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ANCA to showcase the technology range cutting tool manufacturers need to remain agile, improve quality and grow capacity at GrindingHub 2022

Transforming through innovation with ANCA’s AIMS: The future factory is efficient, automated and runs round the clock. It uses modular programs scripts, remote access, and cutting-edge machines to operate at maximum efficiency.

The world of CNC machining thrives on innovation. Grinding machines, cutting tools and software are constantly evolving to be more efficient, flexible, accurate and automated. ANCA chases customer requirements to identify the next challenge to solve — constantly iterating and refining its technology. Over its 40 plus years of operations, developments that were once considered cutting-edge are now business as usual — even at ANCA, we reflect on how revolutionary our early products felt.

Pat Boland, ANCA Co-Founder and Joint Managing Director, said: “We can recall a time when it was almost impossible to resharpen cutting tools on a CNC machine. That was until 1986, when ANCA launched our TG4, the first machine in the world to automate the measurement of tool geometry and regrinding through probing.”

“Or when we introduced the System 32 which, for the first time, applied advanced robotic software to tool grinding which enabled significant opportunities, for example, the soft axis or soft machine kinematics which simplified the grinding of cutting tools. We’ve come a long way, from probing for cutting tools, leading the competition in five-axis grinding or from simulating grinding processes before grinding with the CIM3D.”

“Designing the best technology requires a multi-pronged approach. We immerse ourselves in the market; are continually inventing; keep a keen eye on new developments and bring them into our applications. We seek out intelligent, talented people, and interact with customers daily to understand their specific needs. This is how we design and manufacture our market-leading solutions.”

At GrindingHub ANCA will showcase its technology range at a newly designed stand that enables customers to grow capacity, improve profit margins and gain efficiencies.  Deciding what technology to invest in should be driven by business goals, working with existing objectives, processes, data and ideas.

LAUNCHING THE CPX IN-PROCESS OD MEASUREMENT SYSTEM

The CPX in-process OD measurement system is a quality control system that monitors and controls the OD of ground blanks within a batch production.

 Batch grinding on a CPX with high material removal rates and to tight tolerances is a basic function of the machine, the OD measurement system takes it further by utilizing the Statistical Process Control (SPC) feature that comes standard with the OD measurement software. SPC is user defined, the tolerances along with the Cp and CpK values are constantly monitored, controlled, and reported to the user.

 The OD measurement system is permanently mounted inside the machine and only called upon when required, based on the set tolerances and the frequency of measurement, an accurate in-process measurement and compensation is applied to maintain the blank OD to the nominal diameter.

The system is flexible with the ability to handle multiple diameters in one setup, making it perfect for complex blank geometries/shapes and longer batch runs.

AIMS

ANCA’s Integrated Manufacturing System (AIMS) is the future of optimized cutting tool production through streamlined manufacturing and connectivity. With ANCA and AIMS, customers can achieve continuous, unattended production that dramatically reduces non-productive machine time, with smart automation that connects sequential tool production processes and offers connectivity across the whole factory.

This is Industry 4.0 — factory-wide integration. The technology considers a factory as a single machine, rather than separating it into many different elements of design, blank preparation, grinding, laser marking, washing, packing and shipment. This is a powerful concept that brings together one ecosystem and builds it to be as efficient as possible. AIMS, being a modular solution, could be deployed in stages, allowing for easy, gradual and smooth transition from traditional to automated and integrated manufacturing.

An AIMS manufacturing cell will be displayed at GrindingHub, demonstrating a fully automatic process of tool manufacturing starting from the pallet with blanks and finishing with pallets with ground tools. 

The GrindingHub demo consists of the following components:

  • AutoSet – preparation station, it is a main operator interface. Jobs scheduled for production are downloaded through the AIMS Server to the AutoSet station and are prepared for production here, pallets are being loaded with blanks for further automatic process
  • AutoFetch – AMR (Autonomous Mobile Robot) responsible for material transfer between processes replacing operators carrying pallets or individual tools between machines/processes. The AutoFetch robot will transfer full pallets with blanks to the respective grinder, will pick up an individual tool from a grinder for out-of-process measurement and compensation and then will pick up a pallet of finished tools and transfer it to the Finished Goods area
  • MX7 Linear grinder equipped with AutoLine Advanced loader (Robomate 2 loader with AIMS kit installed), allowing for accepting pallets presented by the AutoFetch
  • Zoller Genius with Zoller AutoLine Advanced responsible for out-of-process measurement of individual tools from a batch being manufactured. Measurement values are transferred to the respective grinder and compensation of grinding parameters is taking place based on individual customers tolerance settings.

