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Facet Precision Tool — Key to Success

Jeremy Bunting leverages insights gained from growing up in a hugely successful cutting tool business to build a brand new specialist company – Facet Tools

Jeremy Bunting, Managing Director of Facet Precision Tool grew up in the cutting tool industry, getting a hands-on education from a young age and then using this experience to start his own business. From laying out a brand-new manufacturing center; to shaping and promoting Facet’s reputation; to training up a high performing team who are passionate about the craft of cutting tools – Jeremy has built the foundations for success.

Jeremy begins:

I started designing my first tools at age 14 in America as part of the family business, using manual grinding as well as conventional grinding to manufacture tools. After that I moved on to the applications side – getting exposure to feeds and speeds and eventually moved to Europe.  In Europe I worked for different tooling manufacturers, seeing different approaches to manufacturing and precision tooling.

I started Facet Precision Tools in 2015 primarily to service the aerospace and automotive sectors. Both these markets require special tools with distinct needs. At Facet we produce PCD, carbide cutting and coated carbide tools through distributors and direct to customers. Based in Germany we sell locally as well as to France, England and Spain. Through distributors we service Africa, Sweden, Turkey, Hungary, Austria, Italy and Mexico.

It’s challenging starting a new business. We had a market and products in mind and were in a unique position where we could decide, if these are our target markets, what machinery and equipment do we need? I considered my past experiences in the industry and how can I apply any learnings to the future. When we entered the market, I wanted to have high quality equipment, robust manufacturing processes and be producing market leading cutting tools.

Since opening we have been growing steadily, in fact last year we doubled our sales. As we expand we are looking at how we can attract more customers, consider if we need to add additional products and as many people in the industry experience – are always looking for good people.

Establishing grinding capabilities

After deciding on a shop floor blue print, we invested in a range of ANCA machines with two MX7 Linear’s, an FX7 and an EDGe as well as other equipment. We use the MX7s primarily for automotive tooling as they work well when grinding tools with larger diameters of 20, 25 and 32. We also run a lot of pocket grinding for PCD cutting tools on this model. The MX7 has a lot of horsepower that allows us to grind these tools in a very stable way. We use the FX for high volume carbide tooling. As an extremely rigid and thermally dynamic, stable machine I can rely on it to grind highly repeatable cutting tools.

On the MX7 we have an ANCA spindle speeder that allows us to achieve higher rpm. We worked with ANCA to adjust the software to be able to provide a better stable pocket and more accurate pockets in our grinding process.

On the EDGe we manufacture PCD tools. In the past couple years we have been developing PCD vein tools with our own blanks and cutting tool designs – working through and refining our processes. The EDGe has allowed us to have a high degree of accuracy when trying to grind a lot of the geometries. I found that as a process, erosion enabled the repeatability and the quality we were looking for. We also added a vision camera system on the EDGe, allowing for a quick inspection inside the machine, to get higher repeatability and better quality versus taking it out of the machine, and putting it back in.

And then there is ANCA’s 3D Simulator program. Up to 95% of the designs and problem solving are done on the simulator; testing the grinding process, reviewing and modifying before you go into a machine. It is our strongest tool to increase efficiency and reduce waste and that is a major help to our profitability. For example, carbide is extremely expensive where you can be paying from 400 euros for a 32mm standard rod.

The simulator also shows estimated grinding times which has been a great tool for us to reduce cycle times. Last time it took us, for example, 20 minutes to make this tool, but after considering a new idea or different approach we can reduce that time to 18, 17 or even 15 minutes all through experimenting in a simulated grinding environment.

We have touch probes on all the machines that allow us to easily change wheel packs, qualify the wheel and start moving quickly. It also allows us to remove human error and ensures a higher finished quality. To be able to dress and probe the wheel, picking back up where you left off without having to change the setup is very advantageous.

One of the main reasons we love the ANCA machines is because of the software. We have found it to be extremely flexible and at Facet we don’t use a lot of the standard ANCA programs and designs and instead do a lot of our work in profile editor, changing angles and profiles to meet the tool designs that we need. My Dad always said that ANCA was a software company that built a machine.

