Nobody likes the thought of cuts or smashed

Transcription

1 Photo courtesy Command Tooling Systems Toolholding Varia VX Quick Change System allows the machinist to replace cutting tools effortlessly, leaving the tool in the machine without risk to hands. A release mechanism ejects the insert without excessive force and makes single-handed operation possible, minimizing risk of injury. Innovative Tooling Puts Security into Tough Machining Standards and special tooling vie to deliver high-precision performance Jim Lorincz Senior Editor Nobody likes the thought of cuts or smashed fingers tooling up a job before the machine is up and running, or tool and spindle-damaging crashes afterwards. Getting the tooling right is the most important part of running any job, said Steve Rose, CNC training consultant and former Swiss machine shop owner. It s amazing how different shops can be in how much time they allocate for tooling up. If done correctly, the process saves time and is worth the effort it takes to find the right round tool or insert, put it in the toolholder, set it (measure it) correctly, get the dimensions right, and then choose the right machining speeds and feeds. But that s the beginning of the story, according to Rose: The real challenge is how to short circuit the process, reducing the time needed to tool up and November 2014 ManufacturingEngineeringMedia.com 57

2 Toolholding guaranteeing quality machining results. It isn t just coming up with a new VDI toolholder, but it sure helps when tooling suppliers are developing innovative product approaches to deal with some of the industry s real challenges today. They include guarding against pullout with quick-change tooling, especially in machining the toughest titaniums and hightemperature alloys, building rigidity into modular tooling, and maximizing use of the available machine envelope, Delivering Cutting Tool Accuracy and Superior TIR Bilz Tool Co. Inc. (Lombard, IL) offers a full slate of new products that are aimed at delivering quality, accuracy, and superior TIR for challenging machining applications. Our principal focus is on the centerline of the toolholder for improved cutting tool accuracy, cutting tool rigidity in medium to heavy radial loads, and increasing metal removal rates while increasing tool life, said Tim Fara, managing director. Development of the patented TER ThermoGrip ER shrink collet by Bilz is intended to revolutionize the use of collets and collet chucks in Bilz Tool s TER ThermoGrip shrink-fit collet can be used for all ER live tools and ER straight shank holders in Swiss machines. Call Today to receive our NEW PRODUCTS brochure or a NEW Inch, Metric or 7MPa Catalog! the production process, said Fara. TER ThermoGrip collets have solid bodies, unlike common slotted ER-style collets and aren t deformed or compressed when clamping, assuring runout of less than 3 µm and significantly improving cutting tool performance when machining tough materials like titanium. Tool change in Swiss-style machines and live tools when holding a cutting tool in a flexible collet can be very timeconsuming. Downtime can be extensive and costly due to the tight tool locations in most Swiss-style machining centers and the need to disassemble and reassemble cutting tool, collet, and collet nut on live tools. Bilz s TER ThermoGrip shrink-fit collet can be used for all ER live tools and ER straight shank holders in Swiss machines. During the shrink-fit process the cutting tool can be preset to required tool length in the collet. All this happens outside of the machine, while the machine continues to make parts. A tool change only takes seconds and the machine is back up and running with single assembly tools back in the machine in the same tool location, gage length, and no concern that tool point location has moved or over torqueing of the collet nut. 58 ManufacturingEngineeringMedia.com November 2014

