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E-Z LOK to Exhibit New Metal Inserts at IMTS 2024, Booth 432123

Sharing a booth with its sister company TCI Precision Metals

E-Z LOK, a leading manufacturer and master distributor of threaded inserts for metal, plastic and wood will display its products during IMTS 2024, in Chicago, September 9-14 in Booth 432123.  The company will be co-located with its sister company TCI Precision Metals, a leading supplier of metal materials and near-net shapes to machine shops and fabricators.  Highlight of the show for E-Z LOK will be its new line of ultrasonic/heat-stake metal inserts and staking tools for plastics, which can be used for OEM builds as well as retrofits and even injection molding over core pins for creation of strong components with higher torque and pullout strength in use. 

Kyle Lindsly-Roach, Director of Sales & Marketing and Steve Schaeper

In addition, the full line of E-Z LOK threaded carbon inserts with factory-applied LOCTITE™ 204 adhesive coating will be displayed.  Once installed in a metal substrate for repair or added strength in an OEM application, the adhesive seals against liquids and gases to 6000 psi and can perform in temperatures up to 300°F.  These proprietary inserts were developed by the current owner Ben Belzer’s grandfather for the aerospace industry as an alternative to helical inserts. 

A new feature of the E-Z LOK website, www.ezlok.com is the CAD file, which allows an engineer to incorporate any of the thousands of E-Z LOK insert into a design.

Director of Sales & Marketing, Kyle Lindsly-Roach and a team of E-Z LOK engineers will attend the show, displaying the full line of E-Z LOK products. Emphasis will be placed on the company’s threaded inserts for metal, wood and plastic. Speaking about his hopes for the show, Lindsly-Roach said, “We are excited to be able to present our portfolio of products to a wide range of customers, including engineers, OEMs and distributors. We hope to be able to expand our customer base and the industries where our products are, as well as our existing supply chain partners in the OEM, fastener distributor and machine shops.”

Visit E-Z LOK at IMTS Booth 432123 during the show.

For more information, please contact: 

Kyle Lindsly-Roach, Director of Sales & Marketing
E-Z LOK
240 E. Rosecrans Ave
Gardena, CA 90248
USA
Phone: 310-323-5613 x221
klindsly@ezlok.com
www.ezlok.com 

E-Z LOK is a leading manufacturer and master distributor of threaded inserts for metal, plastic and wood. Inserts for metal include solid wall and helical wire-thread inserts, while inserts for plastic feature press-in and ultrasonic/heat stake designs. Those for wood are die cast zinc alloy hex drives for softwood and brass knife threads for hardwood. A variety of kits for the above inserts are available and feature installation tools, drill bits, etc.

E-Z LOK is a third-generation family owned and operated company. Founded in 1956, it primarily sells through local, regional and national industrial distributors, as well as direct to major OEM’s in a variety of end user market segments. 

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ANCA MicroX ULTRA Grinding Machine and AIMS Connect Highlighted at IMTS 2024

Eight machines plus the newest ANCA Integrated Manufacturing System (AIMS) to be featured in Booth 237406, as the company celebrates its 50th anniversary and the opening of its LA Tech Center

At IMTS 2024, ANCA CNC Machines has much to offer the market and is also celebrating several highpoints in its storied history.  In addition to the introduction of an advanced, high-precision tool grinder, the MicroX ULTRA, as well as the next generation of integrated manufacturing technology, AIMS Connect, ANCA will further highlight its commitment to offering the best-in-class solutions for tool grinding production, start to finish, with the celebration of its 50th anniversary in business (1974-2024) and the recent opening of its newest Tech Center in Temecula, California to serve its fast-growing West Coast market base. 

ANCA, a global leader in CNC grinding machines and automated manufacturing technologies, celebrates its 50th anniversary, displaying its latest innovations at IMTS. As a mainstay in the precision tool industry, ANCA will showcase its commitment to excellence through new products, cutting-edge technologies and exciting business events, including its popular Tool of the Year and Female Machinist of the Year awards. The anniversary showcase addresses manufacturers’ needs for highest quality and lowest cost tools, plus freeing operators from repetitive and non-value-add tasks to make room for progress and creativity.  