AUTOMARKX: ANCA’S AUTOMATIC LASER MARKING STATION

AutoMarkX is an automatic stand-alone laser marking station replacing manual and labor-intensive processes. It is AIMS Ready, which means it can be used as a standalone machine but could be easily integrated to your lights out, unmanned AIMS manufacturing cell with automatic pallet transfer using AutoFetch robot.

The AutoMarkX eliminates the need for manual laser marking which is a repetitive and labor-intensive job which could be automated and therefore saving you money. By avoiding manual handling, tool quality is protected by eliminating risk of chipping.

AutoMarkX accepts up to two full pallets of tools, which means you can mark a large batch of tools unmanned. Flexible marking means the message could be etched on a single side of the shank or on opposite sides of the shank as well as at the end of tool. The last option is particularly useful for applications where a unique tool identification code (e.g. Datamatrix) needs to be etched on the tool. Codes like Datamatrix are usually etched on the shank where they risk the exposure to excessive surface wear, rendering them unreadable. The end of tool is the best location to etch this type of code to overcome this issue.

AUTOMATED SMALL BATCH AND REGRINDING SOLUTION AND INSERT GRINDING DEMONSTRATIONS

ANCA understands the requirement to continuously reduce cost within the production processes which is a particular challenge in smaller production batches of complex tools and in regrinding process. To address this challenge ANCA has developed a flexible solution utilizing RFID technology, our LaserUltra closed loop measurement and barcode reader interfaced into our iGrind and end-customer’s ERP system. This system will be demonstrated on the FX7 Linear platform. The demonstration will highlight how to set up a tool for regrind utilizing a barcode reader and QR code, how to easily make adjustments within our ANCA software, what inputs are possible in an ERP system, setting up the RFID to allow mixed diameter automation and the actual grinding process itself. The FX7 Linear machine will also be fitted with the Pop-Up Steady, AutoStick, Auto Wheel Qualification and iView.   

The standalone MX7 Linear with RoboMate loader will be demonstrating ANCA’s solution for grinding and auto loading of indexable inserts. The machine and loader will be installed with workholding, grippers, pallets and interchange station specifically for the manufacture of special inserts. Accessories fitted on the machine include the 4-station Auto Stick, Auto Wheel Qualification and LaserUltra.

GCX LINEAR: GEAR UP FOR SKIVING

Driven by the automotive industry’s electrification and the general rise of e-mobility, the demand for skiving cutters has seen 30% year on year growth. The GCX Linear provides a complete solution for customers to tap into this rapidly developing market, including the ability to produce skiving cutters, shaper cutters and regrinding of hobs. It offers advanced stand-alone software to design and optimize the tool, neatly interfaced with the gear tool package inside ANCA’s renowned ToolRoom software. The machine is designed for accuracy with features including all axes with LinX linear motors and an enhanced headstock. GCX Linear also added a series of technologies: AEMS dressing, MTC on grinding spindle and dresser spindle, integrated gear tool measurement and direct compensation – setting the new standard for producing skiving tools that achieve the highest DIN AA quality class.

Due to the skiving tool’s novelty, many gear measurement machines still don’t have the correct mathematical model for evaluating the quality of the cutter. Leading the world in solving the quality control issue, ANCA developed the world-first integrated gear tool measurement system, which enables the grinding-measuring-compensation all done in the machine, as the only practical closed-loop solution.

At GrindingHub, the GCX Linear will demonstrate the skiving cutter production process assisted with the industry-first integrated gear tool measurement system.

NEW TOOLROOM RN35

Besides demonstrations on ANCA’s industry-leading ToolRoom and CIM3D software, visitors will have a special preview of the upcoming RN35 release.

