Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
Jake Farragher, ANCA’s general manager for Asia, observes that dental drill manufacturing has taken off in the region. “Almost all of it is for export, including destinations far beyond Asia,” he explained.
ENG-K is a shining example. Established in Korea in 2014, they partnered with dental implant OEMs and began producing dental drills on CNC lathes. They soon added their first grinding machine, an ANCA FX7 Linear, in the second half of 2015. Since then, they’ve installed 14 more ANCA FX5 Linear machines to satisfy an annual growth rate of 30%. In fact, president Dae-Seong Kwak credits ANCA’s ability to deliver machines quickly as a key factor in their success.
ENG-K actively participates with their client’s research and development of new instruments, thereby “satisfying the customer’s needs as much as possible by reflecting the function and structure in the production,” as Kwak puts it. ANCA also plays a role, he adds. “During the product development of our specialty tools and the R&D of our deburring tools and circular surgical tools, ANCA helped us a lot to improve our processes and quality. ANCA Korea supported our development of small diameter ball nose end mills, and we developed surgical cutting tools together with the help of ANCA’s headquarters in Australia.”
Multi-faceted automation
Profitably meeting customer demand for products like dental drills requires automation. Dental drills use a standard 2.35 mm shank size, explained Farragher, but the material is soft, so auto-loading risks marking the tool. “We integrated a pressure-reducing valve to grip dental drills a little softer than normal, and that opened up the market in grinding these products.” Kwak reported that ANCA’s drill loading system made them more efficient by increasing productivity and significantly reducing operator fatigue. “ANCA’s robot loader can be set up for more than 500 products in one batch,” enabling 24 hour “lights out” manufacturing, he added.
But truly automating production takes more than simply robot-loading the grinder. For example, Kwak points to ANCA’s internal wheel dressing feature. It adds to the overall cycle time, but “has the advantage of maintaining tool specifications” over a long production run, without the need for human intervention or an external wheel dresser.
Kwak also lauds ANCA’s automatic runout compensation. This system uses the standard Renishaw probe to check the tool blank in 3 planes, digitizes the actual centerline of the tool, and then compensates the entire kinematic to grind relative to that center, rather than the centerline of the work head. The resulting grind is nearly flawless, so no wonder Kwak says it’s been “very helpful” in the mass production of micro end mills.
Fast, secure setups
Kwak says ENG-K uses “both automatic and manual modes to produce customized products. ANCA machines have the advantage in either approach, because the operability of both automatic and manual modes is convenient and safe.” He credits ANCA’s latest software release with producing a high-quality tool radius and profile, making them “more competitive in the market.” And he applauds ANCA’s automatic warm-up routine, which he says has resulted in much less variability in grinding parameters. “Size deviations are smaller, so the defect rate is reduced and process reliability is assured.”
ANCA’s iBalance function has also proven to be another key setup feature. This option spins the wheel set at operating speeds and identifies any imbalance. If needed, the software tells the operator where to place threaded weights in the clamping nut in order to eliminate the imbalance. The process takes just 5 to 6 minutes per wheel set. Kwak reports that “iBalance is helpful in producing tight tolerance implant drills. Wheel life has also been increased by using this option.”
Kwak also praised the inspection panel in the software, saying it reduced measuring time during mass production and increased production volume. “It’s really good to be able to do in-process quality checks through the setup without the main door open. It has advantages for temperature changes and production.”
And in a final nod to their enduring partnership, Kwak enthused that “ANCA’s team in Korea has always managed to minimize production disruptions with friendly explanations and quick action. We’re very thankful.”
For further information, please contact:
Amanda Bakun
Marketing & Communications Manager – Americas
248-497-1168
amanda.bakun@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, Korea 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.
Industry 4.0 connectivity and AI-assisted guidance on ANCA’s new edge preparation machine revolutionizes edge preparation for cutting tool performance
Renowned for launching industry-first tool and cutter grinding technologies, ANCA continues its legacy of innovation with the EPX-SF, guaranteeing productivity, quality, and profitability in edge preparation. The new EPX-SF stream finishing machine was debuted at GrindingHub in Stuttgart, coinciding with the company’s 50-year anniversary.
Armando Manzano, EPX-SF Product Manager said, “More than just an edge preparation machine, the EPX-SF is a strategic business asset. Its high level of precision will help manufacturers to secure more contracts by meeting the rigorous standards of industries that demand clean and consistent cuts. Its ability to deliver flawless quality in a single pass enhances operational efficiency, eliminating the need for extensive post-processing and ultimately saving costs for businesses.”
Key highlights of the EPX-SF:
The EPX-SF is a future-ready solution, designed with advanced functionalities to meet the evolving needs of manufacturing. Its performance-driven design with 11 axes, delivers predictable nano-smooth surfaces and micron-honed edges within a minute per tool. The Advanced Cyclic Mode allows users to adjust angles, optimizing chip flow and effectively combatting surface burrs. It utilizes AI-assisted guidance to provide tailored recommendations, enhancing tool geometries and streamlining process efficiency. With Industry 4.0 connectivity, advanced safety features, and remote technical assistance, the EPX-SF seamlessly integrates into production lines.
Contact your local ANCA representation for more information on how the EPX-SF is redefining edge preparation, or visit https://machines.anca.com/Products/Machines/Edge-Preparation/EPX-SF
About ANCA CNC Machines
ANCA CNC Machines is a global leader in the design, manufacture, and service of advanced CNC grinding machines. With an illustrious history spanning over 50 years, ANCA is renowned for its cutting-edge technology, innovative solutions, and exceptional customer support. ANCA’s comprehensive range of products includes tool grinders, CNC grinding machines, software, and automation solutions, catering to diverse industries such as aerospace, automotive, medical, and general manufacturing.
