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Hydraulic Expansion Toolholders With Cool Flow For Optimised Machining

Hydraulic Expansion Toolholders With Cool Flow For Optimised Machining

SCHUNK breaks down the development of its Cool Flow technology—a highly efficient cooling system which feeds coolant directly through the tool mounting, with the help of a model, tool and mould-making company from Germany. 

At the model, tool and mold-making company KRIEGER, standardisation is a key success factor. Within a decade, the variety of machine control systems, tool mountings and tools that had been developed were systematically analysed, structured and overhauled. 

Today, all machines come with standardised control systems, a uniform interface and specific tool pools. Even for special and customised tools, an in-house tool catalog has been drawn up in order to cut down on uncontrolled growth. This creates clarity and makes it easier to detect and eliminate even the smallest of deviations in processes. 

This includes deviations such as vibrations that can occur, in particular on machines with large traverse paths (2500 mm x 2000 mm x 1000 mm). Although the vibrations had been kept in check by changing the cutting parameters, there had long since been dissatisfaction with the overall process. 

Technological Progress with Hydraulic Expansion Toolholders

KRIEGER first deployed the TENDO Slim 4ax vibration-damping hydraulic expansion toolholders in a milling test to replace the previous standard heat shrinking mounting which was susceptible to vibrations. They found that the machines absorb the vibrations considerably better and no longer come to a standstill during demanding processes if they are equipped with the toolholders. 

Particularly on machining centers that lack stability due to their design and size, the effect has been enormous. The toolholders could simply be replaced without any reprogramming or collision check. 

It made sense for the 40-person company to deviate from what was hitherto tried-and-tested and the company was convinced.

Simple Replacement Via Plug & Work

Test series have proven that mounting with the vibration-damping characteristics of hydraulic expansion toolholder technology results in significant process improvements, especially during drilling, as well as demanding finish milling. Users benefit from shining surfaces, long tool service live, and efficient metal cutting. 

Unlike heat shrinking toolholders, the TENDO Slim 4ax can be seamlessly integrated into SCHUNK’s tried-and-tested hydraulic expansion program, with a constant run-out accuracy of < 0.003 mm at an unclamped length of 2.5 x D and a balancing grade of G 2.5 at 25,000 RPM. 

Since precision mountings can replace conventional heat shrinking toolholders by means of Plug & Work without having to reprogram the outside contour, its advantages can be immediately tested in real applications and used in the long term – just like at KRIEGER.

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Changing Times In The Metal Cutting Industry

Changing Times In The Metal Cutting Industry

Today, workpieces need to be machined using multiple tools and fast tool change systems are becoming the norm. Article by heimatec. 

Today, workpieces generally need to be machined using multiple tools, which in turn means that tool changes are required during the machining process. In order to keep the changeover and adjustment times as short as possible, the use of fast tool change systems has become the norm. Here, heimatec, manufacturer of high-precision static and driven precision tools for lathes and machining centers, introduces its wide range of solutions for fast tool changing. 

Flexible System

Efficient manufacture is made significantly easier in two aspects. If machine downtimes can be reduced, the productive time increases automatically. By using flexible universal tools, the tool inventory can also be reduced, resulting in cost savings. 

heimatec developed the flexible heimatec.u-tec tool change system for this purpose, which allows machining companies to utilise different adapters for a wide variety of machining tasks. The driven heimatec.u-tec tools are designed with a collect chuck mount according to DIN 6499, allowing the user to use the driven tools without additional tool adapters. A special feature of the heimatec u-tec change system is the short mounting length which ensures exceptionally stable clamping of the cutting tool with low cantilever forces, leading to excellent machining results and a long service life of the cutters.

Reducing Machine Downtimes

The company has developed the easy-quick HT series specially for fast changes in the area of driven and static tools. This means different tool change inserts with market-standard tool mounts can be preset outside the tool machine and when required, can be simply, safely and quickly installed by the machine operator with one hand. With this series, machine downtimes are reduced significantly. In addition, the overall tooling costs are reduced thanks to the multiple and flexible use of the easy-quick base tools. 

