Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
Partnering with ANCA gave a boost of confidence to the Bengaluru-based company, which extensively uses ANCA machines to make precision cutting tools, prepare blanks, and regrind tools
From a conventional machine operator to the founder of a company that manufactures high-precision cutting tools that employs over 30 people. Sounds like an unbelievable success story? Well, this perfectly describes the journey of Kumar A., a passionate cutting toolmaker from Bengaluru, India. Kumar’s cutting tool manufacturing company, SST Cutting Tools, relies on high-end grinding machines from ANCA to manufacture customized tools for aerospace, defense, and automotive applications. Here’s how it all began…
Journey of growth with ANCA
Kumar started SST Cutting Tools in the middle of the global recession in 2008 with a single tool and cutter grinding machine. The company now has four ANCA machines and many delighted customers.
“I started with one conventional machine and used to regrind tools. My work was received well in the industry and soon I added more conventional machines and operators, but we were not able to speed up the process and procure orders that needed high precision. That’s when I thought of investing in a CNC grinding machine,” says Kumar.
“I had absolutely no idea about CNC grinding machines, as I had never operated one before. All I knew was that I wanted the best one. I evaluated several global brands and found ANCA to be best suited for my application. More than anything, I needed a user-friendly machine, as none of the team members, including me, had any experience with CNC grinding machines,” adds Kumar.
Enhanced output, efficiency, accuracy
SST Cutting Tools added an ANCA FX3 with linear scale technology, which can produce tools with an accuracy of three microns. “We were amazed by the machine’s output and speed. Our efficiency and accuracy went up. This provided a boost to our much-needed confidence and now we’re out in the market looking for precision cutting tools requirements,” says Kumar.
As orders increased, the company grew. A plot of land was purchased and construction of its factory began in 2016. “We were small players, but I always maintained one thing – never compromise on technology. Moving to the new factory in 2017, we added a Zoller tool inspection machine, which could measure any kind of tool profiles with the accuracy of one micron,” he explains.
The company started taking precision cutting tool orders, with many happy customers. “We received several repeat orders and a lot of new inquiries. We needed to enhance our efficiency further by reducing the setup time. I discussed this challenge with the ANCA team, and they suggested the ANCA FX5 fully automatic linear machine. I saw the demo, observed all the features, and opted for it in March 2018. It was the perfect match for my requirements. The machine is equipped with a 2-wheel changer that helps us reduce the number of setups,” informs Kumar. SST added one more advanced version of the ANCA FX5 in 2019. It is fully automatic and provides high accuracy and an in-process measuring camera.
It’s all about meeting requirements
One of the most important and challenging activities for cutting tool manufacturers is to prepare precision blanks with close tolerances. The right blank can define the overall cutting tool. “With time, customers have also become very demanding. They want a cost-effective and accurate product on time. However, in 2021, the volume of orders we had in our current setup needed an upgrade, especially for the preparation of blanks. I wanted to reduce the blank preparation time with 100% accuracy and decided to opt for the ANCA 4 Axes CPX blank preparation machine,” says Kumar.
The CPX Linear is capable of achieving a surface finish better than 0.2Ra with a run out of less than two microns. “With the addition of a CPX Linear, we can make tools in a few hours, thereby meeting urgent requirements,” he adds.
Focus on quality, accuracy for applications
Talking about his vision, Kumar says, “I want to be a world-class manufacturer of cutting tools and provide services to the customer’s speculated time with zero defects and a high degree of accuracy.”
The company specializes in customized cutting tools such as drills with sizes ranging from Ø1 to Ø25 with the L/D ratio of Ø X 12; endmills with sizes ranging from 0.8mm to 25mm and 2flutes to 12flutes; and reamers and holemills, with sizes ranging from 1mm to 25mm, within the tolerance of 0.002 mm. Additionally, the company works with threading tools, boring tools, ID and OD grooving tools, pico bars, and angle grooving tools.
Kumar comes from a very humble background. At the age when most children enjoy their school days, he worked part-time to make ends meet. At the age of 18, Kumar started working as a machine operator in one of the job shops in Bengaluru, the IT and manufacturing hub of India. Motivated to learn more, he took up a Diploma in Mechanical Engineering in the evenings.
“I wanted to learn the fundamentals of mechanical engineering, the functionality of the latest machines, and various advantages of grinding applications. I used to work for 10-12 hours during the day and attend classes in the evening,” he recalls.
SST Cutting Tools’ drive and versatility is also highlighted in their multiple #ANCATooloftheYear entries, showcasing their skill and creativity with ANCA software as well as an enthusiastic commitment to the community of cutting tool manufacturers.
Proudly highlighting one of his projects, Kumar says, “When COVID cases were at their peak, we did our small bit by helping the Indian government make ventilator parts quickly with the help of our ANCA machines. Since the project was related to medical equipment, the accuracy and surface finish needed were high and the turnaround time was short. We acted quickly, gathered all our technical staff and halted all our other projects. I am glad we were able to play a small role in the fight against Corona.”
More growth ahead at home and abroad
After close to 15 years of operations and many happy customers in India, the company is now eyeing exports, and expanding their infrastructure to accommodate more machines. “We are looking forward to adding more ANCA machines in the coming days,” says Kumar.
He adds, “We have big plans for the future. However, it is worth looking back at the journey and remembering all that has worked in our favor. Choosing ANCA was one of the best decisions in my career. ANCA has not only enhanced the efficiency and productivity of SST Cutting Tools, it has also given our confidence the much-needed boost.”
“The ANCA team is well-versed with the technical know-how and their service is nothing short of excellent. Whenever we faced any technical hurdles, the team would quickly respond. We never had to face any major delays in our projects thanks to their prompt support. In fact, there have been instances of executives from ANCA flying down to Bengaluru from Australia only to help us better understand the machine’s features. I am looking forward to working with ANCA; they are our growth partner and not just a vendor,” concludes Kumar.