ANCA’s newest ULTRA machine makes micro tool grinding easier, more precise and more productive as the only nano-level resolution micro tool grinder
ANCA CNC Machines, a leading manufacturer of precision grinding machines, have launched the highly anticipated MicroX ULTRA.
This innovative six-axes grinding machine is meticulously designed for volume production of nano and micro cutting tools down to D0.03mm. Offering a superior solution for manufacturing high-quality, high-performance micro cutting tools, the MicroX ULTRA introduces groundbreaking technologies exclusive to the cutting tool industry.
The brain behind the machine is Pat McCluskey, a passionate machine tool designer, who is this year celebrating the 50th anniversary of ANCA, the company he co-founded with Pat Boland in 1974.
Pat McCluskey remarked, “I have been designing ANCA machines for 50 years – always with the goal of making machines better, more efficient, and user-friendly. It is a trademark of ANCA that you just have to do it differently, and the latest machine, the MicroX ULTRA, is the only micro tool grinder with nanometer resolution. This nano-level precision is a significant advancement in the field, utilizing the very best of ANCA’s technology developed over five decades to offer superior micro tool production.”
Key features of the MicroX ULTRA:
With nanometer resolution and control over the tool grinding path, the MicroX ULTRA delivers a high level of surface and edge quality. This achievement is made possible through intelligent algorithms that operate collaboratively and in synchrony.
The C-axis refers to the wheel swivel axis centerline, which is aligned with the wheel’s 9 o’clock grind point. This specific design is critical in the grinding of ballnose, corner radius and profile tools. In the case of a ballnose tool, the X and Y interpolations during the grinding process will be nearly equal to the radius of the ballnose tool.
Advanced algorithms ensure precise nanometer-level control of tool grinding paths, guaranteeing superior surface and edge quality. These algorithms collaborate and synchronize to reject disturbances swiftly, enhancing axis stiffness and robustness. They actively mitigate disturbances from spindle speed variations caused by imbalanced or runout grinding wheels. Encoder subdivision error compensation automatically detects and corrects inherent encoder errors on both linear and rotary encoders.
The LaserUltra takes process stability to an even higher level by closely controlling tolerances and incorporating in-process compensation mechanisms. This advanced system adapts to factors like wheel wear, resulting in superior precision and reliability.
Seamless integration with ANCA Integrated Manufacturing System (AIMS) facilitates effortless transition to automated, lights-out production, enhancing operational efficiency and productivity.
For more information, visit https://machines.anca.com/MicroX
For further information, please contact:
Amanda Bakun
Marketing & Communications Manager – Americas
248-497-1168
amanda.bakun@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, Korea 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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As ANCA celebrates 50 years of advancing tool manufacturing technology, Edmund Boland, General Manager of ANCA CNC Machines, (Bayswater North, Australia), looks ahead 5 to 10 years.
Just a person and a dog?
The old story about the factory of the future being populated by one human and a dog—the human’s role limited to feeding the dog, while the dog is in charge of keeping the person away from the machinery—will be close to reality for tool grinding.
At a minimum, said Boland, the entire production process will be linked digitally, “from the intake of the raw material, to palletizing, laser etching, and blank preparation…to the tool and cutter grinding, edge prep, coating, and right through to shipping the finished goods.” So, for example, when a particular job transitions from OD prep to the 5-axis grinders, the machines will automatically call up the correct program to finish grinding the tools. Everything will also be linked to a company’s ERP and MES system, providing “very good data analytics, to help make the right decisions and improve your processes.”
It’s already the case that individual processes, such as OD grinding or stream finishing, are often highly automated once they’re setup. So, what will differ among thriving companies, as Boland sees it, is the degree to which those processes have been automated and the degree to which the transfer of material between stations has also been automated.
“A small to medium shop will probably have a person who’s physically moving and scanning let’s say, a pallet from the OD machine to the five-axis machine. But digitally, the five-axis machine receives a file that says it’s getting these blanks, and it’s all tied in with the ERP system. The same thing would happen if they’re subcontracting the coating. Digitally, they’re sending that information to the coater, but somebody is manually moving tools from the five-axis to the shipping department. Whereas in a large shop, a robotized cart would make the physical moves.” That’s the case with ANCA’s Integrated Manufacturing Systems (AIMS).
Improving setups and quality
The more automation a shop achieves, says Boland, the more consistent its output quality and the more its workers can concentrate on solving isolated problems and improving the entire process, aided by AI. “Invariably, there will be tools that are out of tolerance. And someone will need to ask ‘Why? What do we need to tweak? Is there an issue with one of the production steps? Is the program wrong?’”
Competitive companies will therefore rely on a relatively small number of highly skilled problem solvers. These people will in turn rely on the kind of advanced training available at the ANCA Academy.
Boland also envisions a continuing role for skilled people to set up machines, though changes are coming there too. “As an example, technology like steadyrests will have sensors and the ability to make automatic adjustments.”
Automatic compensation to correct errors detected in-process is already a reality, and this capability will only improve, Boland adds. For example, with today’s technology, if the machine loads a blank askew, the probe detects the error and the grinding problem automatically adjusts to produce a satisfactory tool. But, “you still need to manually check the first piece, especially if it’s a new type of tool. After that, the system can take over. ‘First tool right’ is already our big mantra. You should be able to measure the first tool, and if wrong, be able to compensate.”
One contributing factor is the ever increasing capability of internal measurement devices. Boland observes that their new generation lasers can measure in the presence of coolant mist and even some residual oil on the tool itself. Vision systems still require manual placement and removal after use, but “that will change. Camera systems require better ventilation than lasers, but there are solutions. A robot can blow out the debris from the environment within the machine right after grinding. Or you could use a robot to bring the camera into the machine from an external location.”
