

8 Radial sharpened form cutter Programming a form cutter, either a first, second and third relief angle can be sharpened or alternately a single radial relief. The radial relief can be produced in that the relief is offset several times during sharpening. Here the required infeed is automatically calculated so that a corresponding relief angle results. The milling cutter to the right of the page was sharpened in accordance with this principle. Further features Reliefs can be machined from the front or back Cylindrical grinding along the whole contour Flute form compensation for tools with a helix Calculation of grinding time Regular or irregular pitch Grinding of crossed tools, i.e. right and left rotation on the same tool Different forms for each tooth Four different grinding techniques for the reliefs Above: Detail enlargement of the radial relief. Left: Form cutter with radial relief. Form cutter with rising flute Reliefs sharpened in one pass with a point wheel 8

Gundrills With NUMROTOplus «Drills», gundrills can also be manufactured and resharpened. The special feature of these normally single-edged tools is the point, which consists of several surfaces.

With the following two gundrills, it is important to observe the peripheral land which is automatically ground along the point reliefs.

Programming the basic geometry for a solid ball burr with chip breaking flutes A 3-D simulation of a point with 5 surfaces and a point with 7 surfaces Burrs The NUMROTOplus «Burrs» software package

This is executed with a normal peripheral wheel which, depending on the flute depth and rake angle required, usually has an application angle of between 0 and 30.

9 Gundrills With NUMROTOplus «Drills», gundrills can also be manufactured and resharpened. The special feature of these normally single-edged tools is the point, which consists of several surfaces. With NUMROTOplus, each surface can be programmed individually. A point can consist of up to 10 surfaces. With the following two gundrills, it is important to observe the peripheral land which is automatically ground along the point reliefs. Of course, as is always the case with NUMROTOplus, the flute form created can be checked within seconds by means of the tried and tested simulation, and can be optimized if necessary. Programming the basic geometry for a solid ball burr with chip breaking flutes A 3-D simulation of a point with 5 surfaces and a point with 7 surfaces Burrs The NUMROTOplus «Burrs» software package enables you to grind burrs. The number of different shapes is practically unlimited, since the outer form of the tool can be defined with the NUMROTOplus Profile Editor. The usual standard shapes can be selected directly. It is not necessary to draw a separate profile for such tools. The special properties of the burrs is that the flute and the relief are ground in a single operation. This is executed with a normal peripheral wheel which, depending on the flute depth and rake angle required, usually has an application angle of between 0 and 30. The wheel is adapted by NUMROTOplus automatically, so that the required external geometry can be created immediately. Grouped teeth are often ground on the tip of the burr. This means that a section of the teeth passes the center. In this case the grinding length in the center must be calculated so that the teeth next to it are not abraded, but that each tooth is ground as much as possible. NUMROTOplus carries out this optimization for each group of teeth, so that no time-consuming trials or test grindings are necessary. 3-D simulation of a burr with grouped teeth and chip-breaker flutes If necessary, chip breaking flutes can be added, with which the helix can be separately programmed. For example an individual chip breaker with a very high helix angle (85 ) can be ground. Nevertheless, the tool can be ground in one clamping. Simulated cross-section of a burr Further highlights of NUMROTOplus «Burrs» Constant helix angle or constant lead Variable feed rates Freely definable grouped teeth Processing from the rear or the front 9

10 Profile inserts NUMROTOplus can be used for grinding profile inserts for cutter heads as well as profile inserts for lathe tools. Simple and complex profiles are catered for, e.g. deep, sheer recesses or overhanging sections. Wheel profile determination Occasionally profile wheels are used in the production area, with which a specified flute profile is to be created. For this purpose, a wheel profile determination feature was integrated into the NUMROTOplus. In this example, a grinding wheel shape was calculated, which grinds the flute area of a drill and at the same time grinds the peripheral land. Profile insert The undistorted profile, which is to create the profile insert in the final product, can be drawn with the integrated Profile Editor or be imported from an external CAD system as a DXF file. The profile insert can be mounted in virtually any position in the production clamping system, in the cutter body or in the lathe tool retainer. The distorted cutting and relief path is calculated depending on this position. The profile is produced by recess roughing, finishing and fine finishing. These machining operations may be subdivided in selectable machining sections each of which can be ground with up to three reliefs. Complex sections of the cutting edge profile or of the rear profile can be closely checked using the machining simulation. Profile Editor Profile of the calculated profile wheel The left radius-shaped area of the grinding wheel creates the flutes; the right area that is virtually straight creates the peripheral land relief ground. This example illustrates, how strongly distorted the wheel profile must be, due to the twisting, compared to the flute profile to be ground. If you look through the drill bit in the direction of the helix in the 3-D image, you can see the cross-section of the wheel displayed. Naturally, NUMROTOplus can also create the program for the initial profile or for the cyclic dressing of the grinding wheel. In this dressing program the different geometry of the dressing unit has, depending on the application, been completely calculated. 3-D simulation Drill ground with profile wheel Profile insert Simulation of the grinding process for a profile insert 10

