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Category Archives: ANCA

Tool grinding’s talented new ambassador

How Lena Risse went from apprentice to ANCA Female Machinist of the Year

Like many people, Lena Risse didn’t know what career to pursue when she entered young adulthood in 2017. Now she’s won ANCA’s inaugural Female Machinist of the Year contest.

Lena studied media technology at a university for a time, and began a related apprenticeship in supporting trade fairs and concerts, but it didn’t suit her. Then, at 19, she decided to give tool grinding a try, an option that seemed simultaneously obvious and crazy. Obvious, because her father Horst Risse was running a one-man tool grinding company with such love and dedication that he routinely says he’ll be standing at a machine when he’s 85. And crazy, because to this day, Lena finds so few females in the field, though she’ll convincingly explain why that should not be the case.

Lena had helped out at Risse Werkzeugtechnik GmbH (Risse Tool Technology GmbH) in Erkrath, Germany, as a teenager, doing things like packaging and laser marking. But she’d never touched the tool grinders. That changed as she started her apprenticeship in 2018. She took immediately to her father’s four ANCA machines and found that the more she did, the more she liked it.

Her curriculum called for cycles of six weeks of practical work in the company combined with two weeks of classroom theory. By the beginning of 2022, Lena passed her exams to become a fully qualified machinist. By then she was also responsible for all the company’s regrinding, which is roughly half their business, plus many additional duties. On top of that, she’s pursuing a master craftsman qualification—the only woman in the region to do so—and is on track to finish this summer. That would certify her to manage and train production teams.

It’s not the diplomas that motivate her though. It’s the satisfaction of things like starting a week with hundreds of diverse, damaged or worn-out tools, wondering how you’re going to sharpen them all, and then measuring, programming, grinding, and delivering them all to happy customers by week’s end. Or the satisfaction of inventing a dead stop for their automatic chuck, so they could hold a tight tolerance on length when regrinding a series of unequal end mills.

Lena’s training didn’t include the intricacies of ANCA’s iGrind software, but she’s explored it on her own, greatly boosting the company’s capabilities. (The elder Risse never had time to attend any of ANCA’s training courses.) For example, she introduced auto-loading tools of different lengths, expanding the kinds of “lights out” jobs they can do. And when a customer ordered 1,000 drills with through-hole coolant, she immediately recognized that her father’s approach of adjusting the rotational position of the blank by sight was not going to work. So she programmed a probing routine on their 15 year old ANCA RX7 to automate the task.

What’s next? Lena envisions continuing to stand alongside her dad for years to come, and they’re discussing the option of taking on an apprentice when Lena gets her master machinist certification. She’s also considering the possibility of adding the role of teaching other grinders at a nearby school or business.

Whatever she does, Lena is adamant that it’s a wonderful career for women and she decries the fact that virtually everyone she meets in the field, and all her instructors and company managers, have been male. As she sees it, “tool grinding is about patience, precision, logical thinking, and just finding solutions for problems. And I don’t think that men are better at this than women. I never have a day at work where I say ‘I don’t want to do this. This is a job for a man,’ or anything like that.” She adds that while she thinks women can do dirty or strenuous work, they should know that tool grinding is pretty much the opposite, “and I would like to see more women have the courage to just do it.”


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 celebrates a half-century contribution to industrial progress through precision cutting tools

1.1 billion cutting tools and counting have shaped the world around us for 50 years

Family, fulfillment, and a fascination with technology are all part of a formula that has seen ANCA lead the demanding niche of CNC tool and cutter grinders for a half-century.

In its time, the Australia-based global business has made an enormous yet largely hidden contribution to the world, selling over 10,000 5-axis CNC machines to over 2,500 customers. Around 1.1 billion tools have been created using ANCA’s grinders.

“You would be very unlikely to find any bit of advanced equipment, anywhere in the world, that hasn’t been touched by a cutting tool which has been manufactured on one of our machines,” explains co-founder Pat Boland, whose company’s customers include Boeing, Rolls-Royce, Iscar, Sandvik, Sutton Tools and many other household names.

Boland and Pat McCluskey – then an electrical engineer and an industrial electronics tradesman – met at a government-owned munitions factory in Melbourne in 1968. The two Pats started ANCA in 1974 in a spare room at Boland and wife Libby’s home.

“It wasn’t about money in the beginning, and for me it’s not about money now…I get my kicks out of designing new machines,” explains McCluskey. “Even before we started ANCA, Pat and I have always been driven by simply wanting to get machines to do things better. My enduring philosophy in business is if you always do what you’ve always done, you’ll always get what you’ve always gotten. New ideas and new thinking are the basis of our business.”