At the same time, the list of features that can be measured internally and automatically compensated will grow. Today it’s “things like OD, tool profile, and flute depth. In a short time we’ll be able to do more. The threads within a thread mill or a tap, as an example. A K-land. Or the gash. As long as it can be measured within the system, it can be compensated.”
Boland doesn’t think we’ll eliminate the need for stand-alone measuring machines like the ZOLLER Genius, especially when it comes to measuring complex features. But he foresees improvements in the interplay between such systems and tool grinders.
The key, he explains, in the establishment of standardized measurement protocols for specific geometric features. “Until these measurement protocols are created, no tool grinder can compensate for a measured deviation. At the moment, ANCA has a standard set of measurements available for simpler end mills and drills. But as we install AIMS throughout our customer base, we’re also working with these customers to expand the range of measurements we can compensate. We’re getting into quite complex profile tools, and complex end mills, for example.”
Sub-micron tolerances
It’s no secret that tolerances are getting tighter. Boland says achieving micron, and even sub-micron, levels of precision will be the key to capturing many future applications. Demand for such accuracy “will grow, because of the benefits of these cutting tools. Whether it’s the surface finish of the workpiece that’s being machined, tool life, or other factors. Removing all the small inaccuracies within the cutting tool lifts its performance significantly.”
This is also why the market is moving more toward solid round tools, versus indexable cutters. “Customers want the rigidity of a solid round tool and the advantages of being able to push the tool while also achieving an excellent surface finish,” reports Boland.
Maintaining higher levels of precision will take more than the highly functioning automation, in-process measuring, and closed-loop compensation functions covered earlier. “Simple, though expensive, things like air conditioning,” lists Boland. “The coolant systems. The types of wheels you buy… It’s not just the tool and cutter grinder. It’s the whole system around it.
“Eliminating vibration is going to be absolutely critical. No longer will you be able to attach a mist extractor directly under the canopy. The air conditioning unit within a machine tool will become very important. Because if it vibrates, it will cause problems.” Thus, a central coolant system and central mist extraction become requirements.
Although Boland predicts a growing demand for even more accurate tools, he also thinks there will continue to be demand for lower cost tools. That, plus the inherent cost and difficulty of meeting the tightest tolerances, will limit the adoption of the improvements just discussed.
Material trends
Carbide continues to be the dominant cutting tool material, but PCD use is growing faster, according to Boland. Thus, PCD may reach 30% of the market in 10 years or so. Ceramics are also getting more interest, but remain a small part.
Likewise, the need for material removal technologies other than grinding will grow. Wire and rotary EDM are now predominant for PCD, but laser ablation bears watching, says Boland. “It is definitely an emerging technology. Customers with early machines are using them not only for PCD, but also for carbide. In particular, micro tools are now seen as a potential for laser ablation, and tool makers are getting interesting results.
“In terms of PCD, laser ablation definitely has its advantages over erosion. It doesn’t require coolant or consumable copper electrodes.” So, though the machines might remain 40-50% more expensive than competing technology, they might save money over time due to lower consumable costs. Laser ablation also has the ability to produce shapes that can’t be created with erosion, including surface features. Conversely, it doesn’t make sense for fluting larger diameter tools. Boland therefore remains uncertain of laser ablation’s near term future being more than a niche solution.
Similarly, additive machining is not likely to replace more than a few material removal applications in industry. And its applicability to the production of cutting tools appears to be limited. “I don’t see it becoming efficient enough in ten years. But potentially, it has a place in producing special tools, with otherwise impossible internal coolant channels and those kinds of things. It might also have a role in creating big, expensive, cutting tools. But even if it does take off, I don’t believe it will be accurate enough to eliminate the need for finish grinding.”
Other market considerations
Given the production efficiencies Boland envisions, you might expect regrinding to die. But not only will the automation solutions discussed earlier also apply to regrinding, Boland surmises that sustainability concerns will continue to make it a viable business.
At the same time, the greater efficiencies achieved by forward leaning tool producers will create expectations in the market for faster turnaround times, even for small quantities of special tools. As Boland put it, “the ability to easily produce optimized special tools for a specific job is what will be important to our customers.”
Unsurprisingly, the move to electric vehicles is reducing cutting tool demand in the automotive sector by as much as 50%. This varies around the globe, with the U.S. lagging in EV adoption. There are also “growing applications outside of the EV area which might be compensating,” Boland states, though the total impact of EVs will undeniably be large.
“And then there’s the question of where the technology will land. But it’s almost a philosophical discussion rather than a factual one. Will hydrogen take over? Will ultra clean fuel come back and give the combustion engine another lease on life? Who knows?”
Changes to service & support
Boland predicts that AI will “be a huge productivity improvement mechanism for the future,” in part because it contributes to accurately warning of component failures in advance. It can even automatically order the replacement part. Thus, preventative maintenance becomes targeted and efficient while ensuring nearly seamless uptime.
Conversely, Boland points out that multi-machine automation makes any downtime intolerable. “Customers can live without a single machine for a day or two. But if a fully automated system is not up within a couple of hours, that’s a big problem. So, being able to respond rapidly and around the clock is going to be important. There will be different technologies to allow that.” This includes remote and predictive diagnostics, “to reduce the necessity of having a service person on site.”
Whatever the future holds, it’s sure to be interesting. And if Boland turns out to be wrong about anything, you can always count on your dog.
For more information, visit https://machines.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, Korea 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’s RN35 release delivers advanced features to help manufacturers reduce cycle time by 20%
ANCA, a global leading manufacturer of CNC tool and cutter grinders, proudly introduces RN35, the latest version of its cutting-edge ToolRoom software. This significant launch coincides with the celebration of ANCA’s 50th anniversary, marking a half-century contribution to industrial progress through precision cutting tools.
