Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
ANCA’s innovative job management and production control software improves quality and reduces cost for tool manufacturers
ANCA CNC Machines, a world leader in CNC grinding technology, announces the launch of AIMS Connect, a job management and production control software designed to benefit tool manufacturing by optimizing processes, enhancing quality, and reducing costs.
In a highly competitive industry where efficiency is key, AIMS Connect addresses the growing demand for smarter, more streamlined operations. As a smart solution to integrated manufacturing, AIMS Connect has the potential to boost productivity by 20% or more, setting a new standard for excellence in the sector.
“AIMS Connect offers a flexible and customizable solution for tool manufacturers looking to increase efficiency, improve quality, and reduce costs,” said Steffen Kluth, ANCA Product Manager.
“Our goal is to make digital manufacturing accessible to everyone, and with AIMS Connect, we are helping our customers embark on a journey toward a fully integrated smart factory, step by step.”
Key features and benefits of AIMS Connect:
AIMS Connect is an accessible entry point into digital manufacturing, emphasizing the logical connection of machines and systems. It delivers transparent and verifiable processes, featuring a worker guidance system that informs employees about production stages and task schedules. This system frees skilled workers from repetitive tasks, allowing them to focus on areas where their expertise is most valuable. Each tool is meticulously described in a job order process, ensuring consistent quality through defined compensation strategies and logical frameworks.
Building on the foundation laid by AIMS Connect, ANCA’s AIMS Automate transforms tool manufacturing into a fully integrated smart factory. AIMS Automate autonomously adapts to production changes, ensuring smooth operations even during disruptions. With the mobile robot, AutoFetch, it effortlessly manages tool pallet transfers, from raw materials to finished products, maximizing efficiency and minimizing downtime.
To learn more about AIMS Connect, visit www.anca.com/AIMS-Connect
For further information, please contact:
Amanda Bakun
Marketing & Communications Manager – Americas
248-497-1168
amanda.bakun@anca.com
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.
Stephanie Chrystal from Sandvik Coromant USA takes first place in the ANCA Female Machinist of the Year award
The 2024 ANCA Tool of the Year Awards, now in its seventh year, celebrated excellence in the cutting tool industry at an awards ceremony during IMTS in Chicago. This year’s event, coinciding with ANCA’s 50th anniversary, highlighted the continued creative design and manufacturing prowess that continues to wow judges in ANCA’s prestigious awards.
Werkzeugschleiferei Krämer GmbH earned the top honor in the “Made on ANCA” category with their groundbreaking tool. Their innovative design makes exceptional use of iGrind operations and advanced profile software features, such as layers, pivot editor, and 3D hook compensation. This results in outstanding accuracy, with the tool closely aligning with its intended specifications and delivering exceptional profile precision. The contest has highlighted the ability for a smaller company to gain recognition on a global stage and experience a dream come true moment.
In the Virtual Tool Category, XGE impressed the judges with a creative and technically sophisticated entry inspired by the renowned attractions of the Garden Expo Park in Xiamen, China, including the Moonlight Ring and Xinglin Pavilion. Their design integrates iGrind software with profile and end-face operations, and is brought to life by importing 3D models into CIM3D software.
This year also saw Stephanie Chrystal from Sandvik Coromant USA honored with the Female Machinist of the Year award. Launched in 2023 to promote diversity and provide role models for women in the cutting tool industry, this award reflects ANCA’s commitment to fostering an inclusive and supportive environment. Stephanie was recognized for her exceptional problem-solving, leadership in expanding and training her team, and her ability to deliver outstanding results under pressure.
Pat Boland, ANCA Co-Founder, remarked, “For 50 years, ANCA’s software has set industry standards, enabling Tool of the Year entrants to push the boundaries of what’s possible. Our technology not only meets the highest precision demands but also showcases the creativity and capability of our customers, highlighting truly innovative designs.”
Torsten Mende, Managing Director at Werkzeugschleiferei Krämer GmbH said, “This tool is used by one of our customers to create a profile in a gripper for molded parts. Previously, this contour was produced using a 3D milling process. The customer’s tolerance specification is +- 0.01mm. The program was created in ToolRoom RN32/33 and ground using RN34.1 on an FX7.”
“As a smaller company, it is a great honor to participate in this competition. We have been grinding tools on ANCA machines since 1999. The sophisticated software enables us to grind complex geometries and to monitor them during the process, giving our customers a competitive advantage. For this reason, we extend our heartfelt thanks to ANCA for the excellent symbiosis of software and machines.”