ToolRoom RN35 focuses on productivity and cycle time improvements especially machine running costs. New process optimization features help to enable reduction in cycle time which in return provides better quality tools and wheel life. This includes automated reduction in air grinding time and gaps calculated based on tool simulation models. Some of the major enhancements include:

  • Feedrate optimization – Integration of Q-Prime feature in ToolRoom software to achieve constant Material Removal Rate (MRR) based on wheel manufacturers specifications. This is done by calculating and controlling non-constant feedrate where applicable to achieve better cycle time and extended wheel life. 
  • Airtime Reduction – Automated reduction in airtime by optimizing gaps based on tool simulation models and wheel shapes.  
  • Statistical Process Control (SPC) – Gives control of your production process during high volume manufacturing by monitoring the variations due to wheel wear and other process controlled activities. Process capability data can be graphically displayed or stored for future QC purposes or further evaluation. It also helps customers to control critical tool dimensions like diameter by updating wheels at regular intervals.
  • Profile Fluting – Gives the ability to control and maintain hook/rake angle along the trajectory of the cutting edge on a given profile. Increases cutting performance and life of the tool due to uniform hook/rake angle along the edge.

For further information, please contact:

Johanna Boland
Group Strategy and Communications Manager
Tel.: +61 407 799 779
E-Mail: Johanna.Boland@anca.com

ABOUT ANCA

ANCA is an advanced manufacturing company of CNC grinding machines, automation, motion control solutions and sheet metal fabrication. Founded in 1974 in Melbourne, where its global headquarters remain, it has grown to a thriving team with over 1000 talented people who work together to shape the future of technology.

As a global leader in its field, ANCA designs and manufactures highly complex and accurate machinery that requires lasers, automation and robotics to achieve accuracies in microns. It has offices in the UK, Germany, China, Thailand, India, Japan, Brazil and the USA and a comprehensive network of representatives worldwide. Its CNC grinders are used for manufacturing precision cutting tools and components across a diverse range of competitive industries including aerospace, medical cutting tools, automotive (including electric vehicles) and electronics.

ANCA partners with its customers to create bespoke solutions and invests almost 10% of annual turnover on research and development. 

Or for ANCA Europe –

Joachim Jäckl
Marketing & Communications Manager
Tel.: 49 620 184 669 14
E-Mail: joachim.jaeckl@anca.com

About ANCA Europe

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 Europe has its main technology centre in Weinheim, Germany and a smaller facility in Coventry, UK with expert teams covering service and sales, applications, customer training, operations, engineering, finance and administration. Regular customer demonstrations and events are conducted at the Weinheim technology centre. To offer customers a local experience ANCA has sales and service teams in Poland, France, Italy and Turkey as well as sales partners in Spain, Russia, Switzerland, Israel and other key European locations. See all our locations here: https://machines.anca.com/Contact

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

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Brass Fitting for Aerospace Application From Guill

Guill Tool, a growing supplier of components to the global aerospace industry, today announced the production of a new Brass Fitting. The Brass Fitting is made of C706 copper nickel alloy. 

Dimensions on this product are 1.875” outer diameter x 1.25” square each end X 5.40” overall length, or (47.625mm outer diameter x 31.75 square each end x 137.16 overall length). This Guill Brass Fitting is turned on a CNC lathe and milled on a 5-axis milling machine.

Guill now offers its substantial machine shop capabilities as an independent service to customers in aerospace manufacturing. Products are made to customer specification.

For over 55 years, Guill Tool has offered high-quality, precision machined components for the defense and commercial industries. The company manufactures flanges, valves, fittings and various critical components for aircraft, weapons and nuclear submarines.

Guill offers its full capability of CAD/CAM design, plus EDM and 5-axis machining centers to the aerospace industry.  Owing to its many years in the government and defense sectors, Guill also provides industry-standard cybersecurity and NDA confidentiality to its customers.

Guill has the following registrations and certifications: AS9100:2016 – Aerospace Manufacturing, ISO9001:2015 registered, JCP Certified – Government Contracting, ITAR Registered and NIST SP800-171Compliant Cyber-Security.


For more information, please contact:

Tom Baldock 
Guill Tool & Engineering – Aerospace Division
10 Pike Street
West Warwick, RI 0289
USA
Office: 401-828-7600
www.guill.com/aerospace

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ANCA’s FX Linear medical drill application supports tool loading for delicate dental drills

The global dental drills and burrs market is expected to display annual growth rate of approximately 6.5%. While the market is fragmented experts say that oral disease is increasing and is affecting half of the world’s population. A growing number of dental schools and dentists in developed countries is a key driver for accelerating growth in this segment.