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 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.
Using MX7 Linear, the Canadian company helps automotive company make tools within spec and regrinds 1,100-1,500 tools each year
Founded in 1987 by Clorindo Mattei, Clortech Precision Cutting Tools is a family business with wife Carmela handling bookkeeping, while son Patrick is the vice-president of production and sisters Emilia and Mena are the managing director and quality assurance director respectively. The company is a Montreal manufacturer of custom precision tools that sells to various industries including aerospace, recreational vehicles, rail and automotive. Products include shafts, gauges, broaches, bushings, extra-long reamers, special diameter formed end mills, special contouring tools.
In the ‘80s and ‘90s, business was made up entirely of aerospace customers. However, events like 9/11 and the global financial crisis, showed how temperamental that sector could be and prompted diversification beyond it. With its high-performance holemaking tools, including drills and special end mills, Clortech expanded into the automotive industry. It also provides drills for rail and tie installers, as well as tools (reaming, milling and holemaking) to help the Canadian Armed Forces in the maintenance and overhaul of tanks and other military equipment. Besides MRO tooling services, they also offer regrinding and reconditioning services to old tools and kit inventory services. Their 360° Approach is aimed at companies that don’t have the necessary resources or workforce to make their own tools, while the AOG 911 service produces or modifies aircraft tools with the shortest lead times.
Currently, the job shop is equipped with CNC lathes, milling machines, cylindrical grinders, tool and cutter grinders and six 8-axis NC ANCA grinding machines (two TG7 Plus grinders, two TX7 machines and two TX7 Linear machines).
While Clortech uses all of its ANCA machines, Patrick Mattei pointed out that more complex/ higher volume parts are manufactured on the ANCA MX7 Linear due to its speed, precision and software which is more detailed than older machines. The machines are used to make round tools such as: endmills, drills and reamers. Most are solid carbide, while some have carbide tips. All tools are manufactured to customer specifications.
Discussing what features stand out on the MX7 Linear, Patrick mentioned the Toolroom software, which allows them to simulate a tool before making it. This greatly reduces scrap. The program’s integrated 3D graphics make on-machine programming easy, as grinding simulation is performed after any parameter change providing instant feedback. When they are satisfied with the geometry, operators take that program and put it on the machine to run it. “The simulation software and offline programming is a very strong feature allowing the machine to run while [operators] work on other programs for different parts that they will be running later. The versatility with lots of axes allow them to make the most intricate type parts.” The importance of the software is further evidenced by the fact that raw materials are very expensive and hard to come by so the ability to run a 3D model of the tool beforehand makes a big difference. Most of the company’s tools are designed from A to Z, offering a turnkey solution. The 3D model can be taken to the customer, and they can simulate the cutting conditions in their machine tool. Thus, Clortech can give the customer something before the actual part is delivered.
Recently, Clortech helped a customer in the automotive industry who was making dovetail type cutters. These cutters require an extremely high degree of precision, and the company couldn’t maintain the tight tolerances. Clortech received the parts and reground them using the MX7. When completed, not only where the tools done within specification but the “product was better than what the customer was making themselves.”
Before they started using ANCA, Patrick mentioned they were doing a lot of work on conventional machines. Challenges they encountered included capacity and precision. The machines ran continuously but couldn’t match the speed and efficiency of a CNC grinder. Another challenge was having enough people to work the machines. With the integrated automation on ANCA machines, one operator can run more than one machine at once, making the company more profitable and efficient. Additionally, Clortech used to regrind 500-1,000 tools conventionally each year. With CNC machines, they are regrinding 1,100-1,500 each year. This is an efficiency improvement of 1000%. Although the set-up time on a CNC machine is longer, the output efficiency outweighs the time it takes.
The company’s first ANCA machine, a TG7 Plus Grinder, was purchased in 1997 after meeting Russell Riddiford at a trade show. At the time, Clortech was looking to purchase a machine and they chose ANCA because of its software features. Patrick believes ANCA machines symbolize efficiency and reliability, as the first one he purchased is still running smoothly.
Patrick considers ANCA “part of the family” and enjoys speaking to the same people who know the company and his needs. He can call ANCA and there is always someone he can talk to regarding software issues, and everything is always resolved in a timely manner. He added that “… if we want to do something on the machine that hasn’t been done before, ANCA can even develop software for the product. They are always solution focused and working to figure out how to resolve any issue.”
For further information, please contact:
Amanda Bakun
Marketing & Communications Manager, Americas-ANCA
M: +1 248 497 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 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.
One important strategy in remaining competitive in your business today is ensuring you have the tools to adapt to your shifting markets; having the flexibility to adopt new technologies and reap the benefits that they offer. Punch manufacturers around the world know this fact and are seeing the benefits of using ANCA TX7 Linear and TXcell Linear for their production needs.
To begin with, TX7 Linear or TXcell Linear needs to be kitted up with the right tools and accessories to do the job. ANCA has developed several accessories and options that explicitly meet the needs of the punch grinding application.
These accessories are necessary for any good punch grinding machine. So, what makes punch grinding on ANCA TX7 Linear so different? Starting with the basics, TX7 Linear is a 5-axis grinding machine, compared to the 3-axis grinder more traditionally used for punch manufacture. Having these extra degrees of freedom on your grinding machine translates to greater freedom in what applications you can put through it.
In the case of punch manufacture, a traditional punch grinding machine would have been capable of grinding only the outside form of the punch with a single wheel. The TX7 Linear now offers you so much more. Punches will typically have a series of separate machine operations that need to be performed to complete the tool.