Chen Jianming, R&D Engineer at XGE expressed his gratitude for winning the Most Innovative Award, saying, “This award is a high recognition of our team’s innovative capabilities. Our design was inspired by the ‘Moonlight Ring’ and ‘Xinglin Pavilion’ of Xiamen Yuanboyuan, symbolizing the harmony of nature and humanity. The egret in the design, replaced by our company logo, represents both a tribute to our brand and a leap in tool innovation.”
“Competing with industry elites worldwide has been an honor. This recognition reflects XGE’s innovative strength in the global tool industry, and we will continue to deepen R&D efforts, driving progress alongside our global peers for a brighter future.”
ANCA Female Machinist Award winner Stephanie Chrystal said: “It is a privilege to be a part of Sandvik Coromant who is paving the way for women to be recognized for their contributions to the industry. I am honored to have been chosen out of all of the extraordinary women in this field as the Female Machinist of the year for ANCA. I hope to be an encouragement to women looking for guidance on their journey for meaningful careers. I am excited to see ANCA continue to honor women in this industry and inspire other companies with this award.”
The ANCA Tool of the Year Awards 2024 celebrate the passion, creativity, and expertise driving the cutting tool industry forward. ANCA remains dedicated to supporting innovation, excellence, and diversity, ensuring a bright future for precision tool manufacturing.
Made on ANCA
Winner: Werkzeugschleiferei Krämer GmbH
Their tool demonstrates the innovative use of iGrind operations, advanced profile software features, and achieves exceptional accuracy.
Second Place: ARCH Cutting Tools
Their “Master Mill Combo Tool” continues to lead in multifunction cutting tools with exceptional accuracy, utilizing iGrind software’s advanced profile operation features.
Third Place: Precision Tool Company
A versatile tool combining a drill, reamer, and chamfer, optimized using iGrind software for performance and functionality.
Virtual Tool Category
Winner: XGE
Their simulation, inspired by the Garden Expo Park attractions, creatively uses iGrind software and 3D modelling for a striking design.
Second Place: Zakłady Mechaniczne Kazimieruk
Their simulation of the Olympic flame represents the enduring spirit of the Olympic movement, created with extensive iGrind software use.
Third Place: SST Cutting Tools
Their “LINGAM” simulation symbolizes the Hindu God Shiva, showcasing creative use of iGrind software for profile, cross-section profile, and ripper form relief operations.
ANCA Female Machinist of the Year – 2024
Stephanie Chrystal – Sandvik Coromant, USA
ANCA Female Machinist of the Year Finalists
Roksana Grodowska – CNC Progresja Sp. z o.o., Poland
Jessica Sennott – Gorilla Mill, USA
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.
ANCA’s legacy of innovation is shaping the future of technology for lower cost, higher quality cutting tool production
ANCA at IMTS not only celebrated five decades of innovation but 35 years of successful operations in the USA and exhibiting the first machine ever bought in the U.S., a refurbished TG4, was a nostalgic nod to ANCA’s technological journey. Against ANCA’s latest solutions, this was a striking visual display of the company’s journey – from early innovation to being a future-ready leader in the tool and cutter grinding industry.
The North American debut of the EPX-SF, ANCA’s advanced stream finishing machine, became the centerpiece of attention. The EPX-SF’s technology offers consistent micro-cutting-edge preparation, controllable nano-smooth surface finishing, and seamless automation and it sparked widespread interest. Its unmatched ability to increase tool life, precision, workpiece quality and cost-effectiveness redefined expectations for the future of tool finishing.
Producing the highest performance cutting tools for lower cost with ANCA technology
ANCA CNC Machines General Manager, Edmund Boland said: “Given the competitive world that we are living in and the global market that we are challenged with…it is important that we allow our customers to get the best value out of our machines. So, our focus on lowest cost tools is critical and we have a number of technologies for this, AIMS being one of them.”
The manufacturing industry is embracing smarter, more connected solutions and seeking solutions partners. Revealed to the market in the Americas for the first time was AIMS Connect which is the production control of the ANCA Integrated Manufacturing System (AIMS) and enables the integration of different machines, offering full control over all processes and workflows. AIMS Connect’s smart job management and production control solves common challenges to increase productivity, reduce errors, and tackle labor challenges while increasing machine utilization and reducing the cost per tool.
Along with ANCA’s emerging technologies for reducing set up times of machines, software solutions to analyze the production output of machines, and how to optimize this to bring down the overall cost of production – smarter ways to produce quality tools for lower cost are meeting the industry demands for data-driven decision making, cost reduction and efficiency. ANCA is also formulating solutions for reducing the air consumption of machines which not only has a significant impact on machine running costs but also contributes to more sustainable manufacturing processes.
ANCA’s latest range of ULTRA machines are engineered with nanometer feedback resolution to dramatically improve surface finish and accuracy of cutting tools. With software developments, such as the new features of ToolRoom RN35 enabling complex geometries, customers have the flexibility to design high performance, higher accuracy and, if needed, custom cutting tools with specific applications. High performance tools produced with ANCA ULTRA technology deliver batch consistency from tool number one to one thousand.