11 NUMROTOplus Technical Specifications Body shapes Cylindrical Tapered Roughing profile Face forms Flat Flat with chamfer Flat with corner radius Ball nose Milling cutters Lead type/cutting direction Constant helix angle or constant lead Measured lead type on tapered tools Straight (angle 0 ) Right-hand helix / right-hand or left-hand cutting Left-hand helix / right-hand or left-hand cutting Manual helix twist for most machining steps Operations Practically all operations can be programmed several times using different parameters Cylindrical grinding Diameter grinding Form grinding of the entire contour Cyclical grinding Diameter range Limited only by the machine Number of teeth Up to 999 teeth (with equal pitch) Up to 12 teeth (with unequal pitch) Manual pitch for most machining steps Body shapes Up to 10 diameters O.d. taper Drills and step drills Straight steps with angle from 10 to 240 Special form steps defined via DXF file (line, circle and polyline) Point types Spiral point NUMROTO S4 point, S6 point, 4-face point, T3 point, KM-3 point, KM-V point/ Sx point, break point Hertel SE point (regrinding) Hertel TF point (regrinding) Helix Constant lead Straight flute (helix angle 0 ) Variable helix twist Right-hand helix / right-hand or left-hand cutting Left-hand helix / right-hand or left-hand cutting Flutes Core taper or programmable core lead Multi-fluting Use of wheel profile Operations Practically all operations can be programmed several times using different parameters Manual grinding path for special grinding requirements Cylindrical grinding Diameter grinding Form grinding of the entire contour Step pregrinding Cyclical grinding Diameter and number of teeth As for milling cutters 2-D Simulation Integrated simulation of the entire grinding process Virtually unlimited choice of cross-section planes and zoom Fade-in of target flutes (DXF-patterns) / Production of patterns on the basis of the simulation 3-D Simulation Interface to the Vericut 3-D simulation software Display and precision correspond to the tolerances selected in NUMROTO and Vericut Simulation of all machining, with the exception of cylindrical grinding and engagement movements when milling Use of peripheral wheels, cup wheels and point wheels Measurement possibilities within Vericut E/0103

12 NUMROTOplus Technical Specifications Profile definition Form cutter One or more DXF file for profile description (lines, circles and polylines) Programmable origin shift of the profile Tip shapes Flat tip Operations Practically all operations can be programmed several times using different parameters Manual grinding path for special grinding requirements Relief angle Up to three radial and axial relief angles per machining section Variable relief angle along the cutting edge Four different grinding techniques: - Peripheral grinding with specified rotation angle - Peripheral grinding with fixed swivel angle - Face grinding with fixed swivel angle - Face grinding with cutting angle relative to the form Grinding the entire form or only a section Repeating the relief angles up to 200 times to produce a radial relief angle Cutting flutes Core taper or programmable core course Programmable cylinder course of the flute Course of the flute along DXF Use of form wheel profiles possible Profile definition Burrs Cylinder shape: cylindrical, conical, curved, solid ball Tip shape: flat, corner radius, spherical Special shape: defined with the NUMROTOplus Profile Editor or by a DXF file Tip teeth Up to 999 groups of teeth Up to 20 teeth per group With or without group teeth Vanishing point for group teeth freely definable Flute width can be adapted in the center Grinding length can be programmed automatically or manually in the center Cylinder flutes The flute geometry can be modified by selecting the rake angle and the wheel shape Chip braking flutes with separate helix and separate number of teeth Separate flute geometry for chip cutting flutes Machining operations Flute operations Chip breaker Manual grinding path Diameter range and number of flutes Identical with those of the milling cutter PC specifications Recommended minimum system INTEL Pentium 1.4 GHz 256 MB RAM Graphics Resolution: 1024x768 Color depth: 24 bit (True Color) 17-inch color VDU or 14-inch color TFT 2 GB hard-disk space Mouse, tracker ball or equivalent CD-ROM drive for installation Operating system: Windows 95/98/2000 Recommended, optimal system INTEL Pentium 2.0 GHz 512 MB RAM Graphics Resolution: 1024x768 or higher Color depth: 32 bit (True Color) 17 to 21 inch color VDU or 15 to 18 inch color TFT 4 GB hard-disk space Mouse, trackball or equivalent CD-ROM drive for installation Operating system: Windows 98/2000 Internet access PC-Anywhere for remote support The products described in this publication are liable to constant development or improvement. For this reason, none of the information given here is legally binding E/0103

RESHARPENING & INSPECTION

RESHARPENING & INSPECTION 755 E. Debra Lane, Anaheim, CA 92805 (714) 780-0730 (714) 780-0735 Fax Technical Support Page Case for Resharpening: When the product finish becomes worse, the cutting edge must get dulled, chips become