A dental drill is popularly known as a dentist’s drill. While a source of anxiety for many, dental drills are used routinely to perform common dental procedures, like removing decay and are usually fitted to a hand-held mechanical instrument. The hand-held device works at high speeds using dental drills or burrs.

International Standards are defined for all dental rotary instruments, and each instrument is assigned a distinct ISO number code. Most common are HP Shank (ISO104) and RA Shank (ISO204 & 209) with a shank size of Ø 2.35mm.

Due to an increasing demand to grind Ø2.35mm shank medical drills, ANCA has created a special tool loading solution for FX Linear machines to address this need. Many medical drills have a short shank length with a head larger than 2.35mm.

ANCA has designed a special dental drill loading kit including tailored RoboMate pallets for FX machines using a Fanuc 200iD robot loader. The pallet top allows a reduction of the insertion depth of the shank with an 8mm pocket depth, so that drills with only 10mm of available shank length can be loaded. The robot grippers have also been modified for the reduced thickness of medical tools. The medical gripper can accommodate Ø2-10mm x 100mm with a maximum head diameter of 14mm.

Medical instruments are typically manufactured from stainless medical grade alloy, so handling can be sensitive. The small medical drill kit also includes adjustable pressure setting from 1.5bar to 5bar for tool clamping to prevent damage from tool loading, with the pressure adjustable via the RoboMate program.

The medical drill package for FX Linear machines is growing in popularity with orders steadily increasing since 2018.  

ANCA CNC tool grinders are well suited to grind a vast array of medical instruments. ToolRoom software includes tool design applications for a diverse range of round tools and burrs. Available technologies like white-sticking, in-machine wheel balancing and micro adjustable tool steadies, add to ANCA’s solutions for supporting diverse applications.


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.

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Peter Li Named President of Hunter

Peter Li President Hunter Foundry Equipment Corporation

Recently Peter J. Li became the third President in the history of Hunter Foundry Machinery Corporation, a world leader in matchplate molding and sand casting technology.  The announcement was made by Chairman of Board Bill Hunter at the company headquarters in Schaumburg, Illinois, near Chicago.   

Peter joined Hunter in May, 1996 as a sales engineer. He was promoted to Regional Sales Manager Asia Pacific in 1998. In the year 2000, he became General Manager of Hunter Shanghai; in 2016 he was promoted to Managing Director, International.  This history totals 25 years at Hunter, mainly in executive level positions.

Peter graduated from Shanghai Jiaotong University with a B.S. in Foundry Engineering. He then obtained an M.S. in Mechanical Engineering at Oklahoma State University; spent three years in the PhD Metallurgical Program at the University of Alabama, where, by coincidence, the very first Hunter molding machine was donated for that institution’s foundry education programs.

Before joining Hunter, Peter worked for Presto Castings as a metallurgist in Phoenix, Arizona. 

Peter comments, “When I first encountered a Hunter machine, I quickly realized it had a unique and very practical labor-saving aspect and this fact was a big reason for its success in the global foundry market.”  Li knew the reputation of the company’s founder, Al Hunter, as well as Bill Hunter, the two men who preceded him as President of the company. 

Li further observes, “Our challenge for the future is to keep an open mind and remove restrictions on our thinking about the foundry business.  The most successful companies in our industry have automated and that bodes well for Hunter matchplate molding machinery, automated mold handling equipment and the advanced software we bring to our customers worldwide.”  He also commented that his combination of sales, technical experience and corporate management at Hunter, both in America and at the Shanghai plant the company operates, have given him a perspective on the company and the market that will serve him well in his new role as President of Hunter.  “I do consider myself a people person and I believe that remains an important element in our relationship with the foundry business, Li added.” 

Hunter is a global force in the foundry business, with an installed base in nearly every industrialized country in the world.  In addition to the manufacturing locations in Chicago and Shanghai, Hunter has a worldwide network of sales agents.

The company was founded in 1964 by Al Hunter, who pioneered the automated matchplate molding machine concept and held dozens of patents in the industry.  His son Bill, the current Chairman of Board, likewise developed numerous innovations in sand molding machine and mold handling equipment for the global foundry market. 

In naming Peter Li the new President of Hunter, Bill commented, “Peter is exceptionally qualified for this position and we know he will lead Hunter into a bright and prosperous future.  We have a great team of people at Hunter and, under Peter’s leadership, I am certain the company will move forward in a positive direction.”    