3 Toolholding For ultra-high-precision milling for small-to-medium volume manufacturing, Bilz offers the Diebold UltraGrip milling chuck, which combines the best possible cutting tool run-out (TIR) with maximum clamping force. The UltraGrip system provides a concentricity tolerance of 3 µm and the assembled system of toolholder and cutting tool provides a maximum TIR of 3 µm for high-performance cutting for medical, aerospace, and die/mold applications. Holders are all balanced with G 2.5 accuracy and are available in CAT, BT, and HSK tool tapers. toolholder, collet, and cutting tool, provides a maximum TIR of 3 µm for medical, aerospace, and die/mold industry applications. CemtrpGrip toolholders are balanced to G 2.5 and are available in CAT, BT, and HSK tool tapers. New tool clamping technology allows shops to maximize machining operations; however, spindle maintenance is equally important. Any spindle taper wear, tool clamping taper wear, or spindle misalignment To improve the ability to bear radial forces and TIR Duo-Lock features an innovative thread design will have a negative impact on tool clamping assemblies accuracy not available with [toolholder and cutting tool] (blue) with a proprietary other systems, Bilz has regardless of quality of the assembly. Using spindle wipers, double cone connection and introduced the Diebold an additional third supporting area CentroGrip collet chuck. Pull Force gages to routinely (green) in the back of the interface for three It provides concentricity check drawbar force, and contact point connection. test arbors to routinely check spindle alignment and spindle run-out are equally important to maximum machining conditions, said Fara. Photo courtesy Haimer, Kennametal CAPTIS ClAmPIng SySTem The modular and flexible system Modular construction for maximum flexibility Quick conversion from external to internal clamping in less than a minute High concentricity and repeatability of mm RÖHM Products of America office@rohm-products.com I tolerance of 1 µm and the assembled system, including Kennametal, Haimer Team Up on Carbide Cutting Heads There is no shortage of innovative toolholding solutions that have been developed using either standard or proprietary special toolholding designs. Kennametal Inc. (Latrobe, PA) and Haimer GmbH (Igenhausen, Germany; Villa Park, IL) have entered into a joint technology partnership in developing the Duo-Lock modular cutting tool system for carbide cutting heads. Design of the Duo-Lock modular interface is intended to make the modular connection as solid as a carbide end mill and provide maximum stability, increased load capacity, and high run-out precision. Duo-Lock features an innovative thread design with a proprietary double cone connection and an additional third supporting area in the back of the interface. The connection overcomes the interface weakness 60 ManufacturingEngineeringMedia.com November 2014

4 of existing modular systems so that the carbide cutter can be In Haimer s Safe-Lock proprietary system, special drive used to their full potential without breaking. keys in the chuck and grooves in the tool shank prevent the During IMTS, both companies introduced a new portfolio of milling cutter from spinning during extreme machining or cutting heads and mono-block screw fit toolholders with Duo- being pulled out of the chuck. In addition to the frictional Lock technology in all relevant spindle interfaces and extensions. Also new modular cutting toolheads with longer length than currently available in the marketplace will be added to their product portfolio in order to take aggressive cuts in the aerospace and energy industry. The system guarantees 5 µm runout accuracy and a Z accuracy of 1 µm, Cylindrical Drive Technology Revolutionary non-contact design which will eliminate most of the expensive presetting processes, said Doug Ewald, Kennametal director product management system tooling. The superior features of the Duo-Lock technology will provide significantly increased metal removal rates at milling applications and longer tool life. For the first time a modular milling system can achieve similar high performance of a latest generation THE BEST JUST GOT solid-carbide end mill. BIGGER The Duo-Lock system, which has achieved milling performance of 1.5 D depth of cut, widens the application of Compact Head Design modular milling systems compared with Easy indexing during operation current competitive systems. The Duo- INTRODUCING THE NEW MV4800 Lock system can more than double the When we introduced our MV Series wire EDM machines, metal removal rate (MRR) in common we had a feeling they d make waves. A year later, the milling applications. never-before-seen design improvements have reinforced The agreement between Kennametal our leadership in the market and sparked our customers and Haimer is a long-term partnership success. No other machine on the market has our that involves cross licensing. Like non-contact cylindrical drive technology, improved power Haimer s Safe-Lock toolholding system, supply and deeper submerged cutting capabilities all Duo-Lock will be offered as a license to backed by the reliable, expert support our customers expect. leading high-end cutting tool companies See what all the buzz is about at to establish a compatible, highperformance modular end mill system. ONE SOURCE. or call The partners are currently in discussions ENDLESS EXPERTISE. with additional leading cutting tool For current open positions, please visit our website: companies to offer customers multiple or jobs@mcmachinery.com sources of different manufacturers with EOE M/F/D/V one compatible interface. Auto-Threader Allows up to 20.1 inches of through-part wire threading for tall parts Visit Our New WEB SITE November 2014 ManufacturingEngineeringMedia.com 61