So, what operations on the tool require all the additional investment and effort? After OD grinding a punch may require a roof-top or whisper shear on the punch. Additionally, a tool index mark or feature may also need to be included near the shank of the tool. Typical punches include a single radius dressed into the grinding wheel to create a gentle transition between punch section of the tool and its shank, but in some cases, additional reinforcement radii are added. Finally, there is the inclusion of ejector holes in the end face of the punch that requires not grinding but drilling operations. With two-wheel packs available on the 5-axis TX7 Linear, undertaking several of these operations in a single set-up is now possible. But take the next step to a TXcell, with its offering of nine up to 24-wheel packs, and all these operations can now be done in a single set-up, something that was never possible on a standard punch grinding machine.
The TXcell robot used for changing wheel packs is also used for automated loading of tools, which means you can keep it running for those unattended shifts. Having more than one wheel pack on the machine brings other benefits too. By using different roughing and finishing wheels, grinding operations can now be optimized for stock removal or fine surface finish. The TX7 Linear and TXcell Linear are also ideally suited to the use of CBN grinding wheels. Using a much smaller wheel diameter (up to 200 mm (8”). on TX7 Linear and 300 mm (12”) on TXcell Linear), CBN not only delivers superior grinding feed rates compared to conventional abrasives, but also requires less frequent wheel dressing. Both properties ultimately save you time and money.
Many of our customers manufacturing punch tools can demand the highest possible accuracy in terms of dimensional tolerances and surface finish quality. The TX7 Linear and TXcell Linear machines can meets these demands easily to grind punches within 2-3 microns with a surface finish of less than 0.1 Ra (Roughness Average).
Keyhole punches – a key benefit of ANCA’s premium TX machines
One important strategy in remaining competitive in your business today is ensuring you have the tools to adapt to your shifting markets; having the flexibility to adopt new technologies and reap the benefits that they offer. Punch manufacturers around the world know this fact and are seeing the benefits of using ANCA TX7 Linear and TXcell Linear for their production needs.
To begin with, TX7 Linear or TXcell Linear needs to be kitted up with the right tools and accessories to do the job. ANCA has developed several accessories and options that explicitly meet the needs of the punch grinding application.
These accessories are necessary for any good punch grinding machine. So, what makes punch grinding on ANCA TX7 Linear so different? Starting with the basics, TX7 Linear is a 5-axis grinding machine, compared to the 3-axis grinder more traditionally used for punch manufacture. Having these extra degrees of freedom on your grinding machine translates to greater freedom in what applications you can put through it.
In the case of punch manufacture, a traditional punch grinding machine would have been capable of grinding only the outside form of the punch with a single wheel. The TX7 Linear now offers you so much more. Punches will typically have a series of separate machine operations that need to be performed to complete the tool.
So, what operations on the tool require all the additional investment and effort? After OD grinding a punch may require a roof-top or whisper shear on the punch. Additionally, a tool index mark or feature may also need to be included near the shank of the tool. Typical punches include a single radius dressed into the grinding wheel to create a gentle transition between punch section of the tool and its shank, but in some cases, additional reinforcement radii are added. Finally, there is the inclusion of ejector holes in the end face of the punch that requires not grinding but drilling operations. With two-wheel packs available on the 5-axis TX7 Linear, undertaking several of these operations in a single set-up is now possible. But take the next step to a TXcell, with its offering of nine up to 24-wheel packs, and all these operations can now be done in a single set-up, something that was never possible on a standard punch grinding machine.
The TXcell robot used for changing wheel packs is also used for automated loading of tools, which means you can keep it running for those unattended shifts. Having more than one wheel pack on the machine brings other benefits too. By using different roughing and finishing wheels, grinding operations can now be optimized for stock removal or fine surface finish. The TX7 Linear and TXcell Linear are also ideally suited to the use of CBN grinding wheels. Using a much smaller wheel diameter (up to 200 mm (8”). on TX7 Linear and 300 mm (12”) on TXcell Linear), CBN not only delivers superior grinding feed rates compared to conventional abrasives, but also requires less frequent wheel dressing. Both properties ultimately save you time and money.
Many of our customers manufacturing punch tools can demand the highest possible accuracy in terms of dimensional tolerances and surface finish quality. The TX7 Linear and TXcell Linear machines can meets these demands easily to grind punches within 2-3 microns with a surface finish of less than 0.1 Ra (Roughness Average).
Keyhole punches – a key benefit of ANCA’s premium TX machines
The TX7 Linear and TXcell Linear have one final trump card to offer the punch grinding application: keyhole punches. These punches typically feature much more complicated OD profiles including concave forms and require a fundamentally different approach to grinding them. Small diameter wheels with form profiles and run at high RPM; the TX Linear machines handle this with ease. Dedicated keyhole punch software allows you to control every detail of the keyhole punch geometry and grinding process. This means the possible punch applications on TX7 machines have been opened to an entirely new segment of the punch-grinding market, giving you more opportunities to be making money from your investment. In fact, if business in the punch-grinding industry turns down to such a point the machine has spare time available, then re-tooling your machine to ANCA’s bread and butter application of drill or endmill manufacture is a simple exercise. ANCA’s TX7 Linear and TXcell Linear offer you a complete step forward in enhanced punch production flexibility and automation. Diversity like this not only opens new markets and business opportunities, but also delivers future commercial security.
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 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.
The 2022 Tool of the Year entry showcases the capabilities and complexity that ARCH and ANCA can achieve together.
Based in Detroit, Michigan, ARCH Cutting Tools provides an experienced team of application specialists and custom tooling designers, who provide customers with a line of standard cutting tools and custom tooling.