For further information on this announcement, interested parties may contact:

HUNTER FOUNDRY MACHINERY CORPORATION
2222 Hammond Drive
Schaumburg, Illinois 60196-1094
USA
Phone:  +1 847 397 5110
Email:  info@hunterfoundry.com
Web: www.hunterfoundry.com
Attention:  Bill Hunter  

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Man scanning with the 2022 Artec Leo

Exact Metrology Announces the Availability of the 2022 Artec Leo

Exact Metrology: A Division of In-Place Machining Company and a comprehensive 3D metrology service provider and hardware sales company, now offers the 2022 Artec Leo from Artec 3D.  With the new modifications, customers can experience guaranteed accuracy, more power, improved vibrant color capture and multi-language interface.

Artec Leo used to scan a car engine

The new NVIDIA Jetson TX2 processor in this new version runs at more than twice the power of its predecessor, while consuming less than 7.5 watts. Additionally, it’s equipped with multi-core processing with the NIVIDIA Denver 2. This adds two cores and even more horsepower to what’s now a Heterogeneous Multi-Processor Architecture, with 2GHz on each of the six cores. The 2022 Leo also features a new 3D scanning experience with a fresh new user interface and a screen that’s easier to use.

Accuracy is guaranteed with a new calibration certificate. To test the accuracy, every scanner is calibrated with highly precise reference objects in different positions within the scanner’s working volume, using different parts of the scanner’s sensor and at different distances. A calibration kit has also been introduced so users can independently check the scanner accuracy and adjust the parameters. The new Auto Temperature Control enables the scanner to regulate its operation and keep its components at optimum operating temperature for capturing data at maximum accuracy.

Building on the scanner’s advanced color-capture capabilities, the 2022 Leo has algorithms to automatically adjust the brightness level when scanning, providing true-to-life evenly lit color 3D models without the need for manual correction. The new texture optimization algorithm has reduced the size of the texture by 2x, making it faster to process and load data for creating 3D color models.

Lastly, the scanner’s interface is now available in six different languages including English, Chinese, Japanese, Spanish, French and German.


In-Place Machining Company: On-Site Machining Solutions In-Place, Any Place in the World.

In-Place Machining Company, with facilities in Wisconsin, Washington, Virginia, Ohio, and Ontario, Canada, is the premier provider of high-precision engineered on-site machining, metrology, and large scale cutting & drilling services for a wide range of renewable energy, aerospace, industrial, and military customers throughout the world.                                  

Exact Metrology: A Division of In-Place Machining Company, is ISO9001, AS9100 Certified as well as ITAR Registered.

Exact Metrology: A Division of In-Place Machining Company, with facilities in Cincinnati, Ohio, Moline, Illinois and Milwaukee, Wisconsin, plus affiliated offices throughout the country, is a comprehensive metrology services provider, offering customers 3D and CT scanning, reverse engineering, quality inspection, product development and 2D drawings. The company also provides turnkey metrology solutions, including equipment sales and lease/rental arrangements.  

About Artec 3D

Artec 3D is an international company, headquartered in Luxembourg, with offices in the United States (Santa Clara, California), China (Shanghai) and Russia (Moscow). Artec 3D develops and produces innovative 3D solutions and products. Artec has a team of professional experts in the collection and processing of 3D surfaces as well as biometric facial recognition. Artec 3D’s products and services can be used in many industries, such as in engineering, medicine, media and design, entertainment, fashion, historic preservation, security technology and many more.

For more information, please contact:

Exact Metrology: A Division of In-Place Machining Company
Kelly Baldasare
11575 Goldcoast Drive   
Cincinnati, OH 45249 
Local: 513-831-6620
Toll Free: 866-722-2600
www.exactmetrology.com
kellyb@exactmetrology.com

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Acme Shaft

Acme Shaft From Guill

Guill Tool, a growing supplier of components to the global aerospace industry, today announced the production of a new Acme shaft. The Acme shaft is a square head shaft made of K-Monel. 

Dimensions on this product are 2.125” outer diameter X 1.125” over flats X 4.125” overall length, or (53.975mm outer diameter x 28.575mm over flats x 104.775mm overall length). This Guill Acme shaft is machined complete on a Mazak/Mill turn machine.