The RN35 release presents a range of advanced features designed to boost productivity and ensure consistent tool quality, resulting in superior surface finishes. By enabling faster cycle times and enhancing tool performance, manufacturers can drive up their profits effectively.
ANCA’s ToolRoom RN35 software offers:
Thomson Mathew, Software Product Manager at ANCA says: “It is no secret that flexibility, user-friendliness and application diversity have always been key strengths of ANCA software. With our RN34 release, we launched high performance cutting tools of different tool types. Continuing from this, our RN35 release focuses on elevating the user experience, enhancing performance, boosting productivity, and minimizing cycle times – all without compromising quality.”
“ANCA is the only tool and cutter grinder manufacturer in the world that designs and produces the complete machine in-house, including building the CNC, precision motors and spindles, and polymer concrete bases. Our dedicated Software Engineering team is focused on developing software with innovative enhancements, with the goal of making tool production easier, faster and more efficient for our customers. This level of vertical integration means we can consider the entire machine as a single system when developing new solutions,” Thomson concludes.
Established in 1974, ANCA has consistently delivered industry-first solutions that have reshaped cutting tool manufacturing. The introduction of the System 32 CNC software in 1991 marked a groundbreaking moment as ANCA applied advanced robotic software to the machine world, introducing novel concepts in tool grinding, including the innovative soft axis or soft machine kinematics, which simplified the grinding process for cutting tools. In 1998, ANCA was the first to introduce true 3D simulation technology for CNC tool and cutter grinding with the launch of CIM3D software.
Key Highlights of RN35:
Feedrate optimization: RN35 includes feedrate optimization, ensuring improved cycle time and increased productivity. The software facilitates stable tool quality with a superior surface finish, offering enhanced performance for CNC tool manufacturing.
Improved cycle time and wheel life: With RN35, manufacturers can experience improved cycle time and extended wheel life. The software provides uniform wheel wear on the surface of the grinding wheel, contributing to cost savings and enhanced operational efficiency.
SPC (Statistical Process Control): ANCA’s revamped SPC software empowers users with comprehensive control of the production process during high-volume manufacturing. Key features include:
Profile fluting: RN35 introduces profile fluting, providing the ability to control and maintain hook/rake angle along the trajectory of the cutting edge on a given profile. This enhancement increases cutting performance and extends the life of the tool due to uniform hook/rake angle along the edge.
I3dg improvements: ANCA has enhanced i3dg features, allowing for faster comparison of tools on the machine during small changes. The software also enables the measurement of features after changes, providing a seamless validation process.
Profile software improvements: RN35 introduces a new and easy way to define and modify profiles, saving time in the design stage. This improvement makes it easy for new starters to adapt to the software.
LaserUltra enhancements: LaserUltra enhancements allow for the measurement and compensation of more complex tools with line and arcs inside the machine. This feature saves customers cycle time and reduces the scrap rate, ensuring better tool quality independent of operator skills.
Double corner radius enhancements: RN35 brings advancements in manufacturing complex geometry tools for various industries, enhancing the versatility of CNC tool production.
VRML import: The ability to import VRML models in RN35 gives users a strategic advantage by facilitating the easy import and matching of competitor tools.
For further information, please contact:
Amanda Bakun
Marketing & Communications Manager – Americas
248-497-1168
amanda.bakun@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, Korea 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’s prestigious awards for creative trailblazing toolmakers and talented female machinists provide opportunities to seize global spotlight with outstanding designs and skills
The Oscars of the cutting tool industry is back – #ANCATooloftheYear2024 is your chance to achieve global brand recognition as well as cash and a trip to Australia.
With a global digital audience of 8.1 million readers, the award has emerged as the most highly anticipated social media event within the cutting tool industry – bringing together talented machinists from around the world to showcase their creativity and expertise.
You can enter in one, or both categories: #MadeonANCA and Most Innovative Tool Design.
The winner of #MadeonANCA receives:
The winner of Most Innovative Tool Design receives:
“Over 50 years, ANCA has transformed the cutting tool industry with innovative thinking, driving us to continually invent and innovate. As we celebrate this milestone, we are inspired by our customers who share our ethos, creating spectacular designs with our technology,” said Patrick Boland, ANCA Co-Founder.
Submissions are open from May 15th to July 31st. Winners will be announced at IMTS 2024. Enter now at www.anca.com/Tool-of-the-Year
The Female Machinist Award celebrates women’s achievements in the tool and cutter grinding industry
ANCA’s Female Machinist Award returns for its second year in 2024, recognizing and honoring the outstanding achievements of female machinists in the tool and cutter grinding industry.
Women of all skill levels who are actively working with ANCA technology in the tool and cutter grinding industry are encouraged to apply. We are searching for individuals who are passionate about their work, demonstrate a commitment to excellence, and contribute to the advancement of the industry
Submissions are evaluated based on:
The winner of the Female Machinist Award receives:
Meaghan Ziemba, 2024 judge said, “Amidst the cutting-edge technology and innovation showcased at IMTS 2024, I am thrilled to shine a spotlight on women’s remarkable talent and contributions in the machining industry. The ANCA Female Machinist Award competition celebrates not only skill but also diversity, highlighting the vital role that women play in shaping the future of manufacturing. I am honored to have a chance to recognize their excellence and inspire the next generation of female machinists.”
Enter now at https://machines.anca.com/ANCA-Female-Machinist-Award
ANCA Tool of the Year 2024
The competition is based on the passion and the craft of tool making and celebrates our highly skilled tool grinding community. Customers can submit their favorite tool with the winners to be judged and announced live at IMTS 2024. There are two competition categories to recognize both the functionality and creativity of cutting tool manufacturers.
#MadeonANCA
The main prize goes to the winner of this category, where entrants will be judged on the form and performance of their cutting tool. The winner of #MadeonANCA receives a trip to ANCA’s headquarters in Melbourne, Australia and $10,000 AUD worth of parts, accessories or software. This amazing prize comes with access as an ANCA VIP to exclusive opportunities with our ANCA experts.