Throughout the years, ARCH Cutting Tools has supplied custom tools to various industries including aerospace and defense, power generation, transportation and automotive. They also provide custom solutions to clients of their sister division, ARCH Medical Solutions.
They have participated in several ANCA Tool of the Year competitions, winning in 2020 with their complex, multi-functional tool, and placing as the first runner up in both 2022 and 2023. They demonstrated excellent use of multiple Toolroom iGrind software operations with several complex profiles. This started a trend towards multi-functional and complex designs for Tool of the Year winners onward. Turkish company TURCAR won with a similar concept for its tool in 2021, a multi-functional tool with axial and radial cutting features to machine five independent operations in one cycle. The Mexican winner in 2022, SJ Tools, created a cutting tool that combined multiple features into a single tool where all features were finished with a very accurate surface finish.
The idea behind the 2022 entry was to combine multiple tools into one and show what ARCH Cutting Tools could do for customers and what an ANCA tool grinder could produce. The creation of this tool played on the aspect of teamwork and brought in players from multiple ARCH facilities. One of these was Charles Montgomery, CNC Programmer at ARCH Cutting Tools Mentor, Ohio location. Montgomery’s design was chosen as the Tool of the Year entry. The tool was then sent to the Latrobe, Pennsylvania location. Jim Gray, the Regional Director of Operations, programmed it, made the ToolDraft print and manufactured it on an ANCA MX7 grinder.
Commenting on why ARCH entered the competition initially and why they continue to do so, Montgomery, said, “We enter the contest because it gives us the opportunity to be creative and push ANCA [machines] outside their everyday use. Being part of ANCA Tool of the Year annually helps us to continue to improve and showcase our capabilities.” Jim Gray added that the company is excited to continue its partnership with ANCA as it garners more exposure of ARCH through the co-op marketing.
Discussing the impact of their previous win, Montgomery said it brought a positive attitude to the workplace and showed that there is more to tool grinding than solely making tools for customers. Gray mentioned that, as a result, ARCH has become well-known worldwide.
Montgomery described the tool process starting with the tip of the tool as a three-flute right-hand helix endmill with chip breakers, to help stop the tool from creating long chips. Next, it moves into a three-flute form radius cutter for form milling, then transitions into a threadmill. This can be used to create internal and external threads of different sizes. A concave spin grind was added to create relief for chip flow and ejections. Lastly, the back portion changes to a left-hand helix right hand cut reamer to change the forces down into the part to keep it stable in the fixture. Known as the “Fiver,” due to its multiple functions, Gray said that “ARCH Cutting Tools is a solution driven specialty tool company that provides solutions like this tool that cut down on the end users cost in tooling and cutting cost in production.”
This tool was first designed and programmed using the ANCA iGrind software. Next, ARCH used an ANCA MX7 with special wheel packs to grind the tool for their submission. Explaining the complexities in design and production, Montgomery said, “It can be a very complex process to design a tool with multiple functions. You need to use the full capabilities of the software and hardware available, making sure you have all the correct wheels and clearances to avoid any machining issues.”
ARCH Cutting Tools had multiple submissions they prepared for the Tool of the Year contest and company personnel voted on which entry to submit. The tool was made to showcase the capabilities and complexity that ARCH and ANCA could achieve together. The “Fiver” took second place in last year’s competition. Gray mentioned the company’s great partnership with ANCA stating, “ANCA’s ingenuity and advanced technology have given our company the competitive edge that goes along with the expertise of the ARCH team. ANCA and ARCH have a true partnership in the cutting tool industry…The A-Team.”
[SIDEBAR}
Discussing Customization and its Future with ARCH Cutting Tools President
Jeff Cederstrom highlighted that custom tooling is in the company’s DNA. Their manufacturing experts love creating innovative custom tool designs that will solve their customers’ most challenging applications. He also noted that there is an increased demand for custom cutting tools and that ARCH is poised to meet this need with highly skilled design and technology from ANCA. “The breadth of our custom capabilities is second to none in the industry.”
The yearly ANCA Tool of the Year occupies a special place in Cederstrom’s heart as it is “… the Olympics of cutting tool design involving teams from around the world. The friendly competition raises the bar for the industry.”
Lastly, he sees the future of the company being influenced by the growing wave of mass customization. “Technology that continues to evolve will enable custom solutions not only in the design of the cutting tool but custom service offerings. There is a growing need to be flexible, nimble, and speedy.”
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 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.
Jeff Cederstrom
President, ARCH Cutting Tools
M: (989) 615-2356
jcederstrom@archgp.com
Charles Montgomery
CNC Programmer, ARCH Cutting Tools
T: 440-350-9393 ex. 111
cmontgomery@archgp.com
Jim Gray
Regional Director of Operations, ARCH Cutting Tools
T: 724-520-1904 ex. 17
jgray@archgp.com
Visit ANCA in Detroit, MI October 17 – 19, 2023 in booth 3232
Wixom, Michigan – ANCA Inc, a leading manufacturer of CNC Grinding Machines and industry technologies, is excited to announce its participation as an exhibitor at the Motion + Power Technology Expo. The event is scheduled to take place from October 17 – 19, 2023 at Huntington Place in Detroit, Michigan.
Motion + Power Technology Expo is renowned for being a hub of innovation and networking within the mechanical, electric, and fluid power industries, attracting top companies, professionals, and industry experts from across the US. In addition to a prestigious show history, the location of the show is also beneficial as Michigan has long been a large manufacturing hub.
ANCA is delighted to be part of this prestigious event, where we will showcase our latest products, services, and industry solutions. We’re even more excited for this event to be right in our backyard. Just 30-minutes away from our American headquarters in Wixom, Michigan – our team is excited to showcase our technology right here in our home state.