5 Toolholding Photo courtesy Bilz Tool Co. Inc. Using Pull Force gages to routinely check drawbar force (shown) and test arbors to routinely check spindle alignment and spindle run-out are equally important to maximum machining conditions. clamping forces of the particular clamping system, the tool is held using positive locking in the tool holder through the constructive design of the Safe-Lock system. The combination of pull-out protection and best runout accuracy lead to a low vibration and as a result very efficient machining. Due to the increased cutting depths and feeds, the metal removal rate can be increased by up to 100%, and to a similar degree tool wear decreases. Maximizing ER Collet System, More Rego-Fix (Indianapolis, IN) has continued to build on the success of its powrgrip and securgrip product lines, as well as introduce products that enhance performance of its ER systems. The new ER MicRun Collet System has a TIR of less than " (0.003 mm) at 3 D. The Permanently Mark Metals and Plastics in Just Minutes! ///////////////////////////////////////////////////////////////////////////// Etch barcodes, logos and serial numbers. Large 24" x 12" or 32" x 20" work area. Compatible with AutoCAD, Bartender, Illustrator, CorelDRAW, SolidWorks and more. ///////////////////////////////////////////////////////////////////////////// Visit epiloglaser.com/me to see a video of the FiberMark in action! Contact us today to request a DVD demo and receive a free sample: epiloglaser.com/me sales@epiloglaser.com 62 ManufacturingEngineeringMedia.com November 2014

6 MicRun s self-locking design retains the collet in the nut for easier insertion and removal, with no extractor required. To ensure it maintains high repeatability and rigidity in challenging applications, Rego-Fix equipped the system with a special thread that keeps the nut aligned with the holder. Suitable for high-speed machining, the MicRun is available in standard taper types as well as standard and mini-nut designs. Part of Rego-Fix s powrgrip product line, securgrip brings simple, effective tool locking to challenging metal removal applications. The anti-pull system locks the collet and cutter to the toolholder body to eliminate cutter slippage. It does so via a patented locking system that includes a small, profiled locking key insert that fits into a standard Weldon end mill flat. securgrip has a TIR of " (0.003 mm) and enables manufacturers to preset their tool heights. Rego-Fix customers can modify their existing pow- Rgrip holders for use with the system. The securgrip locking system is now also available for milling chucks. To protect operators, especially working in the confined work envelopes of Swiss-style machines, Rego-Fix has introduced the new slip-proof ERMX mini clamping nuts feature a frontal milled slot on their outside diameter that mates effortlessly to a corresponding wrench to prevent slippage during the tightening and loosening process. These new clamping nuts, which are suitable for the company s sealing or cooling disks, have volume a special surface treatment for increased REdUcTion clamping force and a unique coating that prevents corrosion. ERMX works with ER collets in DIN 6499and ISO Among the many benefits of this compact product are lower injury risks due to slip-proof clamping, internal and external cooling, improved chip removal, reduced tool costs and improved productivity. Design Addresses Pull Out with Standard Tooling There are a lot of issues in addressing pull out, especially when machining heat-resistant super alloys [HRSA] like titanium or Inconel, said Alan Miller, engineering manager, BIG Kaiser The New Modular Chip Processing Systems from PRAB FlUid REcYclinG Contact us at sales@prab.com prab.com Engineered to Get You Up and Running Faster Fully-integrated chip processing systems from PRAB combine prewired modules that integrate and communicate seamlessly. They move and process scrap and fluid efficiently and maximize returns. They re also designed for mobility as your process changes. PRAB engineering designs every system to meet your specific application. And they re backed by our industry exclusive Performantee. scrap TRAnsFER load out All-in-onE November 2014 ManufacturingEngineeringMedia.com 63