Most Innovative Tool Design
This category is for virtual tools. Entrants are encouraged to be creative and use ANCA tool design software to push ideas to their limits. The winner of the most innovative virtual tool will receive $10,000 AUD worth of parts, accessories or software.
Submissions are open from May 15th to July 31st 2024.
How to enter
Judging panel
The top five finalist tools will be judged on the following criteria:
2024 Partners & Sponsors
About ANCA CNC Machines
ANCA CNC Machines is a global leader in the design, manufacture, and service of advanced CNC grinding machines. With an illustrious history spanning over 50 years, ANCA is renowned for its cutting-edge technology, innovative solutions, and exceptional customer support. ANCA’s comprehensive range of products includes tool grinders, CNC grinding machines, software, and automation solutions, catering to diverse industries such as aerospace, automotive, medical, and general manufacturing.
Eight machines plus the newest ANCA Integrated Manufacturing System (AIMS) to be featured in Booth 237406, as the company celebrates its 50th anniversary and the opening of its LA Tech Center
At IMTS 2024, ANCA CNC Machines has much to offer the market and is also celebrating several highpoints in its storied history. In addition to the introduction of an advanced, high-precision tool grinder, the MicroX ULTRA, as well as the next generation of integrated manufacturing technology, AIMS Connect, ANCA will further highlight its commitment to offering the best-in-class solutions for tool grinding production, start to finish, with the celebration of its 50th anniversary in business (1974-2024) and the recent opening of its newest Tech Center in Temecula, California to serve its fast-growing West Coast market base.
ANCA, a global leader in CNC grinding machines and automated manufacturing technologies, celebrates its 50th anniversary, displaying its latest innovations at IMTS. As a mainstay in the precision tool industry, ANCA will showcase its commitment to excellence through new products, cutting-edge technologies and exciting business events, including its popular Tool of the Year and Female Machinist of the Year awards. The anniversary showcase addresses manufacturers’ needs for highest quality and lowest cost tools, plus freeing operators from repetitive and non-value-add tasks to make room for progress and creativity.
Pat Boland, ANCA co-founder, remarks, “For 50 years, ANCA has been on a journey to change the shape of the cutting tool industry. To celebrate our 50th anniversary, we look forward to meeting with our customers and partners at IMTS. As innovation has motivated us throughout our history, new products and developments will be at the center of our celebrations. ANCA’s future is exciting, we are focused on continuing to invent and deliver groundbreaking technology to help take cutting tool production into areas not previously thought possible.”
Edmund Boland, ANCA CNC Machines General Manager, adds, “IMTS is the major global event in this milestone year for our company, so it’s thrilling to showcase our latest products and technologies for high performance cutting tools produced with optimized efficiency and cost. Building on ANCA’s heritage of producing industry-leading software, the latest release of our signature ToolRoom software, RN35, takes cycle time optimization even further, elevating productivity – it’s the future of tool production.”
“ToolRoom and AIMS really pave the way for highly productive, autonomous production. Our investment in AIMS for connected and automated processes is our commitment to solving key challenges such as labor shortages and consistent production processes with smart, future-ready solutions. Our ULTRA technology has made a splash in the market, and now enables micro tool production, regrinding and small batch production with the MicroX and FX7 ULTRA,” notes Edmund.
50 years of innovation and “thinking outside of the box”
ANCA started with a minicomputer and teletype installed at co-founder Pat Boland’s home, followed by a CNC and then the design and manufacture of machine tools with co-founder Pat McCluskey. Throughout the years, ANCA has brought significant advantages to the industry with pioneering innovations like the first touch probe, soft axes and 3D simulation.
Naturally, software and automation are key highlights of ANCA’s anniversary innovation portfolio. The latest version of ANCA’s ToolRoom software, RN35, offers:
Experts will present these and other upgrades to IMTS visitors, plus further exciting news in CIM3D simulation software.
The Future of Automation in Tool Production IS here today…AIMS
The ANCA Automated Manufacturing System (AIMS) is a highly integrated, advanced automation system that brings together machining, metrology and materials handling plus data management in a leading-edge ecosystem for a lights-out production of tools used in myriad industries.
https://machines.anca.com/Products/Integrated-Manufacturing/AIMS (includes a video demo)
ANCA’s AIMS (ANCA Integrated Manufacturing System) is the smart manufacturing solution for cutting tool production, enabling manufacturers to connect, automate and create like never before. The modular system comprises hardware and software components for automated, closed loop manufacturing. AIMS Server controls production processes and AutoComp, the intelligent compensation module maintains part quality automatically, while the new AIMS Connect function covers job management.
With AIMS Connect, recently debuted at GrindingHub in Germany, visitors can experience firsthand the power of digital production control and modular automation, now available for existing installations. The system has proven in the field that it empowers manufacturers to explore new opportunities, products and features while maximizing productivity and quality.
AIMS is growing in popularity, as it enables shops of all sizes plus huge production departments the flexibility to integrate machining, metrology and materials handling into a unified ecosystem with full data capture and management capabilities.
Machines and technology for highest quality and lowest cost tools
ANCA’s GCX machine and gear tool technology is set to redefine the production of skiving cutters with a turnkey solution package. To address the complexity of gear tool manufacturing, this offering includes features for the design of gear cutting tools, manufacturing and integrated tool measurement, as well as providing the skiving machine setup parameters.
IMTS visitors will witness live how this configuration enables short setup times, simulation and monitoring, plus quality enhancing features like the ANCA Motor Temperature Control (MTC) and integrated balancing (iBalance) for unparalleled longtime grinding profile accuracy within +/-0.0015mm. This turnkey package facilitates easy entry into the gear tools sector while ensuring top-quality results.