Here’s what you can expect from ANCA at Motion + Power Technology Expo:
“We are thrilled to be a part of Motion + Power Technology Expo this year,” said Russell Riddiford, President at ANCA Inc. “This event provides a fantastic platform for us to showcase our latest innovations and connect with industry leaders. We look forward to meeting and interacting with both existing and potential clients to discuss how ANCA can provide tailored solutions to meet their grinding needs.”
Mark your calendars to visit ANCA at Booth 3232 during Motion + Power Technology Expo, October 17 – 19.
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 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.
Designed for small tools, the new FX7 ULTRA is the latest game-changing innovation in ANCA’s premium ULTRA machine range
Unparalleled accuracy and exceptional quality, the FX7 ULTRA takes small tool manufacturing to new heights.
“The FX7 ULTRA introduces cutting-edge technologies that revolutionize precision grinding for small tools down to 0.1mm diameter. If you produce tools such as ballnose, corner radius endmills, and complex or intricate profile tools, then this machine is for you,” says Darren Fox, ANCA Product Manager.
New software, hardware and design features significantly improve surface finish, accuracy, and controlled runout, ensuring batch consistency from the first ground tool to the last. These advancements ensure that the FX7 ULTRA is the go-to solution for precision grinding in industries that rely on small tools, including electronics, telecommunications, medical devices, aerospace, automotive, diemold, and general machining.
Features of the FX7 ULTRA:
The FX7 ULTRA not only grinds tools faster than other machines, but also produces tools with both finer surface finishes and greater accuracy — which means superior tool performance and quality.
“The ULTRA technology has enabled production of high-quality small tools with the capability to grind down to a size as small as 0.1mm. The nanometer control enables micro-adjustments for smoother axis movement resulting in optimal tool geometry, ensuring superior cutting performance and surface finish. These advancements will have a significant impact across the entire tool range, enabling precise and efficient grinding operations for a variety of applications,” Darren concludes.
Pat Boland, ANCA co-founder says: “Our customers who supply to industries where intricate and precise machining operations are paramount are always striving for the best quality tools, and now they can stay ahead of the game with the FX7 ULTRA. After years of dedicated research and development, the FX7 ULTRA is set to revolutionize the way we manufacture small tools.”
Visit FX7 ULTRA – ANCA – CNC Machines for more information.
A technical look at the FX7 ULTRA’s innovative features:
Greater control for the velocity and acceleration or deceleration along with machine jerk limits: To increase the stiffness of the C-axis, the FX7 ULTRA combines developments to the nanometer or micro degree resolution in the linear and rotary axis, tuning parameters, several system enhancements, and major mechanical changes.
ULTRA-fast response to internal or external disturbances: ANCA’s newly designed servo control algorithm allows silky smooth motion of an axis with the use of a unique algorithm and nanometer measurement in the control system. This will create finer cutting edges and eliminating micro-chips making it more efficient while used in actual machining of materials.
Better cycle time and higher productivity of high-quality cutting tools: The unique algorithm is key to the performance of the machine and ensures outstanding tracking performance. It also allows ULTRA-performance of the servo system without using a complex, complicated, or expensive mechanical system.
Reduces setup times and scrap: Cutting-edge software has been developed by ANCA to ensure batch consistency in large volumes. LaserUltra will maintain consistency and accuracy of the grinding process which includes in-process measurement and compensation to accommodate wheel wear and other external variations during large batch grinding. Its analog capability can maintain less than +/- 0.002mm line form accuracy of any profile which includes ballnose and corner radius tools.
Increased wheel life and better-quality tools: Tool and wheel performance can be further optimized by the iBalance software, which guides a user to the optimal grinding position and RPM for vibration monitoring and balancing the wheelpack inside the machine. Correctly balanced wheelpacks result in superior surface finish and reduced wheel wear due to the elimination of wheel vibration.
Consistency in finished tool quality: The total tool runout measurement and compensation operation is available in the iGrind software. When an endmill is in rotation it is important that each tooth hits at the exact same spot along the workpiece for longer tool life and efficient cutting. Every tool in the batch can be measured and compensated for runout to make sure the entire batch is within a tolerance of 0.002mm. It is another piece of assurance that the first endmill will be as good as the last.
Consistent spindle thermal stability: Motor Temperature Control (MTC) is a patent pending innovation built into the motor spindle drive firmware. Smart control algorithm actively manages and maintains the temperature of motorized spindles in the FX7 ULTRA. Dramatically reduced machine warmup time means production can start sooner, once the machine has reached thermal stability. This improves productivity and machine use. Consistent thermal stability of the spindle over time regardless of changes in load or speed, or coolant temperature, greatly improves the dimensional stability of grinding results.
Post grinding processes: The smoother, finer cutting edge and surface finish as a result of the combination of all the above including the nanometer control will assist in all post grinding applications like edge preparation and coating. A finer edge that has been properly prepared has greater stability, which reduces the likelihood of it chipping, while also decreasing surface roughness which can cause increased friction between the tool and the workpiece.
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 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.
A practical closed-loop solution for producing the highest quality skiving tools.
Vadim Zaiser, Product Manager – ANCA CNC Machines
The popularity of skiving is driven by electric cars. According to the Global Electric Vehicle (EV) Outlook 2023 report, there were over 26 million electric cars on the world’s roads in 2022, 60% more than in 2021 and 5 times as much as in 2018. In 2022 of all new cars sold, 14% were electric.
The forecast in 2023 is 14 million in sales by the end of the year, representing a 35% year-on-year increase. As a result, electric cars could account for 18% of total car sales for a full calendar year.