Pat Boland, ANCA co-founder, remarks, “For 50 years, ANCA has been on a journey to change the shape of the cutting tool industry. To celebrate our 50th anniversary, we look forward to meeting with our customers and partners at IMTS. As innovation has motivated us throughout our history, new products and developments will be at the center of our celebrations. ANCA’s future is exciting, we are focused on continuing to invent and deliver groundbreaking technology to help take cutting tool production into areas not previously thought possible.”

Edmund Boland, ANCA CNC Machines General Manager, adds, “IMTS is the major global event in this milestone year for our company, so it’s thrilling to showcase our latest products and technologies for high performance cutting tools produced with optimized efficiency and cost. Building on ANCA’s heritage of producing industry-leading software, the latest release of our signature ToolRoom software, RN35, takes cycle time optimization even further, elevating productivity – it’s the future of tool production.”

“ToolRoom and AIMS really pave the way for highly productive, autonomous production. Our investment in AIMS for connected and automated processes is our commitment to solving key challenges such as labor shortages and consistent production processes with smart, future-ready solutions. Our ULTRA technology has made a splash in the market, and now enables micro tool production, regrinding and small batch production with the MicroX and FX7 ULTRA,” notes Edmund.

50 years of innovation and “thinking outside of the box”

ANCA started with a minicomputer and teletype installed at co-founder Pat Boland’s home, followed by a CNC and then the design and manufacture of machine tools with co-founder Pat McCluskey. Throughout the years, ANCA has brought significant advantages to the industry with pioneering innovations like the first touch probe, soft axes and 3D simulation.

Naturally, software and automation are key highlights of ANCA’s anniversary innovation portfolio. The latest version of ANCA’s ToolRoom software, RN35, offers:

  • Average performance increase of up to 20% with advanced features and functions, optimizing feedrate, improving cycle time and surface finish, while extending wheel life.
  • New developments including the integration of material removal rate calculations, allowing manufacturers to automatically set parameters for constant removal rates, plus air-time reduction.
  • Statistical Process Control (SPC) software for statistical analysis and evaluation of manufactured part characteristics streamlines manufacturing processes.
  • Profile fluting further enhancing the popular flute from solid feature of the proprietary ANCA software.

Experts will present these and other upgrades to IMTS visitors, plus further exciting news in CIM3D simulation software.

The Future of Automation in Tool Production IS here today…AIMS

The ANCA Automated Manufacturing System (AIMS) is a highly integrated, advanced automation system that brings together machining, metrology and materials handling plus data management in a leading-edge ecosystem for a lights-out production of tools used in myriad industries.

https://machines.anca.com/Products/Integrated-Manufacturing/AIMS (includes a video demo)

ANCA’s AIMS (ANCA Integrated Manufacturing System) is the smart manufacturing solution for cutting tool production, enabling manufacturers to connect, automate and create like never before. The modular system comprises hardware and software components for automated, closed loop manufacturing. AIMS Server controls production processes and AutoComp, the intelligent compensation module maintains part quality automatically, while the new AIMS Connect function covers job management.

With AIMS Connect, recently debuted at GrindingHub in Germany, visitors can experience firsthand the power of digital production control and modular automation, now available for existing installations. The system has proven in the field that it empowers manufacturers to explore new opportunities, products and features while maximizing productivity and quality.

AIMS is growing in popularity, as it enables shops of all sizes plus huge production departments the flexibility to integrate machining, metrology and materials handling into a unified ecosystem with full data capture and management capabilities. 

Machines and technology for highest quality and lowest cost tools

ANCA’s GCX machine and gear tool technology is set to redefine the production of skiving cutters with a turnkey solution package. To address the complexity of gear tool manufacturing, this offering includes features for the design of gear cutting tools, manufacturing and integrated tool measurement, as well as providing the skiving machine setup parameters.

IMTS visitors will witness live how this configuration enables short setup times, simulation and monitoring, plus quality enhancing features like the ANCA Motor Temperature Control (MTC) and integrated balancing (iBalance) for unparalleled longtime grinding profile accuracy within +/-0.0015mm. This turnkey package facilitates easy entry into the gear tools sector while ensuring top-quality results.

ULTRA Technology: the platform for highest precision and micro tool work

Revolutionary ULTRA technology combines nanometer control, servo-controlled algorithms and mechanical stiffness upgrades to achieve unprecedented accuracy. The FX7 ULTRA and MicroX ULTRA demonstrate ANCA’s commitment to precision, enabling continuous batch production down to 0.03mm and setting new standards in tool manufacturing.

