ARNO Werkzeuge presents the AWL direct mount for STAR Swiss type machines.
The tool holder system for turning or grooving tools (patent pending) has an integrated adjustable high-pressure coolant supply of up to 130 bar. When combined with the AFC quick-change system, users can increase productivity for Swiss type machines since the system significantly cuts set-up and non-productive times.
“After Citizen, the new AWL direct mount are available for CNC Swiss type machines from Star Micronics,” says Werner Meditz, Head of Technology at ARNO Werkzeuge. The AWL tool holder system (patent pending) works for the Star machine series SR 20R II, III and IV with immediate effect. The system has two separate cooling channels which can be selectively opened or closed. The various connection options make it adaptable to several machine types. Depending on the machine and execution, the new AWL direct mount can fit two to six tools. Each chamber has an integrated coolant supply to allow the simultaneous use of several tools, whether they have internal cooling or not.
Permits Free Tool Choice
Since the direct mount is designed with integrated cooling, it dispenses with the time-consuming connection of external and cost-intensive tubes. In addition, there are no interfering contours inside the machine. Users can operate with targeted high-pressure cooling pressures up to 130 bar and stable wedged clamping of holders during machining operations to achieve longer tool lives by over 25 percent.
It now takes only a few steps to remove and fit the tools. When turned, an integrated counter nut raises the wedge slightly to permit quick and easy tool removal and fitting. According to Meditz, “The tool system allows fast, simple tool changes with enormous change precision and high process reliability.” The direct mount can also hold the tools of other manufacturers. The freedom of tool choice is one of the greatest benefits of our AWL direct mount,” stresses Meditz, “since users are not forced to depend on only one system.”
No Calibration Required With AFC
“Users have the best benefits when they combine the AWL direct mount with the AFC quick-change system from ARNO,” assures Simon Storf, Marketing Manager. To change a tool, only the front part of the two-part holder needs to be removed and a new tool is then fitted with a different holder. This dispenses with the need for recalibration in many cases. The AWL direct mount and AFC quick-change system back the manufacturer’s claim of increasing productivity at user production locations by developing customised solutions.
Arno’s Solid carbide endmill cutters AFV are equipped with uneven pitch design from 35 to 38ﹾ (four cutting edges) and even pitch design with 45 (six cutting edges), for roughing and finishing of nearly all materials (steel, stainless steel, cast, heat resistant alloys and titanium alloys) with up to 60 percent higher feed rate, less vibration, better surface finish and increased cutting depth.
Explore our huge selection of milling tools, such as shell mills, square shoulder mills and slotting cutters. Achieve outstanding results with indexable inserts for wet or dry milling, for steel, all cast materials and stainless materials, heat-resistant alloys and non-ferrous metals. ARNO’s high performance tools with long wear lifespans allow you to operate more economical.
Arno is expanding its product range with through tool coolant holders integrated with precise coolants straight to the cutting edge.
The holder is available in shank sizes 12 x 12 and 16 x 16. The coolant inlet is individually placed, it can be inserted from the rear of the holder or the side. Various threaded connectors are also available. Efficient cooling of the insert cutting edge protects coatings which can be deteriorate due temperature changes. Swarf control is improved even on problematic materials, owing to secure and reliable machining.
High-precision turning operations using high-positive indexable inserts are able to deliver the required accuracy for machine shops. Contributed by Arno
Heidelberger Druckmaschinen AG (Heidelberg) manufactures high-precision and reliable digital and offset printing machines. The manufacturer has set itself the goal of integrating and automating its entire value-added chain for its customers—the print shops—thereby increasing their competitiveness. The manufacturer has around 11,500 employees worldwide and its highly automated and versatile machines in all format classes are manufactured in accordance with customer requirements.
Keeping Costs Low
Heidelberger set the goal to keep workpiece costs as low as possible without affecting quality. In this context, the company only works with partners who are also constantly pushing forward further developments in this direction such as Arno, a manufacturer of cutting tools in the field of turning, engraving, drilling and milling.