Part 2
Facet Precision Tool comments on why building a team of craftspeople is key to success and whether the electric car be the demise of the cutting tools

Jeremy Bunting, Managing Director of Facet Precision Tool grew up in the cutting tool industry, getting a hands-on education from a young age and then using this experience to start his own business. From laying out a brand-new manufacturing center; to shaping and promoting Facet’s reputation; to training up a high performing team who are passionate about the craft of cutting tools – Jeremy has built the foundations for success.

Specials are a relationship business – requiring communication and trust

As we build our company we want to be known for quality. From the start we have been trying to build our reputation for offering high quality tools rather than just entering a market and throwing anything out there and seeing what sticks. We are methodical in our approach to manufacturing certain tools or entering a marketplace or approaching certain things. Even if this means we are a bit slower and more tactful.

Just as important, is our responsiveness to the customer through deliveries and application support. These are the foundation of our company. We start by listening – what does the customer want to achieve, am I understanding their needs correctly? Then I consider how the product could be improved, can we make other recommendations. We turn that request into a tool design that is checked by the customer.

In aerospace, a common misunderstanding is the need for standard tools. Tools for aerospace require different lengths, diameters and applications. There is also a high requirement for accuracy, in Europe for example, we find aerospace have applications that need to be measured to a couple of microns and use a variety of methodology to make holes in different materials. It is a challenge making a product meet quality standards while working across a range of material applications.

Building a team of craftspeople

I think working in specialty tools excites an element of craftsmanship. Every day is different, and you can take pride in your work, was it correct, was it to print? That is why we look for a person who is flexible, shows an ability to learn, grow, and absorb information.

I train everybody in my plant like they’ve never seen a grinding machine before. We invest time to build their knowledge base to understanding the manufacturing and measuring equipment. Again, partially because we’re into specials where every tool design is different, we don’t have pre-written programs.

I think one of the best characteristics of a toolmaker is an attention to detail. Often people can become over invested in the productivity side – how many parts can I get through, how fast can I get them through the line. I train my team to be focused on the quality of the tool first and productivity second. And to meet these expectations of quality you have to have a high attention to detail.

Just as important is to develop your team to have a passion for grinding. The more passion someone has for the product, the more likely they are to stay. Teaching your employee how to make a better-quality tool feeds their creativity and teaches them it is ok to have your own approach and style. At Facet we have an open dialogue with our teams of why we do the things that we do.

Trends in the market – will the electric car be the demise of the cutting tools?

If I think about what I am seeing in the market I would say there is more competition in the automotive field than there is in the aerospace field, probably because aerospace requires more project work, more support, more testing, more engagement with the customer. Automotive expects high quality tools at very high tolerances, we have reamers that have tolerances of only a couple of microns. Another focus for this industry is price.

As the use of composites in aerospace has increased so has the demand for PCD or diamond coated tools. For example, the Dreamliner or A350 or Boeing Dreamliner uses a large amount of composites. These are extremely abrasive so if you use a carbide tool to grind composite materials, initially the tool works great but the wear curve is extremely high so after a 150 holes, the amount of wear is accelerated on that tool until it becomes blunt.

This changes the dynamic of the cutting, the heat, burr creation; causing problems for the manufacturer. Whereas if you use a qualified diamond or PCD tool, you may be able to make up to 1500 holes. For a customer that means higher productivity, fewer changeovers, less inventory and a higher degree of quality for a longer period of time.

There is speculation that combustion motors will disappear and as motors disappear then the need for a lot of the cutting tools disappears. This is bringing up questions on how much electric cars will replace all other means of transportation. Personally I think there are a lot of hurdles that have to be overcome and we will see other opportunities as the market changes. I think as far as aluminum and composite manufacturing is concerned we will see them trying to go lighter to make combustion engines more efficient.

I think there will always be a need for niche and special products and that means more special cutting tools. That’s one of the reasons why we were very comfortable moving into this industry. So as materials change – if it’s more glass, carbon composites or aluminum – we’re in a good position to move with the market and respond to those changes. I have established the foundations of Facet Precision Tools to be agile with design expertise, workforce skills and manufacturing capabilities. We can and do adapt and invest in the machinery or develop our knowledge so we can meet the markets’ changing needs rather than focusing on materials.