ANCA’s highly sophisticated CNC grinding machines are exported around the world, with 98 percent of its revenue being generated by exports. The ANCA Group also makes associated equipment and software, including robot arms, software, and control systems, and offers automation services and technology to OEM machine builders.

Leading the incredibly demanding tool and cutter market – where nanometer-level details matter – means a reinvestment of roughly a tenth of revenues back into R&D.

A near-obsession with solving customer problems has seen ANCA contribute a collection of world firsts to its industry, including the first probe for digitizing tools, first modem for support and diagnostics in a machine, first full and true 3D simulation of the grinding process, and many more.

Martin U. Ripple, who has been at the helm of ANCA as CEO since November 2022, reflects on the company’s enduring legacy. “In all my interactions, I’ve observed a consistent thread – our customers invariably share fond recollections of their encounters with ANCA dating back to the ‘70s, ‘80s, and ‘90s. It’s evident that there’s a deep-seated loyalty and trust towards our brand,” he notes.

Ripple, always keen on uncovering the unique elements that set a business apart, asks, ‘What is the secret ingredient that differentiates us from our competitors? What makes ANCA exceptional?’ His answer is the involvement of family in the business, a fervent passion driving the company forward, and a steadfast commitment to providing customers with the most innovative products. This blend, according to Ripple, is the essence of ANCA’s success and longevity.” 

Edmund Boland, son of Pat and ANCA CNC Machines’ General Manager, values ANCA’s agility as a privately owned company which enables swift decisions to support ANCA’s people and customers.

“ANCA has always endeavored to stay ahead of the curve, anticipating market trends and delivering cutting-edge solutions which enable our customers to thrive. With 50 years of innovation behind us, our product and technology portfolios are perfectly placed to meet the challenges of the future.”

The delivery of technical and practical excellence has required a sharp focus on both vertical integration – creating everything from the machines’ motors to their polymer concrete bases to their sheetmetal canopies – and both trade and university-taught skillsets.

ANCA has trained more than 60 apprentices and established its formal apprenticeship program in 2011. McCluskey enthusiastically wrote the course material for this.

While being very particular with skill and technology development is one way to look at ANCA’s story, Pat Boland also likes to zoom out to a very general view.

The ANCA era runs 50 years and counting, touching countless lives, operating in the background.

It’s shorter than, but has similarities to the overall story of toolmaking: critical to industrial progress, even if it needs pointing out every now and then.

“For the vast sweep of history, the only evidence of homosapiens and our predecessors are cutting tools,” says Boland.

“And a number of the broad eras of human life are really named after cutting tools. So the stone age, the bronze age, the iron age. What we’re talking about is the technology of cutting tools as much as anything.”

Celebrating a golden achievement across the globe

To mark the occasion of ANCA’s 50th anniversary, the company is hosting a series of open houses, seminars, events, and attending tradeshows worldwide. As innovation has motivated ANCA throughout the company’s history, new products and developments will be at the center of the 50th year celebrations.

At global tradeshows and ANCA Open House events, precision manufacturers can experience new hard- and software for micro tool and gear tool manufacturing, edge preparation, closed loop manufacturing and automation.

Russell Riddiford says: “Our large and experienced group of engineers and developers is continuously presenting new solutions to meet customers’ needs. Highest quality tools and lowest cost per part are the guiding principles leading to groundbreaking, real-world innovations. Examples are our new MicroX CNC grinding machine, using nanometer control technology and ANCA Machine Intelligence to produce micro tools of unseen quality, or our AIMS system, the world’s first and only autonomous system for tool manufacturing.”

ANCA’s U.S. Open House will take place on May 7 & 8 from 9:00-6:00 at their Wixom, Michigan headquarters. Please RSVP to: amanda.bakun@anca.com


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.

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Time-saving, easy and flexible: why the GDS µGrind ANCA workholding is a smart investment

The GDS µGrind ANCA collet adaptor is designed with the highest level of consistent accuracy and improved productivity in mind

The performance of any process relies on the performance of its individual components. This is particularly relevant in the grinding of precision tools. The increasing need for extreme accuracy and tolerances, as well as competitive and labor pressures, result in the demand for accessories that are more precise, easy to use and maintenance-free.

A selection of good quality, easy to use workholding that provides minimal and consistent runout is one of the prerequisites for successful grinding, resulting in quality tools and happy customers – once again reinforcing that the quality of the whole process relies on the quality of all its components.