The MicroX ULTRA premiered at EMO 2023 and was released to the market at GrindingHub, giving micro tool manufacturers all the advantages of the ULTRA technology and ANCA’s Machine Intelligence in a unit tailored to this application. As the only micro tool grinder with nanometer control, optimized mechanical layout and axes travel, integrated tool measurement and progressive automation, this six-axis grinder is the ideal solution for volume production of tools down to 0.03mm.

Customer-centric solutions enable enhancements

Laser measuring on the EPX-SF


The new EPX-SF stream finishing machine was released to the market at GrindingHub. ANCA’s advanced edge preparation and surface finishing solution addresses productivity targets, delivers superior IP cutting tool performance and succeeds in precision-critical industries – in a design that’s ready to be integrated in automated tool manufacturing systems. With 11-axis automation and smart recipe fine-tuning, the machine is engineered by tool experts to optimize media utilization while providing precise edge control. The machine has the capability to reduce edge roughness to under 100 nm and refine edge radii to mere microns with controllable K-factor, achieving nano-smooth surfaces and micron-honed edges in record time.

The EPX-SF’s cyclic mode with pulse rotation serves as a potent defense against surface burrs and edge imperfections. With adjustable positive and negative angles, the EPX-SF spindle traverses the optimal cutting path, optimizing potential chip flow and reducing the surface roughness of the cutting workpiece. Within ANCA’s automation ecosystem, the EPX-SF seamlessly integrates into production lines, operating autonomously with robotic assistance round the clock for tool loading/unloading.

The CPX blank preparation machine is a prime example of how to include the voice of the customer in product development. Tool manufacturers around the world were asked and given their ideal solution for blanks with high material removal rates, application flexibility and integrated quality control. With features like statistical process control and top surface finishes below 0.2Ra, manufacturers can achieve high productivity at minimal cost with the CPX Linear. Some further application capability will be introduced at IMTS. 

ANCA invites visitors to join us at IMTS Booth 237406 to experience firsthand the future of tool manufacturing.


For further information, please contact:

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

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

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

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E-Z LOK to Exhibit at Fastener Fair

E-Z LOK, a leading manufacturer and master distributor of threaded inserts for metal, plastic and wood will display its products during Fastener Fair, May 22-23th at the Huntington Convention Center in Cleveland, Ohio.

Fastener Fair is North America’s premier trade show and conference for the fastener industry and its allied manufacturing sectors. It covers every facet of the industry from manufacturers to master distributors, equipment makers, processors, packagers, and end-users. Industries represented include advanced manufacturing, aerospace, agriculture and off-highway, appliances, automotive, construction, distribution and electronic/telecom. Additional industries are furniture, industrial machinery, maintenance, marine military and renewable energy.

The event provides a unique opportunity for attendees to network with peers, exchange ideas and establish new relationships. They can explore the latest products and technologies in the fastener industry and gain insights into emerging trends. Furthermore, expert-led sessions and workshops offer valuable insights into the latest industry developments, best practices and regulatory updates. Companies can source new suppliers, evaluate products/services and compare prices to make informed purchasing decisions. Lastly, Fastener Fair provides participants with the ability to enhance their professional skills, expand their knowledge base and stay abreast of industry trends and advancements.

Director of Sales & Marketing, Kyle Lindsly-Roach will be at the show, displaying the full line of E-Z LOK products. Emphasis will be placed on the company’s threaded inserts for metal, wood and plastic. Speaking about his hopes for the show, Lindsly-Roach said, “We are excited to be able to present our portfolio of products to a wide range of customers, including engineers, OEMs and distributors. We hope to be able to expand our customer base and industries our products are used in.”

Visit E-Z LOK at stand 542 during the show.

FREE SAMPLE ON REQUEST


For more information, please contact: 

Kyle Lindsly-Roach, Director of Sales & Marketing
E-Z LOK
240 E. Rosecrans Ave
Gardena, CA 90248
USA
Phone: 310-323-5613 x221
klindsly@ezlok.com
www.ezlok.com 

E-Z LOK is a leading manufacturer and master distributor of threaded inserts for metal, plastic and wood. Inserts for metal include solid wall and helical wire-thread inserts, while inserts for plastic feature press-in and ultrasonic/heat stake designs. Those for wood are die cast zinc alloy hex drives for softwood and brass knife threads for hardwood. A variety of kits for the above inserts are available and feature installation tools, drill bits, etc.