For further information, please contact:
Sepideh Zandieh
PR and Communications Manager, ANCA
M: +61 439 316 131
Sepideh.Zandieh@anca.com

ANCA is a market leading manufacturer of CNC grinding machines. It was founded in 1974 in Melbourne, Australia where the company still has its global headquarters. ANCA has offices in the UK, Germany, China, Thailand, India, Japan, Brazil and the USA as well as a comprehensive network of representatives and agents worldwide.

ANCA CNC grinders are used for manufacturing precision cutting tools and components across a diverse range of competitive industries including cutting tool manufacture, automotive, aerospace, electronics and medical.

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Cutting Tool Manufacturers Find Opportunity in the Billion Dollar Deep Hole Drilling Market

Understanding the application and being aware of common challenges can help make a difficult operation both productive and profitable

The global drilling tools market was valued at USD 5.79 Billion in 2016 and is expected to grow at a CAGR of 4.75%, during the forecast period, to reach USD 8.61 Billion by 2022.* Producing deep holes in an effective and efficient way is considered a challenging application. Cutting tool manufactures need to provide their customers with a product that has predictable tool life, accurate surface finish and repeatability at a good price to be competitive in the market. Thomson Mathew, ANCA Product Manager explains the different types of cutting tools for this application and how to overcome some common challenges in deep hole drilling.

Thomson Mathew starts: Deep hole drilling is a process to produce holes in metal at high depth-to diameter ratios on CNC Machines. For normal drilling processes, the length to diameter ratio will be less than five times the diameter and if the length to diameter ratio goes beyond five, the process is called deep hole drilling. This can be effective in diameters ranging from 1mm – 200mm [0.04in – 8.00 in] and will require special drills with through coolant holes to deliver high pressure coolant to evacuate chips cleanly and achieve hole tolerances and surface finish.

Some common deep hole drilling process include gun drilling, BTA drilling (Boring and Trepanning Association) and conventional carbide twist drills. All these processes have their own merits in deep hole drilling based on hole diameter and tolerances.

BTA drilling is an effective method of drilling deep holes, as it is cleaner, reliable and capable of achieving larger diameters at higher feed rates. BTA drilling is effective in holes from 20 – 200 mm [0.80 – 8.00 in], a larger size range than gun drilling and carbide twist drills.

 
Fully automated BTA Drill loading and grinding solution from ANCA including in-process gauging for process control

Gun drilling was originally developed to drill out gun barrels and is used commonly for drilling smaller diameter deep holes. The depth-to-diameter ratio can be even greater than 300:1. The key feature of gun drilling is that the bits are self-centering; this is what allows for such deep accurate holes.

 
ANCA Software for manufacturing and re-grinding a variety of gun drill tooltypes

Carbide twist drills with through coolant holes are also commonly used in several deep hole drilling applications. The challenge is to manufacture and re-grind these drills with minimal runout and requires an additional axis on machines to support the flute grinding process. ANCA CNC Machines has this ability to support and manufacture the full range of long series drills with minimum runout with the P-axis Arobotech system. The system also caters for the back taper on long series drills by allowing the support pads to adjust automatically to the taper.
Image of the P-axis Arobotech support system on the TX7 machine

Common challenges in deep hole drilling

Through coolant or internal coolant – This improves chip evacuation while cooling the cutting edge. Coolant is flushed down to the bottom of the hole, which, in turn, is pushing the chips back up toward the top. ANCA software has the ability to design and verify the coolant holes right at the design stage to avoid coolant hole breakage into flutes and eliminating scrap.

 

Hole Straightness – The “margin or radial land” is the portion of the drill that is actually contacting the hole. A single-margin drill (one margin per flute) is preferred in long chipping materials. Single margin drills provide additional clearance in the longer chipping materials whereas a double-margin drill (two margins per flute) provides excellent hole straightness compared with a single margin drill. Although not as common, double margin drills with a floating second margin are also available where a compromise can be made on hole straightness and chip evacuation. So, more margins add accuracy while maintaining a higher surface finish but restrict the amount of clearance for chip evacuation.
  
ANCA ToolRoom software has the ability to manufacture single, double and floating margin drills.

Tool runout control – One of the most significant challenges of deep hole drilling is maintaining control of runout, which increases with cutting tool length. A more accurate method of tool holding like the premier plus, combined with the P-axis Arobotech support can deliver the tools with minimal runout and deliver longer tool life.