Guill now offers its substantial machine shop capabilities as an independent service to customers in aerospace manufacturing. Products are made to customer specification.

Acme Shaft
Acme Shaft

For over 55 years, Guill Tool has offered high-quality, precision machined components for the defense and commercial industries. The company manufactures flanges, valves, fittings and various critical components for aircraft, weapons and nuclear submarines.

Guill offers its full capability of CAD/CAM design, plus EDM and 5-axis machining centers to the aerospace industry.  Owing to its many years in the government and defense sectors, Guill also provides industry-standard cybersecurity and NDA confidentiality to its customers.

Guill has the following registrations and certifications: AS9100:2016 – Aerospace Manufacturing, ISO9001:2015 registered, JCP Certified – Government Contracting, ITAR Registered and NIST SP800-171Compliant Cyber-Security.


For more information, please contact:

Tom Baldock 
Guill Tool & Engineering
10 Pike Street
West Warwick, RI 02893
USA
Office: 401-828-7600
www.guill.com/aerospace

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Your Technical Guide to Grinding a High Performance Endmill (Part One)

By Thomson Mathew, Software Product Manager, ANCA

Thomson Mathew
Thomson Mathew

Thomson Mathew, ANCA’s software product manager has a huge wealth of knowledge and expertise, having worked in the cutting tool industry for almost 25 years.

The architect of many of ANCA’s market renowned software products – Thomson has written a technical guide on creating the perfect Endmill running through a five-part instructional series.

In this issue, we look at the factors which will impact the overall performance of an Endmill and “weird” Endmills that have higher geometrical levels of complexity.

PART ONE: GEOMETRY DESIGN AND PARAMETER VERIFICATION

Every Endmill begins with design and a well-designed geometry can make a high performance Endmill.

There are many factors which will impact the overall performance of an Endmill. Four major ones that get cited are the grade or quality of carbide material, the cutting tool geometry design, the precision manufacturing process or quality control and the type of coating.

The hardness of an Endmill’s material, usually carbide, will depend on the grade of carbide in the matrix. Smaller grains mean more substance versus binder, and therefore a harder tool. Exotic coatings will improve lifespan and cutting performance. Quality control means a workshop can get a consistent result.

The various type cutting tools of CNC machine on the stock shelf in the store room. The set of CNC cutting tool, solid ball, bull or radius, flat or square, tapping endmill tools.

But geometry has an outsized role, one that highlights the blend of art and engineering – and for a long time, trial and error – involved in creating the ideal Endmill. This begins with design. Some of the important factors in Endmill design include the combination of both variable helix and index flute geometry design, core geometry design, the OD clearance angles eccentric versus facet reliefs design, endface design with wiper flats and pad grinding or end dubbing etc. each time from a set of Endmills.

As I have written elsewhere, the progress of the industry has seen Endmills grow increasingly “weird” as toolmakers have sought high material removal rates while avoiding “chatter”.

Regenerative chatter happens when the harmonics between a tool and workpiece are at different frequencies. The two self-excited objects will hit against each other, which is a negative for surface finish and dimensional accuracy, as well as the lifespan of the tool and machinery. It is a drain on productivity and profits.

High helix tools (over 35 degrees) have long been popular for their strength and fast feed and swarf removal rates. While they have these advantages over low helix Endmills for hard materials, they are also the more prone of the two to chatter. Some of the trial and error to combat this has been around variable helixes and pitches and trying to better balance tools. This has led to “weird” Endmills, with higher geometrical levels of complexity.

Low Helix (15 degrees) to High Helix (60 Degrees)
Low Helix (15 degrees) to High Helix (60 Degrees)

In high helix tools the cutting forces are directed more vertically and less horizontally, which reduces tool deflection and results in quick and efficient chip evacuation.

More positive axial rake lowers cutting forces which helps to increase feedrates. The core of the tool is thicker due to the shape of the helix and the tool is stronger. High helix Endmills are typically used in tougher harder materials because they wear better, although they can also be used in softer materials like aluminium. One disadvantage of high helix Endmills is the tendency to chatter more, and they really bite into the material.

On the contrary, low helix tools are less likely to chatter and typically perform better in soft materials. Their disadvantage is the lower feedrates and hence lower material removal rates. Our understanding of how to mitigate chatter has come a long way and involves no guesswork nowadays. The geometry and design are purely based on material to be cut whether it is soft or hard.