Worldwide, about 500 electric car models were available in 2022, a 100% increase from 2018. 18 of the 20 largest Original Equipment Manufacturers (OEMs), such as the BMW and GM Groups, have committed to increasing the offer and sales of EVs. Manufacturers’ electrification targets align with the International Energy Agency’s (IEA) Sustainable Development Scenario, aiming to reach 245 million EVs in stock, about 30% of the market share, by 2030.
The graph below depicts two major scenarios for global EV stock by drive mode. The passenger light vehicles and plug-in-hybrid and battery electric design are the major two leading the EV sales.
PLDV = Passenger light duty vehicle
BEV – Battery electric vehicle
LCV – Light commercial vehicles
PHEV – Plug-In-Hybrid Vehicle
73% of all gear sales are auto-related. 45% of all gear production is for vehicle transmission. The rise of EVs is changing the requirements for the gear industry. The high engine speed of up to 20,000 rpm means a higher gear ratio is required for efficiency. The planetary gear set is more prevalent in the new design. In a planetary gear set, also known as the epicyclic gear train, the sun and planet gears are external gears assembled inside a ring gear.
The external gears are produced by hobbing then grinding. The internal ring gear, traditionally produced with shaping or broaching, shaping is slow, while broaching relies on cumbersome tooling. Another trend driven by the more compact new transmission design is multiple gears on one shaft that are very close to each other; due to the interference, the smaller ones on the shaft cannot be manufactured by hobbing.
Efficiency poses multiple challenges, but EV’s noise emission is also a much higher priority for customers. Gears for EVs need to meet even tighter tolerances – increased from DIN 10 to DIN 6; the gear industry sees hard skiving as a revolutionary process to produce the millions of gears needed for the new EVs.
Skiving is a continuous material removal process, combining the rolling motion and milling motion. While meshing with the gear as a pinion cutter, the cutter simultaneously travels along the gear’s axial direction. It is as efficient as hobbing, reportedly five to 10 times faster than shaping. Skiving forms shorter chips, skived gears show higher quality, with lower surface roughness. The most challenging solid carbide skiving cutters are needed in the hard skiving process after heat treatment.
GCX Linear for Skiving CuttersResponding to the market demand, ANCA brings a complete solution for manufacturing and sharpening skiving cutters. The GCX Linear sets the new standard for producing the highest quality skiving tools in both carbide and HSS. Its in-process measurement with the analogue probe provides an accurate closed-loop manufacturing process, an industry-first innovation.
The GCX Linear solves challenges for producing high-quality skiving tools:
Challenge No. 1 – Complex geometry
Challenge No. 2 – Tight tolerance
Challenge No. 3 – Measurement
Challenge No. 4 – Dressing diamond wheel into complex shape within tight tolerance
Challenge No. 5 – Quality control
Challenge No. 6 – Knowledge gap
Skiving cutters are classified as pinion cutters. Currently, there are no standard specifications for them. The industry has widely adopted DIN 1829 as the default. Part 2 of DIN 1829 stipulates the features to evaluate and the tolerance to qualify for each quality class. The most critical aspects of the tool are tooth spacing and the tooth profile.
Tooth spacingTooth spacing measures the pitch, fp is the individual pitch error, which is the deviation of a particular tooth to tooth pitch from the nominal value. Cumulative pitch error Fp is the cumulated result of adding the previous tooth errors together. fu is the adjacent error. To qualify as DIN AA class, fp needs to be less than 2.5 microns; cumulative pitch Fp needs to be less than 7 microns. fu needs to be less than 3 microns. On a typical measurement report, tooth spacing measurement is illustrated as a bar chart, with a bar for each tooth.
ANCA implemented the pitch measurement operation on the GCX Linear. The operator can quickly verify the pitch accuracy instead of taking the skiving cutter out of the machine and moving it to the measurement machine. It uses the digital function of the probe to touch the skiving cutter tooth flank close to the pitch diameter. The chart generates instantly as the probing continues; the report is neat and clean, user-friendly and interactive. The measurement result is comparable to a traditional measurement machine. GCX routinely achieves AAA and AAAA class quality on tooth spacing, thanks to the stable machine condition.
The concept of tooth spacing is relatively straightforward, so is the measurement. The skiving cutter tooth form, however, is more complicated. In the DIN standard, three items regulate the skiving cutter tooth form accuracy.
To qualify as DIN AA class, ff must be less than 2 microns across the whole active profile range, cumulative form error must be less than 3 microns, and fhα less than 2.5 microns. On a traditional report, the nominal profile draws as a straight line for each involute flank.
The below inspection chart shows the skiving cutter pitch measurement.
Please note:
Skiving cutter vs Shaper cutterTo compare a skiving cutter with a shaper cutter, although both are classified as pinion-type gear cutters, the relative movements between the gear and the cutter are different. The principles of the shaper cutter are based on a pair of parallel axes gears. In contrast, the skiving cutters are based on a pair of gears with crossed axes. Subsequently, the profile and geometry of a skiving cutter are more complex than a shaper cutter. Although they are indistinguishable to the eye, the skiving cutter tooth profile is different from that of a shaper cutter.
Due to the novelty of skiving cutters, many industry GMMs (gear measurement machines) have in-built mathematical models for evaluating the cutter profile following a true involute. So, the skiving cutter can only be measured as a shaper cutter, which poses a unique challenge for manufacturing and quality control. The skiving cutter tooth profile doesn’t have a true involute profile due to the previously mentioned relative position to the gear.
Tool design engineers have to calculate an approximate deviation for the skiving cutter geometry and compare the deviation to a theoretical involute curve; operators then interpret the measured result against this approximation.
This roundabout way of measurement is mind-bending and extremely difficult in practice. ANCA developed the in-process measurement (IGTM) with an analogue scanning probe, which enables operators to evaluate directly against the theoretical profile, basically the grinding path. While scanning the tooth profile, the charts are drawn on the report window instantly. The report is much easier to decipher.