E-Z LOK is a third- generation family owned and operated company. Founded in 1956, it primarily sells through local, regional, and national industrial distributors.

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ANCA’s AIMS selected as finalist for 2024 Manufacturing Leadership Council Awards

The Manufacturing Leadership Council (MLC) is the digital transformation division of the National Association of Manufacturers and, as part of its mission, annually seeks world-class manufacturing companies and key individuals who contribute to the technology. 2024 marks the 20th anniversary of this premier awards program. 

On June 5, 2024, various companies and individuals who have made significant contributions to the digital manufacturing transformation in America will be recognized and winners named throughout 9 categories.  Among the finalists for the prestigious Engineering and Production Technology award is the ANCA Integrated Manufacturing System (AIMS), a recently developed, fully automated grinding, gauging and materials handling system with workflow monitoring, full tracking and data management capability.  It allows shops and production departments to achieve a lights-out manufacturing ecosystem in coordination with company control protocols.  ANCA is an acknowledged global leader in this technology. 

The ANCA Integrated Manufacturing System (AIMS) offers an open ecosystem that aims to connectautomate and create all steps in the production of cutting tools for a broad spectrum of industrial applications, including automotive, medical, aerospace, electronics and woodworking. 

Manufacturing processes controlled by AIMS achieve higher machine utilization while maintaining consistently high tool quality. Thanks to sophisticated tool measurement and compensation strategies, scrap is reduced and costs per tool are significantly lowered. Comprehensive reporting and intelligent insights supported by machine learning provide complete visibility into all aspects of operations.

AIMS is designed as an open system and allows the integration of third-party machines and workstations, plus AGV’s for material transport. 

AIMS Connect
Connects all operations that are carried out to manufacture cutting tools. The central AIMS server controls compliance with the processes that a tool passes through during its manufacture. It checks whether the various process steps are being carried out and takes action if the process is not being executed to preset standards. An information system guides employees to carry out manual process steps.

AIMS Automate
Automation of connected operations through the use of robots such as AMR for transfer or cobots for palletizing tools. A self-optimizing job scheduler ensures an ideal supply of pallets to the machines or provides individual tools for measurement.

AIMS Create
Create individual and customized workflow for the tool, based on linked operations. Workflows and processes can be described and stored with ISA-95 compliant recipes. Job orders are transferred to production via the link to recipes and the creation of work requests. Work cells, work units and assets are managed just as easily as grinding programs and grinding wheels. AIMS Create provides the cockpit for creating processes. Thanks to the state-of-the-art web application, this can be done on almost all smart devices and computers.

ANCA president for North America, Russell Riddiford, comments, “ANCA is very proud to be in the running for this award from the MLC.  We support the digital transformation effort in both our machine building and motion control operations, as we seek to provide our customers the machines and software needed to move their companies in this exciting new direction, within industries of all kinds.” 

The 2024 MLC Awards feature nine categories to recognize company achievements in AI and Machine Learning; Collaborative Ecosystems; Digital Network Connectivity; Digital Supply Chains; Engineering and Production Technology (the category in which AIMS is a finalist); Enterprise Integration and Technology; Operational Excellence; Sustainability and Circular Economy; plus Transformational Business Cultures.  Additionally, individuals are entered into the Transformation Leadership and Next-Generation Leadership categories.  The finalists represent a cross-section of industries, comprising global multi-nationals and start-up companies.  The awards are judged by distinguished individuals from across many industrial sectors. 

ANCA is based in Melbourne, Australia with its North American headquarters in Detroit, Michigan, where it operates a full tech center, including machines and training for its customers. 


For further information, please contact:

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

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

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

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E-Z LOK Threaded Inserts for Hardwood

E-Z LOK, a leading manufacturer and master distributor of threaded inserts for metal, plastic and wood is now offering E-Z™ Knife brass and stainless steel threaded inserts for wood.