Variable helix end mills with variable index are considered state of the art these days. The idea is to vary the helix along the flute length or from flute-to-flute. The aim of the variable helix is to fight chatter. Since chatter is a resonance effect, anything we can do to break up the resonance of the flutes beating against the workpiece will reduce chatter. The tool balancing capabilities in the RN34 release of ANCA’s ToolRoom software is the perfect solution to combat chatter.


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.

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Exact Metrology Scans an AA Battery

Exact Metrology: A Division of In-Place Machining Company and a comprehensive 3D metrology service provider and hardware sales company, recently used CT technology for an interesting project. The goal was to obtain an inside look at an AA battery.

The ZEISS METROTOM 6 scout, formally known as a GOM CT, was used. Considered the powerhouse of resolution for CT and inspection and metrology, the METROTOM 6 scout digitizes complex parts including the internal geometries at the finest level of detail. Users obtain a complete 3D image for GD&T analysis or nominal-actual comparisons. The metrology CT excels in digitizing small plastic parts.  Furthermore, the combination of a 3k detector and 225 kV X-ray enables ZEISS METROTOM 6 scout to provide high contrast, high-resolution measurement results and exceptional sharpness of detail.

Hayden Lee headshot

Using CT technology, Hayden Lee, Exact Metrology Applications Engineer, separated the battery into several 3D elements. Thus, he was able to obtain several different types of measurements in different portions of the battery and also extract several battery elements such as:  pin, separator wall and case.  A color map using GOM Inspect was also created of the pin cylinder inside the battery.  The software analyzes 3D measuring data from fringe projections or laser scanners, CMMs and other measuring systems. The GOM software is used in product development, quality control and production. Obviously, it’s very dangerous to cut apart a battery or destroy it. According to Hayden, “CT scanning allows you to internally inspect something, even an alkaline battery, without having to destroy it.” This of course allows for better safety and precision.  Additional benefits of CT include very little time to capture data and troubleshoot parts and multiple uses with one scan. In contrast to conventional tactile coordinate measurement techniques, a CT acquires all surface points simultaneously —on even the most complex objects.


In-Place Machining Company: On-Site Machining Solutions In-Place, Any Place in the World.

In-Place Machining Company, with facilities in Wisconsin, Washington, Virginia, Ohio, and Ontario, Canada, is the premier provider of high-precision engineered on-site machining, metrology, and large scale cutting & drilling services for a wide range of renewable energy, aerospace, industrial, and military customers throughout the world.                                  

Exact Metrology: A Division of In-Place Machining Company, is ISO9001, AS9100 Certified as well as ITAR Registered.

Exact Metrology: A Division of In-Place Machining Company, with facilities in Cincinnati, Ohio, Moline, Illinois and Milwaukee, Wisconsin, plus affiliated offices throughout the country, is a comprehensive metrology services provider, offering customers 3D and CT scanning, reverse engineering, quality inspection, product development and 2D drawings. The company also provides turnkey metrology solutions, including equipment sales and lease/rental arrangements.  

For more information, please contact:

Exact Metrology: A Division of In-Place Machining Company
Kelly Baldasare
11575 Goldcoast Drive   
Cincinnati, OH 45249 
Local: 513-831-6620
Toll Free: 866-722-2600
www.exactmetrology.com
kellyb@exactmetrology.com

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Siemens Offers Turnkey Logistic Solutions for Material Handling Processes at MODEX 2022

Displays include hardware automation and software solutions specific to today’s material handling / intralogistics challenges

Siemens will exhibit at MODEX 2022 in Atlanta at the Georgia World Congress Center from March 28-31, 2022. MODEX is the premier supply chain event, attracting industry professionals from across the globe.

With its new SINAMICS G115D, Siemens presents a new, compact and powerful drive system specifically designed for horizontal conveyor applications.

Highlights will include the new SIMATIC MICRO-DRIVE, designed for ultra-low-voltage applications, in a demonstration of an automated guided vehicle (AGV). Also featured will be the new SINAMICS G115D, a recently released distributed drive system, specifically designed for conveyor applications.

Displays in the Siemens booth will include drives for motion control, material handling and intralogistics applications that are controlled by SIMATIC PLCs with unified HMI panels
and integrated safety, all programmed in the Siemens Totally Integrated Automation (TIA) Portal. Additional topics in the booth include Industrial Edge and cybersecurity.