In addition, the in-process measurement significantly improves the process control. For example, when the skiving cutter tooth profile shows different patterns between different teeth, this often indicates that the grinding wheel wear during the finishing cycle is too much; the wheel did not hold the form. By measuring the profile between the roughing and finishing operations, the user can monitor the grinding wheel wear and proactively manage the grinding wheel’s dressing and white sticking. It can help determine the dressing frequency and reliably control the infeed, grinding feedrate and other process parameters. It improves the overall quality and controllability.
Closed-Loop ProductionTo reduce the dressing frequency, ANCA developed direct path compensation on the machine. The design process for skiving cutters requires iterative parametrization of the cutting tool. After carefully choosing the compromises, the software produces a wheel profile and a grinding path. These files are sent to the grinding machine to grind the skiving cutter. If there are errors in the skiving cutter after measurement, the traditional method to compensate was to recalculate the grinding wheel profile and redress it onto the grinding wheel. Which required multiple back and forth between the design station, the grinding machine and the measurement machine; it was time-consuming and made it extremely challenging to establish a stable process.
The GCX Linear approaches compensation differently; instead of changing the grinding wheel profile, the software compensates directly on the grinding path. With the in-process measurement, it localizes the closed-loop all on the GCX Linear. Without taking the skiving cutter or the grinding wheel out of the machine, it can compensate for any error in one clamping of the skiving cutter.
In summary, in-process measurement (IGTM) significantly improves the manufacturing process of skiving cutters: the machine can evaluate the profile against the correct mathematical form, which is a leap forward for the industry. Together with direct compensation, the skiving cutter grinding on GCX Linear is an efficient, practical closed-loop solution.
For further information, please contact:
Johanna Boland
Group PR and Communications Manager, ANCA
M: +61 407799779
Johanna.Boland@anca.com
ANCA is a market leading manufacturer of CNC grinding machines. It was founded in 1974 in Melbourne, Australia where the company still has its global headquarters. ANCA has offices in the UK, Germany, China, Thailand, India, Japan, Brazil and the USA as well as a comprehensive network of representatives and agents worldwide.
ANCA CNC grinders are used for manufacturing precision cutting tools and components across a diverse range of competitive industries including cutting tool manufacture, automotive, aerospace, electronics and medical.
ANCA Inc welcomes Brady Roarke as its new applications engineer and technical sales expert expanding its presence in Canada
Wixom, Michigan – ANCA Inc, a leading manufacturer of grinders used for the creation of precision cutting tools and components, is excited to announce the addition of Brady Roarke to the America’s based team. Brady will be located near Toronto, Canada. This strategic move signifies ANCA’s commitment to further strengthening its operations in the Canadian market and enhancing its ability to serve clients across the region.
Brady comes to ANCA with an impressive background in grinding machines, bringing nine years of experience and a proven track record of success as an applications engineer. Five of those years were spent milling, and four were spent grinding. As the newly appointed Applications Engineer & Technical Sales expert, Brady will play a pivotal role in expanding ANCA’s reach in the grinding industry in Canada, both with new opportunities, and expanding relationships with ANCA’s existing client base in the region.
“We are thrilled to welcome Brady to our team,” said Russell Riddiford, President of ANCA Inc. “With his extensive experience and deep insights into the grinding industry, we are confident that Brady will be instrumental in driving ANCA’s growth and success in Canada.”
Brady expressed his enthusiasm for joining ANCA. “I am honored to be part of ANCA’s talented team and to contribute to the company’s ongoing success in the Canadian market. I look forward to collaborating with colleagues and clients alike to deliver exceptional grinding solutions.”
The addition of Brady is part of ANCA’s larger strategic plan to expand its footprint and enhance its offerings in Canada. This move underscores ANCA’s commitment to delivering top-tier solutions and services that meet the evolving needs of its Canadian clients.
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 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.
For media inquiries or further information, please contact:
Amanda Bakun
Marketing & Communications Manager – Americas
248-497-1168
amanda.bakun@anca.com
ANCA’s AIMS solution addresses the challenges of skilled labor shortage and rising overheads, enabling FABA to increase productivity through automation
FABA S.A., established in 1991, is a leading manufacturer of wood and metalworking tools made from carbide and PCD. Over the years, FABA has seen tremendous growth and is now a public listed company, comprising four business units located in Poland, Ukraine, and Slovakia. With approximately 400 staff members, FABA supplies their tools to 50 countries, predominantly in Europe.
One of the key factors contributing to FABA’s success has been their dedication to innovation and progress. For more than 30 years, the company has continuously invested in modern machinery and infrastructure, allowing them to stay ahead in a competitive market. However, like many others in the manufacturing industry, they have faced challenges in recent years such as low profit margins, a shortage of skilled technical labor, and increasing overheads, including high energy costs.
According to Paweł Hondra, FABA CEO, the company had been considering an advanced automation solution for several years to address these challenges and improve efficiency – and the ANCA Integrated Manufacturing System (AIMS) concept was the answer to their expectations. The integration of machines in the AIMS system promised simplified manufacturing processes, stability, consistency, and ultimately, improved product quality.
Considering the shortage of skilled technical staff in Europe, also very noticeable in Poland, FABA estimated that the implementation of the AIMS system would not only reduce labor costs by approximately 60% but also increase productivity. This solution, an industry-first by ANCA, was crucial in lowering general overheads and addressing the skilled labor shortage simultaneously.
ANCA has leveraged its nearly 50 years of vertical integration and expertise to develop a groundbreaking solution that seamlessly integrates the manufacturing workflow. With the innovative AIMS system, manufacturers can start with a tool blank and receive a fully ground tool at the other end, all in a completely automated process. This allows factories to operate efficiently without human intervention, enhancing flexibility and maximizing machine utilization.