* https://www.marketsandmarkets.com/Market-Reports/drilling-tools-market-18283501.html?gclid=Cj0KCQiAz53vBRCpARIsAPPsz8UfxVUqsd_mfifPc3ddQ3BRTR_ysQk6e3NxsyUuR012VejwWPNMtq0aAgk1EALw_wcB


For further information, please visit:

https://machines.anca.com/Contact

ANCA is a market leading manufacturer of CNC grinding machines. It was founded in 1974 in Melbourne, Australia where the company still has its global headquarters. ANCA has offices in the UK, Germany, China, Thailand, India, Japan, Brazil and the USA as well as a comprehensive network of representatives and agents worldwide.

ANCA CNC grinders are used for manufacturing precision cutting tools and components across a diverse range of competitive industries including cutting tool manufacture, automotive, aerospace, electronics and medical.

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ANCA Factory

ANCA Joins the Fight Against COVID-19 – Manufacturing Components for Ventilators to Support the Medical Industry

ANCA is a partner to the NOTUS Emergency Ventilator Program, a Grey Innovation-led initiative supported by the Victorian Government and Advanced Manufacturing Growth Centre (AMGC) to manufacture and assemble components of ventilatorsANCA Australia Factory

Coming to the aid of a medical system crushed world-wide by the COVID-19 pandemic, ANCA has joined an important consortium to rapidly manufacture invasive ventilators within Australia. This initiative directly addresses the critical supply of mechanical ventilation equipment to support COVID-19 patients requiring ventilation to survive. Banding together with other Australian manufacturing businesses, the consortium can harness various industry capabilities to make more ventilators sooner.

ANCA VentilatorBuilding on over 45 years of innovation, ANCA has taken its industry know-how to pivot to COVID-19 related manufacturing to support national efforts to produce more ventilators. ANCA’s dedicated project team will draw on the skills and experience of engineers and manufacturing production teams to support this venture while maintaining business-as-usual production, service and support for its global customers.

Co-founder and managing director, Pat Boland said: “ANCA is an advanced manufacturer that supplies to a wide range of industries, a key one being the medical industry. In fact, ANCA has been classified in the U.S. as an essential industry because so many of our customers are manufacturing medical components.”

ANCA is an Australian manufacturer of CNC machines that produce quality precision cutting tools. Their experience in advanced manufacturing means they can guarantee a micron precision, a capability which means the company could pivot and utilise its machine shop to manufacture parts for the ventilators. An Australian-based company, ANCA exports 98% of their product and boasts a global network to service global customers. Fully Australian and privately owned, ANCA machines have the capacity to machine components in brass, aluminium, plastic and steel and has skilled assembly capabilities.

ANCA Factory VentilatorsPat adds: “ANCA is Melbourne based, and we are very excited by the prospect of being involved with a home grown project and helping make a contribution to the manufacturing industry; making ventilator components and sub-assemblies to support urgent medical requirements.”

Around the world it is predicted that total demand for ventilators could run into the tens of thousands, with existing manufacturers unable to meet demand.

“This is a global emergency and in my view it is incumbent on every individual in every organization to do everything they can to help deal with it. And in the case of ANCA, we have capabilities that are a good match and it’s the right thing to do. We are very good at manufacturing the kind of parts that are needed for ventilators and it is a really great way for us as an organization to give something back to the community,” said ANCA Group CEO, Chris Hegarty.

ANCA CNC MachinesChris continued: “ANCA is a global company, but while we do have some resources offshore for manufacturing, most of our engineering is in Australia and a significant proportion of our manufacturing capabilities are here as well; so that’s why we are able to help.”

With production already in progress to meet tight timeframes; ANCA has hit the ground running with dedicated machinists willingly working weekends and over the Easter break to make parts and help combat coronavirus.

Production Operations manager, Mark Patman explains: “With an extremely tight timeframe, we’ve jumped in and started manufacturing the parts; it’s a team effort across the business to get it done. As a well-established global business, a lot of the processes required to deliver this type of project are already in place at ANCA. We can leverage off all our systems to be able to deliver the project.”

ANCA is utilizing a cross-functional team comprising manufacturing, supply chain, project management, stores logistics, and safety to support this crucial work.