Suited for use in hardwoods like oak, cherry and maple, these inserts are ideal wherever assembly or disassembly could cause thread erosion or stripping. E-Z Knife™ threaded inserts use a proprietary external “knife” thread to slice into the wood and provide superior holding power.  They are most often machined out of brass when internal thread sizes range from #4 to ⅜ or M3 to M8. Notable features include superior hardwood holding power with sizes available in inch (coarse/fine) and metric. The inserts easily install with a bolt/jam nut or optional drive tool.

Brass inserts are ideal for furniture, cabinetry and partitions, while stainless steel is used in marine applications. Several industries including shipping containers, outdoor furniture and storm shutters use either.

E-Z™ Knife threaded inserts and thread repair kits provide an easy solution for adding machine threads to hard woods. They can also be used for softwood, but they are not recommended for plywood. A proprietary external thread for superior holding power is used by these inserts.

FREE SAMPLE ON REQUEST

CAD files on this product can be downloaded in over 100 file formats from the E-Z LOK website at https://www.ezlok.com/cad-downloads


For more information, please contact: 

Kyle Lindsly-Roach, Director of Sales & Marketing
E-Z LOK
240 E. Rosecrans Ave
Gardena, CA 90248
USA
Phone: 310-323-5613 x221
klindsly@ezlok.com
www.ezlok.com 

E-Z LOK is a leading manufacturer and master distributor of threaded inserts for metal, plastic and wood. Inserts for metal include solid wall and helical wire-thread inserts, while inserts for plastic feature press-in and ultrasonic/heat stake designs. Those for wood are die cast zinc alloy hex drives for soft wood and brass knife threads for hardwood. A variety of kits for the above inserts are available and feature installation tools, drill bits, etc.

E-Z LOK is a third-generation family owned and operated company. Founded in 1956, it primarily sells through local, regional, and national industrial distributors.

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ANCA Expands Its Global Footprint Opening a New Technology Center in Korea

ANCA, a leading innovator in precision grinding solutions, is thrilled to announce the grand opening of its new state-of-the-art Technology Center in Korea. ANCA has offered local sales and service to customers across diverse industries for more than 30 years in the Korean market and opening the new facility is a significant milestone for the company as it expands its presence in the Asian market.

Jake Farragher, General Manager of ANCA Asia, says, “ANCA’s newest technology center is a commitment to our customers in Korea. This investment in our global infrastructure enables our team to deliver premium sales and service support to this important and growing market. We understand the importance of offering customers local support and at our new facility we can showcase the capability of our flexible grinding machines, world-leading software, and market-first automation solutions.”

“Thanks to our long-standing partnership with SH International in Korea, we have a legacy of innovation with our customers in the market, and our local team at our new ANCA office is poised to facilitate our customers’ success into the future.”

“We are excited for our new center to serve as a hub for grinding excellence, innovation and collaboration, confirming our position as a global leader in the tool and cutter grinding industry and medical tools industry.”

For 50 years ANCA has committed to providing cutting-edge grinding solutions worldwide, and ANCA Korea, located near Seoul, is equipped with the latest technologies, such as ANCA’s ULTRA technology with nanometer resolution control.

The demonstration facility provides the ULTRA experience with ANCA’s MX and FX ULTRA machines, as well as automation solutions with ANCA’s Integrated Manufacturing System (AIMS). The facility additionally includes support and training services.

The grand opening event was attended by key stakeholders and customers, industry partners, and local dignitaries.

Celebrating 50 Years and Innovating the Future with ULTRA Technology

Pat Boland, ANCA Co-founder said: “50 years ago, Pat McCluskey and I did not anticipate ANCA to be what it is today. We embarked on a business journey that felt in hindsight like stepping onto a treadmill, with our customers driving the speed. Yet we have not only kept pace with the market, we’ve surged ahead, introducing cutting-edge innovations. I am proud of the technology we are still releasing, such as the ULTRA and GCX packages and the many innovations that underpin these product releases.”

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

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

ANCA’s 50th anniversary marks a half century of the company’s relentless pursuit of excellence and commitment to pushing the boundaries of precision grinding technology. The ULTRA machine range, with its nanometer technology, allows customers to produce the best tools in the market through superior accuracy, quality and surface finish.

The ANCA Integrated Manufacturing System (AIMS) is a groundbreaking advancement in grinding technology. AIMS connects, automates and creates all processes required to manufacture a cutting tool, ensuring maximum accuracy and consistency while minimizing downtime – enabling end-to-end digitally connected and automated production systems for cutting tools.