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CERATIZIT Hosts ECarbide Online Seminar Week

CERATIZIT Hosts eCarbide Online Seminar Week

The CERATIZIT Group’s Hard Material Solutions division will host the eCarbide online seminar week from 15 to 19 March. Covering a wide range of topics from carbide basics to expert knowledge, the series aims to give participants the edge they need in order to prevail.

Cemented carbide stands unrivalled in the fields of tool manufacturing, metal forming and many other industrial sectors. In an upcoming online seminar series, the experts of the CERATIZIT Group’s Hard Material Solutions will share their extensive knowledge free of charge, giving participants the competitive edge that is needed to prevail in today’s markets. The seminars are specifically designed to provide participants with first-hand knowledge and insider perspectives on applications, latest industry trends and the advantages of cemented carbide as compared with other hard materials.

In addition to the wealth of market-critical information, Q&A sessions after each seminar will give participants the opportunity to explore the topics even further. This free online seminar series will take place from 15 to 19 March 2021 in a remote online setting that offers participants an environment both convenient and safe.

Additional information on the eCarbide series and the content of the individual seminars, along with the registration links, is available at https://www.ceratizit.com/int/en/company/trade-shows/online-seminars.html.

 

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At High Speed From Component To Tooling

At High Speed From Component To Tooling

With “Walter Innotime”, Walter is introducing the world’s first digital design wizard for accelerating the consulting and ordering process.

Engineers in Walter Engineering are working with a new digital wizard: Walter Innotime. This web application links existing Walter systems to the Engineering Kompetenz of Walter employees. Based on a 3D model of the component drag-and-drop uploaded to the Walter website by the customer, Walter Innotime analyses which cutting operations are required and suggests to the engineer dealing with the enquiry (in future versions, directly to the customer) the appropriate machining tools with cutting data and prices from the Walter portfolio. This digital search at component level is currently unique in the market.

The engineer checks the proposal and optimises it, if necessary, according to the customer’s needs. As a result, the design process for complex enquiries is fast-tracked considerably – and the customer receives the most economical tailored tooling solution and a valid quote in the shortest time. Walter field service employees and engineers benefit from the preliminary work done by the system: in the physical design and the development of the optimum machining strategy for the customer component. “For our engineers and technical distributors, but primarily for our customers, Walter Innotime represents a milestone.

We deliberate intensively over the component and can deal with enquiries so much faster – for our customers, that’s something directly tangible,” explains Dr. Michael Hepp, Vice President Digital Business at Walter. “By combining the Engineering Kompetenz of our employees with the virtual intelligence of our software systems, we can assist our customers in quickly and easily finding, purchasing and employing the most economical tooling solution for them. In future, our customers will have to do nothing more than upload their 3D component – quick and easy.”

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ESCO Tool Enables Easy Modular Tooling

ESCO Tool Enables Easy Modular Tooling

A new clamshell style, O.D. mounted split frame machine that features fast, accurate, and easy to setup indexable tooling to part and bevel tube and pipe from 51 mm TO 1220 mm dia. is being introduced by ESCO Tool of Holliston, Massachusetts, U.S.A.

The Esco COHOG Split Frame Machine has a robust stationary ring machined from 7075 aluminum alloy that is hard coated and supports a custom steel forged, heat-treated and nickel-plated rotating ring using precision tuned eccentric bearings.  Featuring indexable tooling with slides and trip mechanisms and a marked locating system, this clamshell style machine can be precisely aligned and quickly attached without shims or guesswork.

Providing vibration-free operation, Esco COHOG Split Frame Machines have sealed construction to protect bearings and bearing races from debris.  Modular tool slides use tool steel blades or inserts with multiple cutting edges that offer more cuts per blade, and come in a variety of sizes for space-restricted applications.  Motor options include pneumatic, hydraulic, and electric power that can be mounted in different orientations.

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TaeguTec Launches Specific Sleeves For HUSH-BORE Boring Bars

TaeguTec Launches Specific Sleeves For HUSH-BORE Boring Bars

Vibration free HUSH-BORE boring bars are cylindrical shank type products, with no flat parts, for deep internal turning operations in 7xBD to 10xBD (BD: shank diameter) range. Therefore, based on the flat surface design of the head, set-up time can become an issue.

