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Walter Enables Automatic Detection And Alignment Of Tools And Blanks

Walter Enables Automatic Detection and Alignment of Tools and Blanks

Walter Enables Automatic Detection and Alignment of Tools and Blanks For correct pre-positioning prior to machining, WALTER now offers a new TOOL VISION SYSTEM for all its tool grinding / eroding machines with robot loader. This Walter Automatic Detection system detects contact free, the orientation of the tool or blank, with e.g. brazed PCD plates on the front, sintered PCD veins or with cooling channels. The detecting is done automatically and during idle time. This means significant timesaving compared to the manual measurement method, eliminates human errors and avoids damage to the tool due to the non-contact method.

The WALTER TOOL VISION SYSTEM is permanently installed in the robot cell and available with two lenses. The one lens for tool diameter from 1.7 mm to 12 mm, the other lens for tool diameter from 6 mm to 32 mm.

 

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A Look At Walter’s Two-in-One Machining Concept

A Look at Walter’s Two-in-One Machining Concept

For 17 years now, tool manufacturers have been successfully implementing Walter’s two-in-one concept in production. Here’s a look at what exactly is behind this concept. Article by Walter Maschinenbau GmbH.

Now more than ever, the ability to be flexible and agile in your production is a key competitive advantage in the metalworking industry. The more process steps you can eliminate, the leaner your become, with improved efficiency and less waste—in terms of the time it takes to switch to a new machine to do a second process, and the energy needed to run the machine; what more in a volume production operation.

From a production viewpoint, the two-in-one concept means that users can completely erode tools (PCD or polycrystalline diamond) and also completely grind tools (carbide) using one and the same machine. What is more—and this is one of the key advantages of a two-in-one concept—both processing methods can be used on one and the same tool without the time-consuming step of switching to a second machine. This is especially necessary and more efficient in the case of modern PCD tools where the carbide blank already has soldered PCD.

The ability to erode, grind, or even do both in one clamping operation gives the user an unparalleled level of flexibility in their production processes. Walter Maschinenbau GmbH’s two-in-one machines can be used to process any PCD tool in any field, whether it be the wood, automotive or aerospace sectors, or even special applications. As the use of complex and modern full-headed PCD tools is constantly increasing, so is the demand for combined processing, i.e. eroding and grinding using a single machine. This trend is already clearly evident when one considers the new kinds of PCD tools required, amongst other things, for carbon fibre reinforced polymer (CFRP) processing in the aerospace sector, for example. Combined processing is the only way to efficiently produce such PCD tools.

A further advantage can be derived from this in business terms: The fact that the user can perform both eroding and grinding or combinations of the two processing methods using one machine means that investing in such a two-in-one machine represents a risk-free introduction to the PCD field for companies that have not been able to or have not wanted to produce such tools until now. If it turns out that the PCD business does not develop as expected, the same machine can simply be used to completely grind the previous product range.

Enhancing the Two-in-One Concept

Ever since presenting it to the world at the EMO tradeshow in 2001, Walter has been continuously further developing this two-in-one concept, and today offers a total of three machines based on it. Even back then, the company knew that a powerful grinding spindle was essential for perfect production results and that many tools could be manufactured more efficiently with rotary eroding than with wire eroding.

In 2006, Walter introduced a software module that boosted the benefits of the two-in-one concept because it now also allowed electrode/grinding wheel changers to be automatically implemented. That same year also saw the introduction of ‘Fine Pulse Technology’ for all two-in-one machines, setting new standards in terms of the surface quality, cutting edge roughness, and process reliability of PCD tools.

In particular, the generator was recognised as a central element and therefore has been completely redesigned. Improvements in eroding software and a variety of other factors based on the machine design were also optimised as part of Fine Pulse Technology. The difference to the other tools on the market can even be seen with the naked eye on the most common PCD types with 10µm grain size. A tool produced with Walter’s technology on a two-in-one machine shines on its free surface, similar to a polished (ground) tool. Even coarse-grained PCD types, which previously could not be fine finished on the market, can be eroded with the new technology, and a perfect surface quality can be produced.

In some cases, even entire steps in the production chain can be omitted because the eroded tools no longer have to be re-sharpened or polished. Finally, the Helitronic Tool Studio software solution was enhanced with the software licence ‘Eroding’ in 2017, making the tool shaping process even easier and clearer, especially for PCD tools.

 

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Walter Ewag: Laser Line Precision

Walter Ewag: Laser Line Precision

The enhanced laser source offers highly efficient machining results for commercially available diamond cutting materials such as CBN, PKD, CVD-D and now also MKD.  Thanks to this further development, PKD materials can be machined up to 2.5 times faster and MKD up to 1.5 times faster. Rotationally symmetrical tools of up to 200 mm diameter and up to 250 mm length as well as indexable inserts from 3 mm inside diameter and up to 50 mm perimeter diameter can be machined with the laser line precision.

The Laser Touch Machining process offers excellent surface quality, even on tools with complex or delicate geometries. Any cutting contours, clearances and 3D machining of chip groove geometries are performed in one clamping operation. The resulting flue gas and the vaporised material are suctioned according to the process and carried to a corresponding suction/filter system.

Walter Ewag Helitronic Vision 400 L Tool Grinding Machine

Walter Ewag Helitronic Vision 400 L tool grinding machine

Walter Ewag’s new Helitronic Vision 400 L high-performance tool grinding machine is designed for machining rotationally symmetrical precision tools such as hob cutters, step drills and profile tools made of HM, HSS, ceramic, cermet and CBN.

With an identical work area size compared to its predecessor, the new machine produces tools with a circumferential machining length of up to 420 mm compared to the former 370 mm as well as diameters from 3 to 315 mm.

The polymer or mineral casting machine base and portal design for extreme rigidity translate the high dynamics of the digital drives into virtually vibration-free grinding precision.

The wheel changer is capable of changing grinding wheels up to 254 mm in diameter and up to 24 grinding wheel sets.

 

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