7 Toolholding Precision Tooling Inc. (Hoffman Estates, IL). We have taken the existing standard of Weldon flats for end mills and applied it to be compatible with our high-performance milling chucks. We came up with a new milling chuck product line called the Mega Perfect Grip milling chuck. A special keeper key is positioned into the Weldon flat of the end mill and together the key and cutter are inserted into the bore of the milling chuck with three axial grooves that accepts the keeper key. Once the cutter and key are inserted to the bottom, a 20 twist clockwise places the key against a hardened pin and into a stop groove of the milling chuck. Final tightening of the clamping nut closes the milling chuck, making it impossible for the cutter to pull out, said Miller. The Mega Perfect Grip milling chucks combine the cutting performance of heavy-duty milling chucks with security against pullout of solid side lock tool holders. High-pressure and high-volume jet-through coolant is a standard feature. To improve upon the ER standard, we developed the Mega ER solid nut which is a slot-free clamping nut without ball bearings as a lower cost option to the standard Mega ER Nut. We ve incorporated a friction-free surface treatment of the internal collet raceway to minimize collet distortion during clamping. The slot free nuts use our popular Mega Wrench that improves balance and tool holder symmetry. The result is that it allows us to make a replaceable ER collet nut for anybody with ER product and it s available in ER16, ER20, ER25, and ER32 sizes, said Miller. When it comes to building tools to fit into the available machining space, BIG Kaiser has developed an extension system that is designed to eliminate up to 40% of the weight of a very large boring tool assembly. Larger diameter tool assemblies with long projections can be built up with both steel and aluminum components, providing an ideal length to weight ratio for most machines with automatic tool changers, said Miller. It could make the difference between using the existing machine with the largest tool and travel available for a job, or having to make a capital investment to buy a larger machine. Another way to maximize the machine s available work envelope is BIG Kaiser s Smart Damper for face mills that eliminates unwanted vibrations inherent due to excessive toolholder length and cutting conditions. The modular design provides versatility for gage lengths up to16" (406 mm) and is available for BIG-PLUS CAT 50 or BT50, and HSK- A100 metric face mills. Leave the Tool in the Machine for Quick Change Command Tooling Systems (Ramsey, MN) has introduced its Varia VX Quick Change System that allows the machinist to replace cutting tools effortlessly, leaving the tool in the machine without risk to hands. The Varia VX utilizes three contact points to pull the Varia VX insert into position. A release mechanism ejects the insert without excessive force and makes single-handed operation possible, minimizing risk of injury. Tool change times take as little as 20 seconds with a single screw solution. The modular system allows tool preparation 64 ManufacturingEngineeringMedia.com November 2014

8 Want More Information? BIG Kaiser Precision Tooling Inc. Ph: Web site: Bilz Tool Co. Inc. Ph: Web site: Command Tooling Systems LLC Ph: Web site: Haimer USA Ph: Web site: during machine operation and doesn t require block realignment after changing the Varia VX insert. The Varia VX quick-change system is now available for the complete bandwidth. The taper/planar support interface ensures maximum concentric accuracy. The torsional moment happens with a positive polygon that transfers up to 200 N//pd//m. Tightening and release take place via a turn gear segment with three multifunctional cams. When a radially attached tension screw is tightened, the three-point tension pulls the tool insert evenly into position. When releasing, the insert is mechanically loosened via sliding cams and released from the holder for removal. For use in inner cooling, a diametrically acting membrane seal ensures the leak-free coolant transfer between adapter and VX insert, thus bringing the medium directly to the cutter. Advantages to the VX system include preset cutting tools are laying ready at the machine; quick change through only one clamping point; no risk of injury when changing tools; clamping of the inserts without any radical force; safe torque transmission. ME ERI AMERICA TOOLHOLDING SOLUTIONS Complete Live Tooling Solutions by Kennametal Inc. Ph: Web site: Rego-Fix Tool Corp. Ph: Web site: Rose Training srose@rose-training.com Web site: DMG/Mori Seiki BMT45-85 VDI Haas & many more Tool Discs TestRapid quick change Machine spindles 2 year warranty info@eri-america.com November 2014 ManufacturingEngineeringMedia.com 65