To solve this issue, TaeguTec has launched HUSH-BORE sleeves that can be easily set up in the machine’s tool holder.

These specific sleeves with one-sided slit maintain a robust clamping force and high precision because of its wide contact area when combined with the new HUSH-BORE shank. First, gently tighten the flat surface onto the sleeve with a screw onto the holder. Second, match the HUSH-BORE’s shank line with the sleeve-line. Third, check the zero setting with the dial gauge, ensure it is within ±0.01 mm. Fourth, secure the sleeve by screwing tightly to the tool holder. Thereby, making for easier, faster setting time with better accuracy.

Features

  • Easier and faster shank setting time due to simpler, yet practical design
  • Robust clamping force and high precision
  • Full sleeve line for HUSH-BORE shank diameter range(Ø16-50mm)

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Hoffmann Group Connected Tools Accelerating Digitalisation In Tooling

Hoffmann Group Connected Tools Accelerating Digitalisation In Tooling

The new “Hoffmann Group Connected Tools (HCT)” product family Hoffmann Group is driving digitalisation forwards in the field of tooling. The range includes Bluetooth-capable tools which at the push of a button send measured values directly to a PC application such as Excel, a tablet or the newly developed HCT smartphone app. The GARANT IP67 HCT digital caliper with Bluetooth connection has now been launched on the market as the first HCT product. This tool is also available as a depth gauge. The free HCT app is now available for download from the App Store and Google Play.

GARANT Digitaler Messschieber IP67 HCT

The new Hoffmann Group Connected Tools link the analogue and digital tooling worlds without any additional software or dongle. The tools send measurement data via Bluetooth over a range of up to 15 metres and thus make documentation particularly convenient. At the same time they improve quality management because they eliminate errors arising from manual data transmission.

The Hoffmann Group has also developed the HCT smartphone app for users who place a special value on mobile working. The app provides an overview of up to eight HCT tools. It reliably saves newly recorded measurement results and permits the export of the measured data including tool name, measurement date, unit and target value in CSV format for further processing in any PC application such as Excel or Word. The app can also display values both in the metric system and in inches.

The new GARANT IP67 HCT digital caliper not only has sophisticated functions but also features an outstanding design. That was confirmed by the jury of the prestigious Red Dot Award in 2019: The GARANT IP67 digital caliper provides a large LCD display on which the measured values are displayed at an easily legible height of 11.5 millimetres. The measurement system is embedded in a clearly structured stainless steel body sheathed in an ergonomically shaped enclosure with Santoprene coating. This provides the necessary grip for working in dusty, wet or oily environments. After 10 minutes the system automatically switches into power-saving mode. Any slight movement reactivates it and the last measured value and the zero point are displayed. This saves energy. The tool satisfies protection class IP67 and is protected against dust, water, coolant and oil.

 

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Cutting Costs, While Saving The Planet For Tool Makers

Cutting Costs, While Saving The Planet For Tool Makers

The main driver of business sustainability goals is to make an impact on the wider world. Another benefit that is often overlooked is the economic value of implementing sustainable actions. Can businesses save money, while helping to protect the planet? Here, Sachin Pimpalnerkar, global segment manager for renewable energy at global engineering group, Sandvik, explains how Sandvik Machining Solutions (SMS) has optimised two crucial toolmaking technologies to achieve just that.

Almost everything made of metal is machined with an insert. The insert has to withstand extreme heat and force, so is made of some of the hardest materials in the world. Typically, an insert is made using 80 per cent tungsten carbide, renowned for its superior durability, and a metal matrix that binds the carbide grains together, where cobalt is the most common.

Tough components created to withstand some of the most intense working environments require manufacturing processes that are equally strenuous.

Sintering

One of the most intense steps in tool insert manufacturing is the sintering process. After the carefully selected metal powders are milled and then pressed into shape, the inserts are very fragile. It is at this stage that the inserts are fused, or sintered, into solid pieces.

Sintering is not a quick process — but time is money. Keeping powerful furnaces in operation for many hours at a time uses up immense amounts of energy, but cutting corners and producing fragile inserts would be even more wasteful. If a reduction in energy consumption is to be made possible, it would require a reduction in cycle times without compromising product quality.