ANCA has partnered with GDS, a renowned German manufacturer of high-quality precision accessories for grinding and machining processes. One of their flagship products is the µGrind workholding, which is now available from ANCA’s distribution network. The µGrind has been customized to suit the requirements of ANCA grinding machines and can be set up in a matter of minutes.

Benefits of the µGrind workholding:

  • Time saving – thanks to minimal and consistent 2um runout which provides consistency over large batches and collet changes.
  • Easy and fast setup – it only takes minutes to get the µGrind ready for grinding and readjustment between collet changes is not needed. Concentricity and wobble adjustments are easy to perform.
  • Flexible – a suite of compatible collets with form factors to suit almost all applications is available. µGrind comes in two form factors (standard and long nose) to suit almost all applications. 

µGrind performance has been tested in real-life applications and the results are very consistent. A test was performed over a large batch of 6mm tools where runout was measured before and after grinding at 2.5 x Ø and 10 x Ø. Even with thousands of clamping and diameter changes, the runout remained virtually unchanged.

The GDS µGrind ANCA workholding is a smart investment that will serve you for years to come. By saving time and improving tool quality, this translates into satisfied customers and better business outcomes.


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.

Continue reading

ANCA TapX: A Customized Grinding Solution for Tap Manufacture

Projected global demand for products such as taps, dies, and thread forming tools is anticipated to rise from 2.75 billion to 3.42 billion over the next five years, with a compound annual growth rate (CAGR) of 5%. The high-tech industries, particularly automotive and aerospace sectors, are expected to sustain a significant portion of this growth, accounting for 16% of the overall market demand. Additionally, there is an expected increase in demand from medical applications, which is projected to contribute another 7% to the total market share within the next five years.

Given the impetus from these high-tech markets, tap producers will need to enhance their designs to meet the escalating market share of specialized materials. Notably, composites (expected CAGR of 8.5%) and super alloys (expected CAGR of 7.5%) are anticipated to experience the most substantial growth, necessitating the development of tailored designs in response.

With the boom of automotive and aerospace applications, ANCA sees great potential for the future of the high-end tap market.  ANCA’s years of experience working with tap manufacturers has given the company valuable insights into the industry challenges, making it well-equipped to offer the right solution. The TapX is a machine specifically designed and integrated with automation to ensure high productivity in mass production. As a one-machine solution with single clamping, it guarantees substantial benefits for manufacturing standard and special taps by eliminating the traditional requirement of needing several grinding machines.

Flexible, precise and efficient one-stop tap grinding is simply unimaginable on ordinary grinding machines, as high-speed steel taps, carbide taps, micro taps and non-standard taps require different and detailed solutions. The difference lies in the performance of a single grinding process, a parallel grinding process or a combined grinding process. In addition, several grinding machines are usually required, each performing a specific tap grinding task. TapX integrates the various processes into one machine.

Flexibility is a key feature of the tap grinding process on the TapX. The specially designed machine and powerful ToolRoom software ensure a vast range of tap types and sizes can be designed and manufactured in one set-up. Combine this with the benefits of quick changeover time and it’s not hard to see how TapX can increase productivity and reduce lead times.

The production of taps in different materials is an example of how this highly flexible solution can contribute to productivity. Taps are mainly made of HSS and carbide materials, which require high precision, surface finish and reliability for grinding. TapX is suitable for the complete production of HSS or carbide taps. With a single set-up, it can grind various types of standard taps, micro taps and non-standard taps. Its excellent rigidity guarantees repeatable, high-quality results, while its CNC control plus programmable force of the center ensures reliability of high frequency movements.

The TapX uses ANCA’s own LinX motor technology for all linear axes and direct drive technology for all rotary axes. By eliminating all belts, pulleys, and gears, the TapX is not only a more precise machine, but a more reliable one as well.

Although HSS will remain the dominant material of choice, carbide tools are growing in popularity with the increase in thread milling applications and introduction of more exotic materials. Compared with HSS, carbide offers high rigidity, good machining quality and long service life. Consequently, the production of carbide taps presents challenges for machine productivity, accuracy and dressing of special thread grinding wheels.

TapX offers the perfect solution with its single clamping to optimize the grinding process. Combined with greater flexibility in wheel selection and process deployment, this revolutionary solution means more flexibility, reduced costs and increased tap production output. The total set-up time for multiple general machines is reduced from three to four hours to one hour for one TapX machine, which significantly reduces lead time for small to medium batch production, urgent order response and customer changes. In recent years, ANCA continues to innovate and has developed a unique solution for dome carbide taps with a wider application. Its superior performance is unmatched in the industry.