Demonstrating agility in moving from machine tools to ventilators ANCA already has a working relationship with the AMGC and is pleased to be collaborating with Grey Innovation to ensure that Australia does not have a shortfall in ventilators, critical for our COVID-19 response. Answering the call from the Australian Government, rapid production will continue to supply contracts and contribute to the coronavirus crisis strategy.


For further information, please contact:

Sepideh Zandieh
Acting PR and Communications Manager, ANCA
M: +61 439 316 131
Sepideh.Zandieh@anca.com

ANCA is a market leading manufacturer of CNC grinding machines. It was founded in 1974 in Melbourne, Australia where the company still has its global headquarters. ANCA has offices in the UK, Germany, China, Thailand, India, Japan, Brazil and the USA as well as a comprehensive network of representatives and agents worldwide.

ANCA CNC grinders are used for manufacturing precision cutting tools and components across a diverse range of competitive industries including cutting tool manufacture, automotive, aerospace, electronics and medical.

Continue reading

KV Tooling Wins First Place at ANCA’s Industry First ANCA Tool of the Year

As an industry #ANCATooloftheYear celebrates the knowledge and imagination of cutting tool craftsmen, creating tools with the perfect geometry, profile, and finish that shape and build our world everyday.

ANCA Tool of the YearKV Tooling took out the coveted first place in ANCA’s industry first competition, ‘ANCA Tool of the Year’. The cutting tool industry has cultivated and refined their craft over the years to design beautiful tools, applying science to achieve a sub-micron surface finish and superior cutting performance.

Pat Boland, ANCA Co-founder said “All finalists were of a very high standard and demonstrated a deep understanding for tool geometry as well as taking full use of ANCA’s software to design unique and special cutting tools. We congratulate the winner KV Tooling, runner up Eshed Tools and Zakłady Mechaniczne Kazimieruk who we gave a special creativity award for daring Bat Man design.”

KV Tooling takes out first place at ANCA’s industry first ANCA Tool of the YearBrian Beland, President at KV Tooling Systems said on winning the award: “Competing with world class tool grinding shops from around the world with same grinding machines and winning – regardless of the size of the shop – is something we are particularly proud of.”

“Our entry was a very complex tool with many features incorporated into one tool. We designed the cutting tool to satisfy a customer’s problem, where our one tool replaced a machining requirement that previously required six tools. The customer was very happy with the production gains and for us to submit to ANCA Tool of The Year. We believe winning the competition makes our company more marketable and will give us great exposure and hopefully expand our customer base,” concluded Brian.

Eshed Tools entered the competition to share their special tool manufacturing skill set with ANCA users. Shmulik Arbel, Production Manager commented that they were proud of their expertise that means they can “produce special geometries that are difficult to achieve and save our clients expensive production time.”

Reflecting on coming runners up Shmulik continued, “Taking out this prize creates a great opportunity for global exposure through the Tool of the Year competition. For us ESHED tools as a small and growing tool manufacturer, world wide recognition is important and will help us expand beyond the local market.”

Zakłady Mechaniczne Kazimieruk on winning the ‘Most Creative Tool’ said: “We thought outside the box and were motivated to inspire the grinding community with our entry. During everyday work our team make a lot of customized tools so we wanted to make something fresh and unique – even to us. Furthermore, entering was a great test for our grinding skills. We relished the opportunity of seeing others craftmanship and the entries in the tool of the year competition demonstrated to us the range and type of cutting tools that are possible.”

The competition was based on the passion and the craft of tool making and celebrate our highly skilled tool grinding community.  Watch the live announcement of winners at EMO 2019:

KV Tooling Finalist ToolsWinners

Judging Panel

  • Pat Boland, Co-Founder and Managing Director at ANCA
  • Ralph Van Hoorn, owner at Van Hoorn Carbide
  • Thomson Mathew, Product Manager at ANCA
  • Alicona – measurement of surface finish
  • Zoller – measure profile and diameter

The top five tools were judged on the following criteria:

  • Best surface finish in Ra (roughness average) value on the flute or gash surface

For further information, please visit:

https://machines.anca.com/Contact

ANCA is a market leading manufacturer of CNC grinding machines. It was founded in 1974 in Melbourne, Australia where the company still has its global headquarters. ANCA has offices in the UK, Germany, China, Thailand, India, Japan, Brazil and the USA as well as a comprehensive network of representatives and agents worldwide.