ULTRA Technology: the platform for highest precision and micro tool work
Revolutionary ULTRA technology combines nanometer control, servo-controlled algorithms and mechanical stiffness upgrades to achieve unprecedented accuracy. The FX7 ULTRA and MicroX ULTRA demonstrate ANCA’s commitment to precision, enabling continuous batch production down to 0.03mm and setting new standards in tool manufacturing.
The MicroX ULTRA premiered at EMO 2023 and was released to the market at GrindingHub, giving micro tool manufacturers all the advantages of the ULTRA technology and ANCA’s Machine Intelligence in a unit tailored to this application. As the only micro tool grinder with nanometer control, optimized mechanical layout and axes travel, integrated tool measurement and progressive automation, this six-axis grinder is the ideal solution for volume production of tools down to 0.03mm.
Customer-centric solutions enable enhancements
Laser measuring on the EPX-SF
The new EPX-SF stream finishing machine was released to the market at GrindingHub. ANCA’s advanced edge preparation and surface finishing solution addresses productivity targets, delivers superior IP cutting tool performance and succeeds in precision-critical industries – in a design that’s ready to be integrated in automated tool manufacturing systems. With 11-axis automation and smart recipe fine-tuning, the machine is engineered by tool experts to optimize media utilization while providing precise edge control. The machine has the capability to reduce edge roughness to under 100 nm and refine edge radii to mere microns with controllable K-factor, achieving nano-smooth surfaces and micron-honed edges in record time.
The EPX-SF’s cyclic mode with pulse rotation serves as a potent defense against surface burrs and edge imperfections. With adjustable positive and negative angles, the EPX-SF spindle traverses the optimal cutting path, optimizing potential chip flow and reducing the surface roughness of the cutting workpiece. Within ANCA’s automation ecosystem, the EPX-SF seamlessly integrates into production lines, operating autonomously with robotic assistance round the clock for tool loading/unloading.
The CPX blank preparation machine is a prime example of how to include the voice of the customer in product development. Tool manufacturers around the world were asked and given their ideal solution for blanks with high material removal rates, application flexibility and integrated quality control. With features like statistical process control and top surface finishes below 0.2Ra, manufacturers can achieve high productivity at minimal cost with the CPX Linear. Some further application capability will be introduced at IMTS.
ANCA invites visitors to join us at IMTS Booth 237406 to experience firsthand the future of tool manufacturing.
For further information, please contact:
Amanda Bakun
Marketing & Communications Manager – Americas
ANCA MACHINE TOOLS
248-497-1168
amanda.bakun@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, Korea, Mexico 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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The Manufacturing Leadership Council (MLC) is the digital transformation division of the National Association of Manufacturers and, as part of its mission, annually seeks world-class manufacturing companies and key individuals who contribute to the technology. 2024 marks the 20th anniversary of this premier awards program.
On June 5, 2024, various companies and individuals who have made significant contributions to the digital manufacturing transformation in America will be recognized and winners named throughout 9 categories. Among the finalists for the prestigious Engineering and Production Technology award is the ANCA Integrated Manufacturing System (AIMS), a recently developed, fully automated grinding, gauging and materials handling system with workflow monitoring, full tracking and data management capability. It allows shops and production departments to achieve a lights-out manufacturing ecosystem in coordination with company control protocols. ANCA is an acknowledged global leader in this technology.
The ANCA Integrated Manufacturing System (AIMS) offers an open ecosystem that aims to connect, automate and create all steps in the production of cutting tools for a broad spectrum of industrial applications, including automotive, medical, aerospace, electronics and woodworking.
Manufacturing processes controlled by AIMS achieve higher machine utilization while maintaining consistently high tool quality. Thanks to sophisticated tool measurement and compensation strategies, scrap is reduced and costs per tool are significantly lowered. Comprehensive reporting and intelligent insights supported by machine learning provide complete visibility into all aspects of operations.
AIMS is designed as an open system and allows the integration of third-party machines and workstations, plus AGV’s for material transport.
AIMS Connect
Connects all operations that are carried out to manufacture cutting tools. The central AIMS server controls compliance with the processes that a tool passes through during its manufacture. It checks whether the various process steps are being carried out and takes action if the process is not being executed to preset standards. An information system guides employees to carry out manual process steps.
AIMS Automate
Automation of connected operations through the use of robots such as AMR for transfer or cobots for palletizing tools. A self-optimizing job scheduler ensures an ideal supply of pallets to the machines or provides individual tools for measurement.
AIMS Create
Create individual and customized workflow for the tool, based on linked operations. Workflows and processes can be described and stored with ISA-95 compliant recipes. Job orders are transferred to production via the link to recipes and the creation of work requests. Work cells, work units and assets are managed just as easily as grinding programs and grinding wheels. AIMS Create provides the cockpit for creating processes. Thanks to the state-of-the-art web application, this can be done on almost all smart devices and computers.
ANCA president for North America, Russell Riddiford, comments, “ANCA is very proud to be in the running for this award from the MLC. We support the digital transformation effort in both our machine building and motion control operations, as we seek to provide our customers the machines and software needed to move their companies in this exciting new direction, within industries of all kinds.”
The 2024 MLC Awards feature nine categories to recognize company achievements in AI and Machine Learning; Collaborative Ecosystems; Digital Network Connectivity; Digital Supply Chains; Engineering and Production Technology (the category in which AIMS is a finalist); Enterprise Integration and Technology; Operational Excellence; Sustainability and Circular Economy; plus Transformational Business Cultures. Additionally, individuals are entered into the Transformation Leadership and Next-Generation Leadership categories. The finalists represent a cross-section of industries, comprising global multi-nationals and start-up companies. The awards are judged by distinguished individuals from across many industrial sectors.