Another highlight will focus on a project Siemens recently completed for a customer in Kentucky. Siemens supplied a fully automated mega warehouse with 200,000 pallet positions as a turnkey project which distributes laundry and home care products to 60% of the U.S. market, with all logistics operations performed at this production site. The benefits Siemens offered, in addition to all mechanical deliveries, include a modular automation standard by SIMATIC, SINAMICS, SIMOTICS and SIMOGEAR standard components and INTRALOG TIA software modules resulting in increased delivery reliability (on-time and defect-free.)

Smart factories, the foundation of smart manufacturing, connect the digital and physical worlds to monitor an entire production process — from supply chain management to manufacturing tools and even the work of individual operators on the shop-floor. Explore the Siemens Automation portfolio for a fully integrated, collaborative manufacturing system on your journey to a digital transformation.

In the booth, Siemens technical experts will be available for hands-on demonstrations and to answer questions. Editors are welcome to stop by.


For specific product information and inquiries, send an e-mail to:
mc.us@siemens.com

Smart factories, the foundation of smart manufacturing, connect the digital and physical worlds to monitor an entire production process — from supply chain management to manufacturing tools and even the work of individual operators on the shop-floor.

Explore the Siemens Automation portfolio for a fully integrated, collaborative manufacturing system on your journey to a digital transformation.

Siemens Digital Industries (DI) Siemens Digital Industries (DI) is an innovation leader in automation and digitalization. Closely collaborating with partners and customers, DI drives the digital transformation in the process and discrete industries. With its Digital Enterprise portfolio, DI provides companies of all sizes with an end-to-end set of products, solutions and services to integrate and digitalize the entire value chain. Optimized for the specific needs of each industry, DI’s unique portfolio supports customers to achieve greater productivity and flexibility. DI is constantly adding innovations to its portfolio to integrate cutting-edge future technologies. Siemens Digital Industries has its global headquarters in Nuremberg, Germany, and has around 72,000 employees internationally.

Siemens Corporation is a U.S. subsidiary of Siemens AG, a global technology powerhouse that has stood for engineering excellence, innovation, quality, reliability and internationality for more than 170 years. Active around the world, the company focuses on intelligent infrastructure for buildings and distributed energy systems and on automation and digitalization in the process and manufacturing industries. Siemens brings together the digital and physical worlds to benefit customers and society. Through Mobility, a leading supplier of intelligent mobility solutions for rail and road transport, Siemens is helping to shape the world market for passenger and freight services. Via its majority stake in the publicly listed company Siemens Healthineers, Siemens is also a world-leading supplier of medical technology and digital health services. In addition, Siemens holds a minority stake in Siemens Energy, a global leader in the transmission and generation of electrical power that has been listed on the stock exchange since September 28, 2020. In fiscal 2020, Siemens Group USA generated revenue of $17 billion and employs approximately 40,000 people serving customers in all 50 states and Puerto Rico.

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90 Degree Adapter From Guill

Guill Tool, a growing supplier of components to the global aerospace industry, today announced the production of a 90 degree adapter. The adapter is made of 304 stainless steel and measures 1.498” X 1.825” X 3.188” (38.049mm x 46.355mm x 80.975mm) overall length.

The adapter is turned on a Yama Seiki turning center and finished machining on a Bridgeport manual milling machine.

Guill now offers its substantial machine shop capabilities as an independent service to customers in aerospace manufacturing. Products are made to customer specification.

For over 55 years, Guill Tool has offered high-quality, precision machined components for the defense and commercial industries. The company manufactures flanges, valves, fittings and various critical components for aircraft, weapons and nuclear submarines.

Guill offers its full capability of CAD/CAM design, plus EDM and 5-axis machining centers to the aerospace industry.  Owing to its many years in the government and defense sectors, Guill also provides industry-standard cybersecurity and NDA confidentiality to its customers.

Guill has the following registrations and certifications: AS9100:2016 – Aerospace Manufacturing, ISO9001:2015 registered, JCP Certified – Government Contracting, ITAR Registered and NIST SP800-171Compliant Cyber-Security.


For more information, please contact:

Tom Baldock 
Guill Tool & Engineering
10 Pike Street
West Warwick, RI 02893
USA
Office: 401-828-7600
www.guill.com/aerospace

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