Recognizing the efficiency, accuracy and reusability of TapX, customers have begun to expand their product range to include spiral, straight flute and forming taps, and even micro parts. Micro taps are mostly used in smartphones, glasses, consumer electronics, aviation and military industries. Any miniaturized part may be machined with a small or micro tap.

In recent years, the growing demand for mobile devices and new materials has led to a sharp increase in the consumption of thread tapping tools, which in turn resulted in an unprecedented boom for machines grinding small or micro taps. This means that manufacturers such as ANCA, who have the capability to manufacture these tools, have great potential to meet the ever-growing market demand. To grind small batches of taps, conventional machines simply take too long to set up. With ANCA TapX, customers can integrate the entire process into just one machine, significantly increasing productivity through rapid tap design, set-up and changeover.

The TapX grinding solution is an excellent option to meet the high demand for high-quality tap products or to fulfill the needs of emerging manufacturers in the market. The TapX one-machine grinding concept provides faster tap design, set-up, and changeover to reduce lead times and boost competitiveness. Gone are the high costs, inflexible production and low productivity due to lengthy machine set-ups. ANCA remains committed to offering comprehensive grinding solutions for its customers.


For further information, please contact:

Amanda Bakun
Marketing & Communications Manager – Americas
248-497-1168
amanda.bakun@anca.com

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

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

Continue reading

ANCA TX Linear leads the way in tackling long drill production challenges

Long drills present several difficulties and challenges in the production process. Their elongated physical size is not the only concern; ensuring accuracy throughout the entire length of the tool can be equally challenging. The extended nature of these drills introduces a host of potential issues that need to be carefully addressed.

One challenge is the need to control grinding forces consistently throughout the entire length of the tool. This is crucial because long drills are designed to create holes that are not only accurate but also maintain their straightness over extended distances. The reduction of deflection caused by grinding forces is important. When fluting the drill in the shortest possible time, high feed rates and forces are necessary. It becomes crucial to find ways to minimize deflection while maintaining the required machining efficiency.

Another concern is runout, which refers to the error that occurs when the tool deviates from the center axis at an angle. While a standard setup may allow for an acceptable 5 µm runout for a 100mm tool, the same setup could result in up to 40µm runout for a 400mm tool. Achieving acceptable runout becomes a priority when dealing with such lengthy tools, as it directly impacts the performance of the tool.

Additionally, long drills often feature coolant holes integrated within their bodies. To ensure proper functioning, these coolant holes must be correctly identified by the machine during the machining process, avoiding any damage that could impede their functionality. Managing grinding forces and preserving the integrity of coolant holes are critical considerations when working with long drills.

By addressing the challenges of tool deflection, runout, fluting, and coolant holes, ANCA’s integrated solutions and software capabilities provide a comprehensive approach to effectively produce long drills with accuracy and efficiency.

ANCA’s TX7 is the machine for long drill production

ANCA is the only CNC grinding machine manufacturer with complete vertical integration in its manufacturing process. This integration not only fosters innovation across all aspects of design and production but also enables ANCA to respond swiftly and effectively to demanding requirements with unique solutions.

The TX7 machine’s powerful 37kW (49hp) direct drive spindle, facilitates the efficient grinding of long drills without putting excessive strain on the machine. It boasts a spacious working envelope and a 6th axis with a traveling steady support that can be positioned strategically to provide support in the grinding zone, allowing for the accommodation of tool lengths of up to 480mm. This setup eliminates deflection and minimizes vibrations caused by grinding forces on the tool. It also addresses the issue of runout, as the steady supports enable compensation control to mitigate runout errors effectively.

One of the remarkable advantages of the TX platform is its ability to grind drills from start to finish in a single setup. This capability grants greater flexibility in production, enabling the manufacture of both high-volume tools and highly customized tools on the same machine with minimal hassle. Customers opting for the TX7 model with a robot cell can achieve fully automated manufacturing, unlocking new possibilities and efficiencies for their operations.

ANCA’s specialized software for long drills

ANCA offers several software solutions for long drill production. The first is ToolRoom, which provides a drill wizard as a standard feature. This wizard is a great starting point and includes convenient features like wheel pack auto-select. Users can easily add and define coolant holes in the blank editor for simulation. The software also integrates many tool features, including advanced ones like S Gash, K land, C land, and variable helix. The ToolRoom software also includes runout compensation capabilities, providing further adjustments to compensate for runout errors.

For formed flutes, ANCA offers iFlute software. Long drills often require specific flute forms, and iFlute simplifies the process. Users can simply import their DXF file, and iFlute will determine the wheel profile and grinding paths accordingly.