Harald Johann, head of work planning for cams, gears and model parts, and Andreas Knopf, technical expert for turning and tools at Heidelberg, are responsible for the production of gear wheels for offset printing presses. As part of an integral review of the existing production process for gear wheels, the company examined the indexable inserts being used in the turning process in detail.
These inserts can be an important cost-reducing factor when tool lifetimes are increased. Significantly increased tool life and the resulting reduction in tool change and calibration times will have a positive impact on unit costs in the longer term. As a result of this investigation, Mr Knopf was looking for an economically attractive alternative to the previously used indexable insert.
Supported by an application technician at Arno, Mr Knopf attempted to use the indexable insert TCGT16T308FN-ALU AL10 to carry out inside turning and finishing of gear wheels made from cast steel. The indexable inserts have a rake angle of 27 deg, which are periphery ground with polished chip breakers and thus have a sharp cutting edge, which means they only require minimal cutting forces.
The challenge lies in maintaining the required accuracy for each and every gear wheel.
Increasing Tool Lifetime
High-quality print products can only be produced with a high-precision printing machine. This begins with the internal fit of the gear wheels. Each printing unit is connected to the next printing unit via the gear wheel, which is optimally adjusted via the gear train. Unless the internal fit is exact to within one-thousandth of a millimetre, the toothing will not mesh correctly with the next gear wheel. Machines containing a larger number of printing units require a correspondingly larger number of gears, making the degree of precision even more important.
“The results we achieved in the field matched those that had been previously promised. In production, you quickly realise whether someone can actually put theory into practice,” explained Mr Knopf.
This laid the foundation for further collaboration between the two companies and a wide range of parts were inspected and new indexable inserts tested. At the same time, challenging fitting tolerances was required. The quality achieved was not only very good, but the new indexable inserts also increased tool lifetimes by up to 100 percent, even with difficult-to-produce workpieces.
Achieving Consistent Quality
The tool manufacturer implemented a number of specific measures, which led to very high-quality results when the indexable inserts were used in the grinding process. For example, Arno only produces indexable inserts on Swiss grinding machines using the EcoDress process. During this process, the grinding wheel is cleaned and stripped after each grinding operation to ensure that the quality of each grinding operation remains consistent, the grinding wheel does not become clogged and no cutting pressure is generated. This allows very close machining tolerances to be maintained.
Compared to the conventional grinding process, the process reliability and removal efficiency are both increased, which in turn improves the finish quality and edge roughness of the indexable inserts. Depending on the insert type, a distinction is made between a sharp cutting edge or a rounded version.
The standard rounded cutting edge contributes to a considerable increase in tool life and smooth running of the indexable inserts. Each insert’s cutting edge is created by wet blasting or slide grinding, after which an automated or optical 100 percent inspection of all finished indexable inserts is carried out, underlining its commitment to quality assurance.
Quality and reliability are also important criteria at Heidelberger. With a weight of around 600 kg, the cast iron gear wheels have a material value of several hundred euros. For this reason alone, special attention was paid to process reliability during the test phase. The new indexable insert runs without problems.
Customised Tool Order
From Mr Knopf’s extensive experience with indexable inserts, he knows that they are prone to damage from cavities. That costs time and money—a key factor given the lot sizes at Heidelberger, which range from 50 to 500 pieces. One major advantage of this particular indexable insert is that, as a standard item, it is always in stock with only a small minimum order quantity.
By contrast, the inserts that were used previously were subject to relatively large minimum purchase quantities. Punctual delivery, the stocking of enough indexable inserts to be able to react quickly to specific requirements, as well as generally shorter delivery times were all important additional factors. One month’s supply of the indexable inserts can usually be delivered within three days, due to precise coordination between the business partners.
A broad usage range is very important for Mr Johann when it comes to developing the machines. A reduction in complexity is also a major focus. This means using fewer indexable inserts for a wider range of applications. Understandably, he also wants to minimise both the degree of utilisation and downtimes. The technical expertise of its internal and field sales staff and application engineers allows Arno to meet these requirements and, in collaboration with Heidelberger, to lay the optimal foundations for the future. Finding solutions remains everyone’s focus, which is why the partnership is successful.