For media inquiries or more information, please contact:

Sepideh Zandieh

Acting Group Communications Manager
sepideh.zandieh@anca.com
Phone: 0439 316 131

About ANCA:

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

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

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ARCH Cutting Tools produces a unique 3-flute carbide helical cutter that delivers unequaled part finish, higher throughput, and longer tool life in machining a polyethylene tibial insert

Creating High Performance Tools for Machining Medical Components

Truly optimizing medical machining often requires specialized cutters, and there’s no better model for designing and grinding them than ARCH Cutting Tools, headquartered in Warren, Michigan, USA.

Take the task of machining a polyethylene tibial insert. As ARCH Cutting Tools’s northeastern regional director of operations, Jim Gray, spelled out, this has almost always been done with a single, flat blade mounted in a holder so as to maximize the shear angle. But, said Gray, this design often produces lines on the surface, or an “orange peel” effect, due to burning, as it doesn’t cut the polyethylene as cleanly as desired. A straight flute design also impacts the part with a lot of force on each rotation.

Gray’s team instead used their knowledge and ANCA’s programming software to create a unique 1½” (38.1 mm) diameter 3-flute carbide helical cutter with high shear and multiple radii along the profile. They grind it on an ANCA MX7 machine, using a dozen wheels to create a mirror finish and a cutting edge “sharper than a razor blade,” as Gray described it. “You need a very sharp edge to cut the plastic perfectly cleanly. Even a diamond grain that goes through cutting edge, leaving a tiny chip, will show up in the insert. We inspect these tools under a microscope to confirm the edge is crisp and clean.” Gray added that their helical design also distributes the cutting forces, in contrast to a straight flute. In sum, the ARCH Cutting Tools solution delivers an outstanding part finish, higher throughput, and longer tool life.

These ball nose end mills (for machining hip stems) feature a perfect transition from the ball radius to the OD, and an end face gash that meets exactly at the center
ARCH Cutting Tools produces a unique 3-flute carbide helical cutter that delivers unequaled part finish, higher throughput, and longer tool life in machining a polyethylene tibial insert
This complex trepan cutter was created to meet an urgent need for cutting non-ferrous material used in respiratory equipment. The tool features a very fine finish and leaves no marks on the part. Gray reported that “the customer was ecstatic”

Replicating perfection

Gray also pointed out that in addition to the tool design assistance derived from ANCA’s programming software, which includes full 3D simulation, the ToolDraft feature enables detailed documentation for process control. “Instead of relying on 2D drawings on the shop floor,” Gray expounded, “ToolDraft gives us the ability lay out every aspect of the tool and the required grinding wheels. One page covers the gullet shape, with the roughing wheel, the finishing wheels, and any information related to fluting. The next page covers profiling, again with all the wheel shapes and data, and the required clearance angles, land width, and other tool geometries. And so forth for the end face. We also add notes to each drawing to provide detail on what’s pertinent to this tool…what really makes it work.

“We love what ToolDraft does for us. Because if all you put out on the floor is a 2D drawing with an outside diameter or shape of the tool, the operator can say ‘This tool is good. It’s to print,’ when in reality, the body’s thin and the rake is not right. There are so many things that go into why we designed a tool a certain way, that if we don’t get complete information to the operator, everyone can have a different opinion about what constitutes a correct copy. We’ve promised our customers that no matter what person and what machine grinds their tool, they’ll get the same tool every time. And the only way we can keep that promise is with the documentation we’ve created with ToolDraft.”

Gray added that although it’s possible to grind such tools with a ball screw driven machine, it’s much easier to produce them with ANCA’s newer linear motor technology. “Linear motors have definitely changed our world when it comes to finishes and transitioning for profile cutters,” he explained. “They make it easier to grind the profile, especially with a tool like a condyle cutter, because multiple radiuses go up and over the edge. If you’re grinding in just one direction, a ball screw machine is fine. But if you go up and over and you need to produce multiple radiuses in the front and multiple radiuses in the back, that little backlash or wear in the ball screws will force you to fight until you get it all settled and tweaked in. Whereas with a linear motor machine, it’s just true from the start.”