ANCA is based in Melbourne, Australia with its North American headquarters in Detroit, Michigan, where it operates a full tech center, including machines and training for its customers.
For further information, please contact:
Amanda Bakun
Marketing & Communications Manager – Americas
248-497-1168
amanda.bakun@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, Korea 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, a leading innovator in precision grinding solutions, is thrilled to announce the grand opening of its new state-of-the-art Technology Center in Korea. ANCA has offered local sales and service to customers across diverse industries for more than 30 years in the Korean market and opening the new facility is a significant milestone for the company as it expands its presence in the Asian market.
Jake Farragher, General Manager of ANCA Asia, says, “ANCA’s newest technology center is a commitment to our customers in Korea. This investment in our global infrastructure enables our team to deliver premium sales and service support to this important and growing market. We understand the importance of offering customers local support and at our new facility we can showcase the capability of our flexible grinding machines, world-leading software, and market-first automation solutions.”
“Thanks to our long-standing partnership with SH International in Korea, we have a legacy of innovation with our customers in the market, and our local team at our new ANCA office is poised to facilitate our customers’ success into the future.”
“We are excited for our new center to serve as a hub for grinding excellence, innovation and collaboration, confirming our position as a global leader in the tool and cutter grinding industry and medical tools industry.”
For 50 years ANCA has committed to providing cutting-edge grinding solutions worldwide, and ANCA Korea, located near Seoul, is equipped with the latest technologies, such as ANCA’s ULTRA technology with nanometer resolution control.
The demonstration facility provides the ULTRA experience with ANCA’s MX and FX ULTRA machines, as well as automation solutions with ANCA’s Integrated Manufacturing System (AIMS). The facility additionally includes support and training services.
The grand opening event was attended by key stakeholders and customers, industry partners, and local dignitaries.
Celebrating 50 Years and Innovating the Future with ULTRA Technology
Pat Boland, ANCA Co-founder said: “50 years ago, Pat McCluskey and I did not anticipate ANCA to be what it is today. We embarked on a business journey that felt in hindsight like stepping onto a treadmill, with our customers driving the speed. Yet we have not only kept pace with the market, we’ve surged ahead, introducing cutting-edge innovations. I am proud of the technology we are still releasing, such as the ULTRA and GCX packages and the many innovations that underpin these product releases.”
Edmund Boland, General Manager of ANCA CNC Machines and son of Pat Boland, highlighted ANCA’s agility as a privately owned company, enabling swift decisions to support ANCA’s people and customers.
“ANCA has always endeavored to stay ahead of the curve, anticipating market trends, and delivering cutting-edge solutions that enable our customers to thrive,” Edmund said. “With 50 years of innovation behind us, our product and technology portfolios are perfectly positioned to meet the challenges of the future.”
ANCA’s 50th anniversary marks a half century of the company’s relentless pursuit of excellence and commitment to pushing the boundaries of precision grinding technology. The ULTRA machine range, with its nanometer technology, allows customers to produce the best tools in the market through superior accuracy, quality and surface finish.
The ANCA Integrated Manufacturing System (AIMS) is a groundbreaking advancement in grinding technology. AIMS connects, automates and creates all processes required to manufacture a cutting tool, ensuring maximum accuracy and consistency while minimizing downtime – enabling end-to-end digitally connected and automated production systems for cutting tools.
For media inquiries or more information, please contact:
Sepideh Zandieh
Acting Group Communications Manager
sepideh.zandieh@anca.com
Phone: 0439 316 131
About ANCA:
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, Korea 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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Truly optimizing medical machining often requires specialized cutters, and there’s no better model for designing and grinding them than ARCH Cutting Tools, headquartered in Warren, Michigan, USA.
Take the task of machining a polyethylene tibial insert. As ARCH Cutting Tools’s northeastern regional director of operations, Jim Gray, spelled out, this has almost always been done with a single, flat blade mounted in a holder so as to maximize the shear angle. But, said Gray, this design often produces lines on the surface, or an “orange peel” effect, due to burning, as it doesn’t cut the polyethylene as cleanly as desired. A straight flute design also impacts the part with a lot of force on each rotation.
Gray’s team instead used their knowledge and ANCA’s programming software to create a unique 1½” (38.1 mm) diameter 3-flute carbide helical cutter with high shear and multiple radii along the profile. They grind it on an ANCA MX7 machine, using a dozen wheels to create a mirror finish and a cutting edge “sharper than a razor blade,” as Gray described it. “You need a very sharp edge to cut the plastic perfectly cleanly. Even a diamond grain that goes through cutting edge, leaving a tiny chip, will show up in the insert. We inspect these tools under a microscope to confirm the edge is crisp and clean.” Gray added that their helical design also distributes the cutting forces, in contrast to a straight flute. In sum, the ARCH Cutting Tools solution delivers an outstanding part finish, higher throughput, and longer tool life.
Replicating perfection
Gray also pointed out that in addition to the tool design assistance derived from ANCA’s programming software, which includes full 3D simulation, the ToolDraft feature enables detailed documentation for process control. “Instead of relying on 2D drawings on the shop floor,” Gray expounded, “ToolDraft gives us the ability lay out every aspect of the tool and the required grinding wheels. One page covers the gullet shape, with the roughing wheel, the finishing wheels, and any information related to fluting. The next page covers profiling, again with all the wheel shapes and data, and the required clearance angles, land width, and other tool geometries. And so forth for the end face. We also add notes to each drawing to provide detail on what’s pertinent to this tool…what really makes it work.