To simulate the tool grind and account for machine features, ANCA provides CIM3D. Users can add all the necessary machine features to the simulation, including a 6th axis, to determine the setup and control before proceeding to the actual grinding process. Not only can users set up the required operations, but they can also optimize the grind from their desk with accurate simulations of all features. CIM3D includes intuitive coolant hole collision detection within the simulation, ensuring that potential issues are identified and addressed beforehand.

ANCA’s comprehensive integration, combined with the advanced features and software of the TX platform, establishes the company as a flexible and agile provider of grinding solutions. With this powerful combination, ANCA effectively meets a wide range of challenging demands in long drill production.

Overview

  • ANCAcrete is a unique ANCA innovation that provides excellent dampening and thermal properties, delivering a robust polymer concrete base with high stability on which to grind
    • 2 position wheelpack changer as standard for quick and easy change of wheel packs in under 8 seconds
    • Bi symmetrical gantry design provides the large TX platform with the high stability required for exceptionally high precision grinding of large tools. This design has the grinding spindle center of rotation on the machine centerline, delivering high rigidity while mitigating the effects of thermal growth.
    • LinX linear motors drive all the linear axes, with a unique counterbalance design to counter gravity for the Z-axis.
    • The powerful 37kw direct-drive spindle are the “muscles” of the machine, with unparalleled strength and creativity to achieve superior surface finish and depth of cut
    • The addition of the 6th Axis (P-Axis) provides support when and where it is needed. Using workholding such as Arobotech offers an automated travelling support at the grind point during production.
    • Measurement options such as probing and LaserUltra, can be utilized throughout the tool production process, from digitizing tool features and compensation to quality control
    • Optional headstock and/or secondary dresser to automatically maintain wheel forms at specified intervals
    • More unique solutions are available through the TXcell automation – including unattended operation, and unique camera systems to detect coolant hole positions on the tool before being loading into the machine for grinding

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.

Continue reading

EMUGE-FRANKEN Takes Home Top Honors in ANCA’s Prestigious Tool of the Year 2023 at EMO Hannover

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

ANCA CNC grinding machines have helped SST growFrom 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.

Efficiency and accuracy have been boosted thorugh ANCA technology“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.

Efficiency and accuracy have been boosted thorugh ANCA technologyAs 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

Producing the right blank can define the overall cutting toolOne 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.

SST can meet market needs for precision cutting toolsKumar 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.

SST produces customized tools for a range of industriesProudly 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.

Continue reading
Efficiency and accuracy have been boosted thorugh ANCA technology

ANCA’s grinding technology offers India-based SST Cutting Tools a high-precision boost

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

ANCA CNC grinding machines have helped SST growFrom 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.

Efficiency and accuracy have been boosted thorugh ANCA technology“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.

Efficiency and accuracy have been boosted thorugh ANCA technologyAs 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

Producing the right blank can define the overall cutting toolOne 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.

SST can meet market needs for precision cutting toolsKumar 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.

SST produces customized tools for a range of industriesProudly 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.

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ANCA TX7 Linear machines

Clortech Precision Cutting Tools Uses ANCA Machines to Achieve More Regrinds, Tighter Tolerances

Using MX7 Linear, the Canadian company helps automotive company make tools within spec and regrinds 1,100-1,500 tools each year

ANCA TX7 Linear machinesFounded 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).

Abraham meticulously inspecting the incoming pieces before grindingWhile 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.

Front Row from left to right Emilia, Carmela and Clorindo with Patrick and Mena Mattei in the back rowRecently, 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.

ANCA TX7 Linear machinesPatrick 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.

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Beat them to the punch with ANCA TX7 and TXcell Linear

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.

  • iPunch: dedicated punch programming software gives you complete flexibility on punch geometry and grinding process parameters.
  • iBalance: on-machine wheel balancing software.
  • Rotary wheel dresser units fully supported by ANCA dressing software delivers in-process dressing to keep your wheels running true and sharp.
  • Auto adjusting coolant nozzles that change position as the wheel diameter reduces.

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.

  • iPunch: dedicated punch programming software gives you complete flexibility on punch geometry and grinding process parameters.
  • iBalance: on-machine wheel balancing software.
  • Rotary wheel dresser units fully supported by ANCA dressing software delivers in-process dressing to keep your wheels running true and sharp.
  • Auto adjusting coolant nozzles that change position as the wheel diameter reduces.

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.

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The A Team: Innovating Today’s Custom Tooling Process

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

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