AIMS revolutionizes the tool and cutter grinding process by integrating, connecting, and automating discrete manufacturing processes. By intelligently linking various grinding operations and factory IT systems, AIMS streamlines production and enables a smooth transition from traditional to automated and integrated manufacturing through its modular design.
One of the key benefits of AIMS for tool manufacturers is the ability to operate and respond to market demands without being constrained by labor shortages. By implementing automation solutions, manufacturers can optimize their machine uptime and operate unattended, enabling them to onshore and re-shore their manufacturing processes. AIMS reduces scrap, eliminates human errors, and enhances workplace safety, leading to improved productivity and increased competitiveness. It also effectively addresses rising overhead costs and energy expenses through an expected increase of machine-operator ratio by 100-150%.
“We have worked with ANCA since 2007, and they have been a trusted partner and software solutions provider for our organization. Their consistent delivery of reliable products and services throughout our long-standing partnership has solidified ANCA as the ideal choice to implement the AIMS system,” Mr Hondra said. “The AIMS project was conducted in a highly professional manner, with consultation and collaboration between ANCA and FABA to ensure that concerns are addressed and expectations are met.”
The installation of the full AIMS system is planned in a few months, marking the beginning of FABA’s transformative journey towards integrated manufacturing. Mr Hondra recognizes that building such a complex system will take several years, but they are prepared to invest the time and effort required. They understand that this is not just a one-time solution but a long-term commitment to continuous improvement and growth.
FABA’s collaboration with ANCA and the implementation of the AIMS system are testaments to their commitment to innovation and progress. By embracing automation and advanced manufacturing technologies, FABA is positioning itself to overcome the challenges of a competitive market, low profit margins, and skilled labor shortage. With the support of ANCA and the AIMS system, FABA looks forward to a future of increased efficiency, reduced costs, and improved product quality.
ANCA is a market leading manufacturer of CNC grinding machines. It was founded in 1974 in Melbourne, Australia where the company still has its global headquarters. ANCA has offices in the UK, Germany, China, Thailand, India, Japan, Brazil and the USA as well as a comprehensive network of representatives and agents worldwide.
ANCA CNC grinders are used for manufacturing precision cutting tools and components across a diverse range of competitive industries including cutting tool manufacture, automotive, aerospace, electronics and medical.
For further information, please contact:
Amanda Bakun
Marketing & Communications Manager – Americas
248-497-1168
amanda.bakun@anca.com
ANCA is proud to announce the appointment of Edmund Boland as the new General Manager of ANCA CNC Machines. Edmund is the son of ANCA co-founder Pat Boland and brings an impressive 15-year tenure at ANCA. Pat Boland, ANCA co-founder said, “When Pat McCluskey and I founded ANCA, our primary goal was to design the best technology that solves real customer problems. I am proud that my son has joined this mission and has accepted this important leadership role in the business to continue fostering a culture of innovation.”
ANCA is a privately owned business and proud of its reputation for being first to market with technology that has proven time and again to revolutionize the cutting tool industry. Celebrating its 50th anniversary next year, Pat McCluskey, ANCA Co-founder comments that “being privately owned brings great benefits as it means that we can focus on investing and developing new innovations while maintaining our long-term view of the market to design products with longevity and customer focus.”
Edmund Boland said: “I am honored and thrilled to be a part of ANCA CNC Machines, such an exciting company in the cutting tool industry. Every day, I am amazed by the skill and prowess of our customers, who continue to push the entire industry forward. ANCA is in my blood, and our commitment to innovation is unparalleled. Throughout our extensive history, we have consistently been the first to market with new technology, investing over 15% of our revenue every year into research and development.
“Technology is truly in our DNA, for example, ANCA’s Integrated Manufacturing System (AIMS) which is one of our latest products could be considered akin to the impact of a printing press and is set to revolutionize the cutting tool industry. I am excited to lead ANCA into a future of continued innovation, growth, and success, while educating the market about the transformative power of our new nanometer control system and ensuring the success of our internal investments such as in our machine shop or our sub-micron metrology equipment.
“We take pride in hosting the only customer competition in our field, the ANCA Tool of the Year, and I am particularly excited that this year we will have a new category of Female Machinist of the Year. Together, these, and many other initiatives will contribute to the continuous growth and prosperity of our esteemed company.”
Edmund’s journey at ANCA began in February 2008, and throughout his career with the company, he has held key positions in the finance, operations, strategy, regional management and applications teams. This diverse experience has afforded him a deep understanding of ANCA’s operations and a comprehensive perspective on the company’s strategic goals.
Prior to assuming his new role as General Manager, Boland led ANCA’s European Branch with remarkable success during the unparalleled challenges presented by the COVID-19 pandemic. His exceptional leadership and strategic vision enabled ANCA to navigate through this disruptive period while ensuring uninterrupted supply of high-quality CNC machines to customers worldwide.
As General Manager, Boland eagerly looks forward to collaborating with the talented team at ANCA to address the challenges and seize the opportunities presented by the current global environment.
Boland’s exceptional expertise and leadership make ANCA CNC Machines well-positioned to further solidify its position as a global leader in CNC machines. His strategic direction and unwavering commitment to excellence will drive innovation, enhance customer satisfaction, and foster overall company growth.
ANCA CNC Machines extends its warmest congratulations to Edmund Boland on his new role as General Manager, marking 15 years of dedicated service and expertise. The company looks forward to a bright future under his guidance and leadership.
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.
For further information, please contact:
Amanda Bakun
Marketing & Communications Manager – Americas
248-497-1168
amanda.bakun@anca.com