“We love what ToolDraft does for us. Because if all you put out on the floor is a 2D drawing with an outside diameter or shape of the tool, the operator can say ‘This tool is good. It’s to print,’ when in reality, the body’s thin and the rake is not right. There are so many things that go into why we designed a tool a certain way, that if we don’t get complete information to the operator, everyone can have a different opinion about what constitutes a correct copy. We’ve promised our customers that no matter what person and what machine grinds their tool, they’ll get the same tool every time. And the only way we can keep that promise is with the documentation we’ve created with ToolDraft.”
Gray added that although it’s possible to grind such tools with a ball screw driven machine, it’s much easier to produce them with ANCA’s newer linear motor technology. “Linear motors have definitely changed our world when it comes to finishes and transitioning for profile cutters,” he explained. “They make it easier to grind the profile, especially with a tool like a condyle cutter, because multiple radiuses go up and over the edge. If you’re grinding in just one direction, a ball screw machine is fine. But if you go up and over and you need to produce multiple radiuses in the front and multiple radiuses in the back, that little backlash or wear in the ball screws will force you to fight until you get it all settled and tweaked in. Whereas with a linear motor machine, it’s just true from the start.”
Not all ball nose end mills are equal
Moving on to hip stems, Gray said machining up and over these parts requires ball nose end mills in which the radius and its transition to the OD must be perfect. The end face gashing must also meet exactly at the center. “Any mismatch in the center of the ball nose will put a line in the hip stem, and that’s not acceptable.” Any error in the radius will create geometrical distortion in the part profile, he added. “We scan that whole radius to ensure it’s correct.”
Hip stems have generally been made of titanium and cobalt chromium, Gray explained. These materials are challenging enough, but Gray said the new 3D printed titanium alloys from leading medical suppliers are even more difficult to machine. They’re porous, to facilitate integration with the patient’s bone, which essentially guarantees an interrupted cut. The material is also highly abrasive. Thus, minimizing tool changes and increasing manufacturing speed to achieve an acceptable level of efficiency requires an engineered solution from the likes of ARCH Cutting Tools.
Fast turn-around for custom tools and regrinds
In another example of ARCH Cutting Tools coming to the rescue, a customer suddenly ran out of an imported, replaceable head, keyseat cutter during production. ARCH Cutting Tools delivered a custom engineered, solid carbide version, with coating, in under 48 hours. In another case, ARCH Cutting Tools created a multi-step counterbore that combined 6 different operations in one tool for machining titanium and superalloys. Both examples again point to the power of combining experienced grinding professionals with ANCA’s software and machines to produce high quality medical devices that improve a person’s life.
Regrinding is yet another such area. Not only does ARCH Cutting Tools reliably return used tools to new condition, Gray said there are numerous cases in which they’ve actually improved upon the original tool. “One of our bigger medical customers was buying a faceted drill from one of the world leaders in cutting tools,” recalled Gray. “The drill was being used on titanium, and we put a roll point on it and made some other changes to the geometry that made the reground drill run better than the new tools.”
In this context, Gray praised ANCA’s integrated laser to automatically check for and correct errors in tool runout, and ANCA’s probing capability. In addition to probing coolant holes to ensure proper tool orientation for a regrind, Gray said ANCA makes it easy to probe the entire point profile to enable K-land grinding, a notoriously fiendish task. “You adjust how many points you want along that edge,” Gray expounded. “And if you’re manufacturing the tool, you can probe the profile once and store that data. From then on you don’t have to re-probe to produce a good K-land, until wheel wear becomes a factor.”
Wheel wear would cause the K-land to vary, Gray added, but he again pointed to the ease of re-probing the profile to make adjustments, plus the existence of wheel probes on their ANCA machines. “The wheel probe is absolutely awesome, because it takes human error out and it’s really accurate,” said Gray. The older method uses a measuring bar, and Gray recounted that operators all too often forgot which orientation they should use and destroyed an expensive wheel.
The science of productivity
As Gray put it, ARCH Cutting Tools has to be fast to be competitive, and that requires a process that’s “down to a science.” Things like matching different wheel specifications to the diverse tool materials they have to grind, proper coolant placement, and adaptable tool support. In the latter category, Gary praised ANCA’s P-axis traveling steadyrest and said that for some challenging applications they use an Arobotech, which grips the tool at 3 points and adjusts to changes in diameter as the P-axis moves below the grinding wheel, providing support. “These are all things that give us an edge to be able to do these instruments,” Gray concluded. “They virtually eliminate runout and allow us to run faster.”
But Gray reserves his highest praise for ANCA’s simulation software, calling it “the greatest tool…We used to go to the machine blind. We’d end up scrapping blanks to figure out these complex tools right at the machine. With ANCA’s software, you create complex tools before going to the machine and you’re close to perfect when you run your first part.”
From creative tool design, to efficient machine setup and operation, to tight quality control, ARCH Cutting Tools consistently exemplifies what it takes to meet the challenges of machining medical components.
Images
Condyle Cutter.jpg
ARCH Cutting Tools produces a unique 3-flute carbide helical cutter that delivers unequaled part finish, higher throughput, and longer tool life in machining a polyethylene tibial insert
Ball Nose End Mills.jpg
These ball nose end mills (for machining hip stems) feature a perfect transition from the ball radius to the OD, and an end face gash that meets exactly at the center
Key Cutter.jpg
ARCH Cutting Tools delivered this custom engineered, solid carbide keyseat cutter, with coating, in under 48 hours
Multi-Step Counterbore.jpg
ARCH Cutting Tools created this multi-step counterbore to combine 6 different operations in one tool for machining titanium and superalloys
Carbide Trepan Cutter.jpg
This complex trepan cutter was created to meet an urgent need for cutting non-ferrous material used in respiratory equipment. The tool features a very fine finish and leaves no marks on the part. Gray reported that “the customer was ecstatic”
For further information, please contact:
Amanda Bakun
Marketing & Communications Manager – Americas
248-497-1168
amanda.bakun@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, Korea 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