Dietmar Kogler, managing director, Arno Werkzeuge SE Asia, speaks to APMEN on how his company provides specific tooling services for manufacturers in the region.
With Southeast Asian manufacturers predominantly specialising in the automotive industry, how does German cutting tools and inserts company Arno provide services for the sector?
What are your thoughts on the Southeast Asian Market for Arno Tooling Services?
We are fairly new in the Southeast Asian market, as we started our own subsidiary in end 2014. Compared to the larger companies, we are more of a niche product company. Our approach is, therefore, more focussed and different, we are looking for smaller companies where we can go in with our strengths.
We also do some cost-per-part projects, which is a bit different. This means to say that we do not want to sell a “cut-and-go” product. We want to give them a solution and break it down to a cost-per-part analysis. The customer does not pay for the tools anymore; he pays per produced part instead.
The markets are quite similar in Southeast Asia; Most are dominated by the Japanese, especially into the two-wheeler or four-wheeler business. Many business goals then depend on the automotive industry: if things are good, business goes up; but if things are not so good, sales goes down.
But this does not affect us much, because we are more niche-orientated and we are not going into mass production. Since we are a newcomer, we do not have much to lose; we can actually have everything to gain. And so far, the past two and a half years were quite successful to us. We also have good partnerships in almost all markets, and we still have the potential to grow.
And what about the company’s goals for the next few years?
I think that within the next three years, the company will be very much recognised in the region as a niche-orientated solution provider. This is because as a smaller company, we are much more flexible than the bigger ones, and a lot of companies want such a supplier.
The trend in Europe is that you tend to see big companies consolidating their suppliers. We do not see that trend here, and because of this, we will be one of the companies that will have an advantage because we are more flexible and niche-oriented.
Of course, you have to have a different strategy and approach. Just to give you an indication: we have roughly 50 million euros turnover with 170 staff worldwide. While the turnover is quite good per head, but if we want to compete directly, then there is no chance in terms of manpower and pricing.
Therefore, we look at products where we have a standard where others do not. If a customer tells me, “I need something that is not standard, I can consume 20 a month”, we can provide that as a standard. Other companies are looking at 1,000 a month, so that amount is not interesting for them. But it is interesting for us. This is our general strategy worldwide, and we are copying and adapting that to the local market here in Southeast Asia.
We also do not supply a lot to the automotive industry in Europe. But in Southeast Asia, we go into the automotive sector. This is because yet again, we are not going for mass consumption, but by picking out the niche markets here.
What are your company’s strengths in Tooling?
Our company strength is in grooving and parting off. Grooving and parting-off are one of our key products, and in the past, the coolant was always external. But the drawback is that when you go deep, the coolant will not reach the cutting edge.
So we developed a through-coolant system for the parting-off tool called the ACS cooling system. We have two versions. The first has a cooling system at the cutting edge. The other has an additional coolant jet targeting the insert flank for underneath. There are dual functions for this: You provide cooling and also chip control. We also found out that with this cooling system, tool life can actually be up to double the original.
This is suitable as our tools do not need a top-end machine tool to be attached to. This is especially suitable in Asia, as manufacturers here will typically buy one machine tool for a specific purpose. This is different in Europe, where they will invest in a high-end machine tool for different purposes.
The customer just needs to tell us where they need the hole, and we make it accordingly to his specifications. With that, you can put it on the machine, and get through coolant with little effort.
We also work with machine tool makers, and we have special holders for companies like Daewoo Doosan, DMG Mori, Miyano, Nakamura and Tornos. We are investing a lot in direct mounting as well. The tool goes direct on the machine; it is very rigid with through coolant, so the output is more. If something happens, you do not have to change the block, you can just change the module.
What other area does your company specialise in?
We do have a wide range of high-positive inserts. In the past, these used to be used for machining aluminium. But with all the new coatings available, there is used for medical applications and even for work where you need to have very fine surface finishing. They can also be used for small parts machining.