Not all ball nose end mills are equal

Moving on to hip stems, Gray said machining up and over these parts requires ball nose end mills in which the radius and its transition to the OD must be perfect. The end face gashing must also meet exactly at the center. “Any mismatch in the center of the ball nose will put a line in the hip stem, and that’s not acceptable.” Any error in the radius will create geometrical distortion in the part profile, he added. “We scan that whole radius to ensure it’s correct.”

Hip stems have generally been made of titanium and cobalt chromium, Gray explained. These materials are challenging enough, but Gray said the new 3D printed titanium alloys from leading medical suppliers are even more difficult to machine. They’re porous, to facilitate integration with the patient’s bone, which essentially guarantees an interrupted cut. The material is also highly abrasive. Thus, minimizing tool changes and increasing manufacturing speed to achieve an acceptable level of efficiency requires an engineered solution from the likes of ARCH Cutting Tools.

Fast turn-around for custom tools and regrinds

In another example of ARCH Cutting Tools coming to the rescue, a customer suddenly ran out of an imported, replaceable head, keyseat cutter during production. ARCH Cutting Tools delivered a custom engineered, solid carbide version, with coating, in under 48 hours. In another case, ARCH Cutting Tools created a multi-step counterbore that combined 6 different operations in one tool for machining titanium and superalloys. Both examples again point to the power of combining experienced grinding professionals with ANCA’s software and machines to produce high quality medical devices that improve a person’s life.

Regrinding is yet another such area. Not only does ARCH Cutting Tools reliably return used tools to new condition, Gray said there are numerous cases in which they’ve actually improved upon the original tool. “One of our bigger medical customers was buying a faceted drill from one of the world leaders in cutting tools,” recalled Gray. “The drill was being used on titanium, and we put a roll point on it and made some other changes to the geometry that made the reground drill run better than the new tools.”

In this context, Gray praised ANCA’s integrated laser to automatically check for and correct errors in tool runout, and ANCA’s probing capability. In addition to probing coolant holes to ensure proper tool orientation for a regrind, Gray said ANCA makes it easy to probe the entire point profile to enable K-land grinding, a notoriously fiendish task. “You adjust how many points you want along that edge,” Gray expounded. “And if you’re manufacturing the tool, you can probe the profile once and store that data. From then on you don’t have to re-probe to produce a good K-land, until wheel wear becomes a factor.”

Wheel wear would cause the K-land to vary, Gray added, but he again pointed to the ease of re-probing the profile to make adjustments, plus the existence of wheel probes on their ANCA machines. “The wheel probe is absolutely awesome, because it takes human error out and it’s really accurate,” said Gray. The older method uses a measuring bar, and Gray recounted that operators all too often forgot which orientation they should use and destroyed an expensive wheel.

ARCH Cutting Tools created this multi-step counterbore to combine 6 different operations in one tool for machining titanium and superalloys
ARCH Cutting Tools delivered this custom engineered, solid carbide keyseat cutter, with coating, in under 48 hours

The science of productivity

As Gray put it, ARCH Cutting Tools has to be fast to be competitive, and that requires a process that’s “down to a science.” Things like matching different wheel specifications to the diverse tool materials they have to grind, proper coolant placement, and adaptable tool support. In the latter category, Gary praised ANCA’s P-axis traveling steadyrest and said that for some challenging applications they use an Arobotech, which grips the tool at 3 points and adjusts to changes in diameter as the P-axis moves below the grinding wheel, providing support. “These are all things that give us an edge to be able to do these instruments,” Gray concluded. “They virtually eliminate runout and allow us to run faster.”

But Gray reserves his highest praise for ANCA’s simulation software, calling it “the greatest tool…We used to go to the machine blind. We’d end up scrapping blanks to figure out these complex tools right at the machine. With ANCA’s software, you create complex tools before going to the machine and you’re close to perfect when you run your first part.”

From creative tool design, to efficient machine setup and operation, to tight quality control, ARCH Cutting Tools consistently exemplifies what it takes to meet the challenges of machining medical components.

