What to do when the HSK interface between spindle and tool does not work?

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1 What to do when the HSK interface between spindle and tool does not work? HSK tapers are over-determined and must be deformed by the clamping force so the tool will be pulled up to face contact. If the spindle taper and the tool taper are at the top ISO tolerance, then 35% of the clamping force against the face contact is lost. In this case, high speed processes are unstable and the tool begins to swing. Poor surfaces and a short tool life are the results. In long terms the bearing of the spindle will be damaged by these vibrations. these problems happen. In the market for tool holders, there is a very wide range of different HSK tool holders, unfortunately, characterized by huge differences in quality. The user recognizes these accuracy differences often too late. Usually just when the process fails. More problems occur when machine manufacturers receive tool holders from there costumers to test new machines. Often these tool holders are far away from being manufactured in the required accuracy. You can t blame the customer, he surely bought these holders from his trusted provider and this provider normally has no possibilities to test the quality of these tool holders. If the machine manufacturer uses these faulty tool holders to test new machines, unexpected delivery delays will occur. It happens a lot, that such machine manufacturers contact us to receive support. Often they buy our measurement devices to make sure to use only holders of good quality. In the end that saves them a lot of money. Modern high-performance machine tools are equipped with HSK tool holders and powerful motor spindles. To take advantage of the technical skills of such a machine, it is necessary that the spindle taper and the tool taper perfectly fit to each other. HSK-Taper resolved-taut When using machine tools with the very precise HSK interface, concentricity problems repeatedly occur, which lead to poor results and which do not allow compliance with the required tolerances on the workpiece. The more accurate and precise the machines are, the more often HSK spindle

2 HSK tool holders If concentricity problems occur, a number of factors must be reviewed. First you have to check the cutting tool, then the tool holder especially the taper of the tool holder. After that you have to check the taper, the concentricity and the clamping force of the spindle. To check the taper of the tool holders, Diebold offers very accurate measurement devices. With these Devices you are able to measure every micron of your taper. You can find these devices worldwide. Despite the availability of these devices you can find huge quality differences on the market. These differences become very noticeable, when the user manufactures highly accurate products. Here, tool holders can become the key part to achieve the required tolerances. Some processes even won t work, in case the taper isn t at least manufactured in the ISO tolerances. HSK spindle taper measuring device Diebold manufactures devices for measuring spindle tapers and tool holder tapers HSK/SK/BT/MK, BBT and other, special tapers. Our devices work tactile because this is the safest possibility to measure infallibly. Our slogan Simply the Finest is not just a slogan, it s promise to you. HSK measuring points With our device you are able to measure the taper completely. HSK taper gauge

3 At Diebold, the calibration and certification of our gauge masters happens on the highest level. We possess gauge masters, certificated by inter-national institutes. Based on those masters we can produce gauges on the highest level of accuracy and precision. Theses gauge masters give tool holder producers the opportunity to produce tapers with very exact and small tolerances. From the arrival of the tool holders at your company until the usage in the machine we guarantee that the HSK tool holders correspond with the ISO norm. Therefore the reliability of the HSK interface is ensured. Our additional service is, to offer you a constant and regular calibration and certification of your masters. Every instrument we use to measure is recorded in a database and the accuracy of these tools is documented throughout the life of the measuring instrument. machine manufacturer. Whenever a service technician comes to our factory, we take their arbor gauges and they get a free calibration. Initially we started this out of curiosity, now this has become a ritual and this service is often used by service technicians. We had extremely bad experiences as the first arbor gauges were checked. Tolerances, that were exceeded over 10 times, were not uncommon. Gauges which carried the logo of well-known manufacturers were totally useless for the measurement task. Often we could track down that the company, that had its Logo on the arbor gauge wasn t the actual producer of the gauge but he may have bought it from a good and trustable provider. In one case a technician wanted to change the spindle of our machine under warrantee. After measuring the spindle with his arbor gauge he thought the problem was the spindle. After we measured the gauge we realized: the problem was the gauge. The spindle was fine and his company saved HSK arbor gauge with vertikal box HSK gage master Even before our entry into the world of the taper measurement, we had other metrological products. A complete range of test arbors for measuring and aligning machines, balancing masters for measuring the unbalance of machine spindles, mechanical pull force gauges, 3D edge finders and presetters. We produce our products with more than 50 modern CNC machines. These machines require constant service by technicians, of the

4 Since then, our metrology department offers the service: calibration of arbor gauges. A system was installed that includes the temporal tracking of due checks in the manner of ISO 9000 for the measuring equipment of the customer. New devices are automatically recorded in this system. We remind our customers of the calibration of their instruments on time. Even "foreign" instruments that got measured in our house are recorded into this system. To build up our calibration service some investments were necessary. For the taper measuring the traceability onto reference standard of the DKD (German calibration service) had to be installed. For the certification of arbor gauges we invested in the latest measuring technology. A class 2 laboratory with two measuring machines PMMC is used. The temperature is hold constant (+/- 0,5 C) and the humidity is monitored. Architecture of climate controlled factory Knowing about the devices for taper measurement, famous producers of cutting tools saw the possibilities for measuring their interfaces. These days, there are different modular constructed systems. Here, cutting tools are fitted with a cone with face contact and a thread. The manner of measuring is very similar to measuring HSK tapers with face contact so it seemed obvious to us to develop a similar taper measuring device, satisfying the needs of cutting tool producers. Measuring laboratory NCT measure device NCT-tool

5 In most cases people worked with quite good measuring devices, but usually the reference of the taper to the face contact wasn t perfect. With our devices we solved this problem completely. Another very helpful device for machine producers and machine users is our pull force gauge. With this device you are able to check the pull force of your spindle. electronic device costs. For service technicians, we offer individually configurable metrology suitcases. It contains tension devices, plug gauges and other instruments needed to be accommodated to the customer needs. We deliver the matching mold inserts and the suitcase together with the requested calibration records. Typical metrology set Mechanical pull force gauge Electronical pull force gauges that work with a power supply and use piezo elements are very common. Our patented mechanical pull force gauge measures the elongation of a special designed tubular profile. The result is sent to a 1/1000 mm indicator. This indicator shows you the pull force in kn. We offer you the service to recalibrate your metrology set constantly, so your technicians are always equipped with precise and reliable devices. Diebold metrology: Simply the Finest Sincerely Your Hermann Diebold Tests showed that these mechanical tension devices are insensitive to temperature differences. Our pull force gauge measures repeatable, even if a service technician takes the device out of his car and attaches it to the machine, where the temperature is very different. And last but not least there is an interesting price advantage for these mechanical devices, they just cost about a third of what an