Teams at Dormer Pramet, part of the Sandvik Group, have successfully reduced the cycle time of their sintering process by almost 100 minutes. To achieve this reduction, Dormer Pramet engineers worked in close collaboration with research and development specialists from Sandvik Materials Technology (SMT) in Pune, India to redesign the gas flow passing through the charge of the sintering furnaces.

Coating

When machining ferrous materials such as cast iron or stainless steel, a coated insert is the favoured tool of choice. CVD coating involves placing tools into a chamber, which is pumped with gases at 950-1100 deg C. These gases react inside the heated chamber, depositing a thin layer onto each tool that reinforces its strength.

High temperatures are key to effective CVD coating, but maintaining them is an energy intensive process. How do we keep heat inside a building? We insulate it. To prevent heat from escaping CVD coating chambers, Dormer Pramet added new insulation onto the furnace’s coating. Trapping heat inside the chamber has shortened the cycle times of CVD reactors, and is estimated to lower emissions by 25 tonnes every year.

Combined, these two actions are calculated to not only reduce annual emissions by around 40 tonnes, but also save around 230,000 euros every year. Sustainable action will always focus on environmental improvement, but by implementing simple changes, manufacturers may also enjoy the business benefits that process evaluation can bring.

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Tungaloy Adds Longer Flutes To Popular TungMeister Exchangeable-Head End Milling System

Tungaloy Adds Longer Flutes To Popular TungMeister Exchangeable-Head End Milling System

Tungaloy has announced that its TungMeister series of exchangeable-head end milling system now includes long-flute end milling heads and new high-rigidity shank holders.

With TungMeister, significant reduction in tool changeover time can be achieved through the ability to replace used heads instead of an entire tool. Since it takes no more than one minute for tool exchange, setup time can be significantly reduced to as short as one tenth of the time it would typically take to replace solid carbide end mills for maximum productivity and cost effectiveness.

Responding to market demands, TungMeister now offers a range of VEH-style square shoulder end milling heads whose maximum cutting depth (APMX) is twice the length of that of the existing range. This provides the new VEH head with a capability of 1.5xD. Its variable-pitch and variable-helix cutting edge design, combined with tapered core geometry, will enhance the tool’s chatter stability while machining at demanding depths of cut.
The new VSSD-style shank holder is offered with thicker shank diameters than those of the existing range, increasing the tool’s flexural rigidity by 200 percent to 320 percent for added more reliable and productive machining.

With over 13,000 possible head-shank combinations available, TungMeister is able to readily provide tooling flexibility that enables users to find a solution for almost every application.
Ten VEH-style end milling heads and five VSSD-style shank holders are added in this expansion.

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Doosan Robotics Launches New Cobots Including Support For Machine Tools

Doosan Robotics Launches New Cobots Including Support For Machine Tools

Doosan Robotics Inc. is introducing six new collaborative robots (cobots), diversifying its innovative product offerings. The new lineup includes four models from the A-SERIES and two from the H-SERIES, adding to the company’s selection of innovative, future-proof cobots.

The A-SERIES, which has achieved the industry’s best speed and affordability, is comprised of four models, A0509, A0509s, A0912 and A0912s, and offers payload range of 5kg to 9kg. Each model features safety algorithms that protect workers, and meets the highest level of safety standards set by an accredited international testing & certification organisation TÜV SÜD. The equipped mountable force torque sensors enable the A-SERIES cobots to provide versatility required by many applications such as polishing and assembly.

The H-SERIES models offer 1.7m reach and up to 25kg payload, marking the heaviest payload among currently available cobots in the market. Comprised of two selections, H2017 and H2515, this high-power lineup weigh only 75 kg, only half of other comparable robots with the same payload. Equipped with six torque sensors on all six axes, the H-SERIES provides the dexterity and flexibility required in variety of applications, in particular logistics and automotive.

“The new A-SERIES and H-SERIES will set a new standard with distinctive advantages such as best-in-class speed, superior performance and outstanding price competitiveness,” said Sangchul Kwak, CEO of Doosan Robotics. “Doosan Robotics will lead the growth of the smart factory industry in the post-pandemic era and drive the momentum of new vertical markets in service, logistics and manufacturing.”

 

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