A celebration of industry
ANCA’s 50 years in the grinding industry is thanks to the partnerships and loyal customers that have accompanied its journey. The 50th anniversary milestone was celebrated with partners, customers, and industry at a gala dinner during IMTS.
IMTS also provided the stage for the announcement of the winners of the ANCA Tool of the Year and Female Machinist awards which are consistently supported by industry and partners. The 2024 winners Werkzeugschleiferei Krämer GmbH (Made on ANCA) and XGE (Virtual Tool) once again demonstrated the possibilities of creative design, precision and craftmanship with today’s technologies. Witnessing Krämer, a smaller company take out a competition at a global level was a dream come true for taking precision to the world stage.
Stephanie Chrystal from Sandvik Coromant USA was awarded the ANCA Female Machinist of the Year for her exceptional problem-solving, leadership in expanding and training her team, and her ability to deliver outstanding results under pressure.
Industry collaboration is pushing innovation further and offering unique solutions to customer challenges. ANCA’s new partnership with Tetralytix introduces sophisticated digital interface solutions that reduce tool design and development time with Toolyzer. This partnership empowers manufacturers with the most advanced and powerful software tools available.
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.
Introducing sophisticated digital interface solutions that reduce development time and cost
ANCA, a market leader in CNC grinding machines who is this year celebrating 50 years of innovation, and Tetralytix, a developer of simulation software for superior metal cutting technology, are pleased to announce their strategic collaboration in the field of virtual design for cutting tools.
This partnership leverages the combined expertise of both companies to offer unique capabilities for the development of superior precision cutting tools and enhancing metal cutting technology.
The collaboration integrates ANCA’s expertise in virtual modelling of tool geometries and industry-revolutionizing CIM3D tool verification software with Tetralytix’s expertise in technological analysis through Toolyzer, a simulation tool for designing and optimizing cutting tools. An interface between CIM3D and Toolyzer will enable cutting tools to be developed faster and more cost-effectively, providing significant benefits to tool manufacturers.
“ANCA welcomes this partnership as it signals our commitment to empowering our customers with the most advanced and powerful software tools available. By working together, we’re ensuring that cutting tool manufacturers have everything they need to innovate, optimize, and stay ahead in a rapidly evolving industry,” said Martin U. Ripple CEO at ANCA.
Dr.-Ing. Arne Mücke, Managing Director, Tetralytix, added, “The partnership with ANCA is a significant step towards creating added value and competitive advantages for our customers. The cooperation will make the benefits of digital cutting tool development visible in an unprecedented way.”
“ANCA understands the constant challenges for tool designers for achieving longer tool life and the demands to cut newer materials. With this partnership, our customers can seamlessly design a tool and access cutting analyses even before the first test cut. When ANCA first introduced CIM3D, customers couldn’t believe the sophistication of the solution and this is now the next revolutionary step in reducing tool development time and cost,” said Santosh Plakkat, Product Manager, ANCA.
This strategic cooperation is a significant step forward for the development of cutting tools, offering considerable cost advantages for both standard and special tools. The reduction in time-consuming, manual work to prepare digital tool models for simulation also significantly shortens development times.
Untapping development potential to optimize tool design
Testing multiple tool prototypes is time-consuming and cost-intensive, ANCA and Tetralytix recognize that the time has come to leverage this potential with the help of a continuous interface from tool modelling to simulation.
The tool is designed using ANCA’s iGrind software and can then be used seamlessly in Toolyzer for analysis.
Within a brief time, performance conclusions can be drawn, and recommendations for improving the tool geometry can be derived. This enables users to determine whether a tool prototype meets the requirements even before it is produced for the first time.
About ANCA
ANCA is a market-leading manufacturer of CNC grinding machines. The company was founded in 1974 in Melbourne, Australia, where it still has its global headquarters. ANCA CNC grinding machines are used for the manufacture of precision cutting tools and components in a wide range of demanding industries including cutting tool manufacturers, power generation, woodworking, automotive, aerospace, electronics and medical.
About Tetralytix
Tetralytix is a leading provider of simulation solutions for the machining industry. Tetralytix develops practical software solutions based on in-depth knowledge of production engineering and computer science as well as practical experience in machining. With Toolyzer, users can optimize both cutting tools and entire machining processes quickly and easily. In addition to complicated multi-axis processes, special processes and procedures such as gear skiving and gear hobbing are also supported.
For further information, please contact:
Amanda Bakun
Marketing & Communications Manager – Americas
248-497-1168
amanda.bakun@anca.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.