ANCA CNC grinders are used for manufacturing precision cutting tools and components across a diverse range of competitive industries including cutting tool manufacture, automotive, aerospace, electronics and medical.

Continue reading

For Almost 45 Years Anca Has Been on the Journey to Help Our Customers Move Towards a Smart Factory Solution

Visit ANCA at EASTEC at booth 1244 to learn more about how our world-first technology developments have helped reduce production costs by 50% through lights out manufacturing

From 3D simulation software to LaserPlus, an in-process measurement system, to RoboTeach, which makes robotic loaders accessible and easy to program – ANCA has been building a tool box of technology for our customers to reap the benefits of automation and Industry 4.0.

Visit us at Booth 1244 and learn more about how ANCA is enabling manufacturers to run ‘lights out’ and download our practical guide on how to build a Factory of the Future.

Thomson Mathew, Software Product Manager says: “Get a live demo of the soon to be released ToolRoom RN34 software and learn how it specializes in complex cutting tool geometries for the aerospace, die mould and power generation industry.”

ANCA’s latest ToolRoom RN 34 software release focuses on manufacturing the most complex tool geometries with a perfect balance. Visitors can get a demo of the endmill cycles for ballnose and corner radius, tool balancing and next generation fluting cycles.

Also at the show will be ANCA’s Management Suite, which either on the premise or in the cloud is a game changer for the CNC grinding industry. It provides customers the technology to monitor the performance of their machines no matter where they are in the world. The new software also enables companies to run smart factories by providing live production information to make data-based decisions on operational improvements. Also launching soon is a new USB WiFi dongle that will add seamless connectivity to machine users.

Email us at marketing@anca.com to book a free demo at EASTEC 2019 to see ANCA’s latest ToolRoom version or our Management Suite software.

Ideal for light manufacturing, regrinding and full production – see the FX7 Linear at EASTEC

For customers that require increased flexibility or more spindle power, or increased automation capacity that a robot can provide, the FX7 Linear offers these. The FX7 Linear offers a wide range of options for those looking to increase productivity and accuracy. Available as an option is the AR300 robot loader to increase efficiency by automating repetitive manual tasks.

Features include:

  • Linear motors on X and Y axes
  • AM5000 control system for faster processing
  • HSK40 taper provides increased rigidity and accuracy for improved tool surface finish results

Embrace automation with ANCA’s AR300 loader

With over 70% of ANCA customers buying machines with robotic functionality, it’s fair to say the age of the robots has come. Far from a nice-to-have add on, many CNC machines now come with operator panels that provide in-built control over both the grinding software and the robotics function, opening the door to greater automation efficiencies.

At ANCA we provide a complete solution to our customers, designing and manufacturing almost all our technology in-house. As part of this we developed our own low-cost solution for tool loading.

The 3-axes ANCA robot has a capacity of 380 tools and accommodates tool sizes up to Ø20mm (Ø3/4”) x 150mm (6”) long. The AR300 loader is contained within the compact FX Linear machine footprint, so there is no need for extra floorspace. In addition, there is no need to change gripper fingers between batches, which further maximizes productivity.

Utilizing the latest control technology from ANCA Motion, the AR300 loader is an excellent value-for-money auto tool loading solution for the FX5 Linear and FX7 Linear two-wheel changer machines. The loader provides quick tool loading, as the tool is passed directly from the pallet to the collet in a single gripping action.


For further information, please contact:

Sepideh Zandieh
PR and Communications Manager, ANCA
M: +61 439 316 131
Sepideh.Zandieh@anca.com

ANCA is a market leading manufacturer of CNC grinding machines. It was founded in 1974 in Melbourne, Australia where the company still has its global headquarters. ANCA has offices in the UK, Germany, China, Thailand, India, Japan, Brazil and the USA as well as a comprehensive network of representatives and agents worldwide.

ANCA CNC grinders are used for manufacturing precision cutting tools and components across a diverse range of competitive industries including cutting tool manufacture, automotive, aerospace, electronics and medical.

Continue reading