Images

Condyle Cutter.jpg

ARCH Cutting Tools produces a unique 3-flute carbide helical cutter that delivers unequaled part finish, higher throughput, and longer tool life in machining a polyethylene tibial insert

Ball Nose End Mills.jpg

These ball nose end mills (for machining hip stems) feature a perfect transition from the ball radius to the OD, and an end face gash that meets exactly at the center

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ARCH Cutting Tools delivered this custom engineered, solid carbide keyseat cutter, with coating, in under 48 hours

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ARCH Cutting Tools created this multi-step counterbore to combine 6 different operations in one tool for machining titanium and superalloys

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This complex trepan cutter was created to meet an urgent need for cutting non-ferrous material used in respiratory equipment. The tool features a very fine finish and leaves no marks on the part. Gray reported that “the customer was ecstatic”


For further information, please contact:

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

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

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

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The Press Shop of the Future Starts Today

Schuler’s Digitalization & Modernization Workshop provided innovative and practical solutions for creating a fully networked press shop

Canton, MI, March 2, 2023Schuler North America, subsidiary of Schuler Group GmbH, hosted a Digitalization & Modernization Workshop last week. The workshop was also the grand opening of Schuler’s Michigan Ave Service Facility.

Attendees included senior leaders, directors, and engineers from major OEM and Tier-One suppliers, the Supervisor from the Charter Township of Canton, Anne Marie Graham-Hudak, and senior editors from top trade publications.

Schuler’s Visual Die Protection (VDP) is a camera-based system designed to stop presses before damages or failures occur.

“We want our customers to take tangible information back to their shop and know that Schuler is available to support them in their digitalization journey,” states Kevin McAllister, President of Schuler North America. “I can safely say we achieved this objective based solely on the feedback we received. We will certainly host more workshops to support those that could not attend last week.”

Domenico Iacovelli, CEO of Schuler Group GmbH and Member of the Executive Board Andritz Group, and Kevin McAllister opened the workshop with a live press conference. Session topics included:

The Press Shop of the Future, presented by Tiago Vasconcellos, Sales Director at Schuler North America, identified key technologies used at Schuler’s Smart Press Shop that reshape costs, output, and carbon footprint. The Press Shop of the Future was instrumental in laying the foundation for the entire workshop as it provided attendees with the current market status and future expectations of digitalization.

Optimize Shop Floor Operations, presented by Andreas Gebele, Product Manager of Digital Automotive Solutions at Schuler Pressen GmbH, provided solutions to achieve increasements in availability, performance, and quality with Schuler’s Track & Trace, laser serialization, blank measurements, and downtime detection.

Protect Dies & Prevent Damages with VDP, presented by Samuel Czyzewski, Service & Digitalization Engineer at Schuler North America, included a live demo of Schuler’s Visual Die Protection (VDP) and the immediate ROI from the camera-based system’s capability to detect foreign objects, inspect processes, and monitor die functions.

The Shop Floor Tour, presented by Robert Tyler, Facility & Operations Manager at Schuler North America, gave attendees an inside look at the 32,000 sq. ft. facility’s 50-ton crane, in-house press pit for rebuilds and assembly, specialized equipment, and team of field service and engineering support at work.

Press Shop Planning with Cloud Solutions, presented by Andreas Gebele and Flavio Rudiger, Lead Digitalization Engineer at Schuler North America, included a live demo of Schuler’s machine applications that provide predictive maintenance to avoid efficiency losses and damage risks.

Schuler Connect provides remote service and troubleshooting support via smart glasses, smart phone, or tablet.

Get Proactive with Service Agreements, presented by Andy Osborn, Director of Modernization at Schuler North America, provided value-add predictive maintenance, remote service, and spare parts with Schuler’s Service Agreements. Two supporting topics included Schuler Smart Inspections, presented by Rodrigo DePaula Branco, Engineering Group Lead at Schuler North America, and Schuler Connect, a live demo of the smart glasses and application for safe and cost-effective remote support and troubleshooting, presented by Flavio Rudiger and Samuel Czyzewski.

Future Products, presented by Flavio Rudiger and Andreas Gebele, covered all Schuler Digital Suite products coming soon to the USA. Solutions included DIGISIM simulation software to increase productivity, Smart Assist to increase output, Smart Monitoring System (SMS) to detect machine stress from older equipment, Visual Quality Inspection (VQI) to detect part quality issues efficiently, and Service Portal to access contracts, warranties, technical equipment data, inspection protocols, service history, Schuler’s 24/7 helpline, and spare parts stock availability.

“The Digitalization & Modernization Workshop highlighted our local availability,” explains Telvi Zanin, Vice President of Service at Schuler North America. “Schuler North America has over 300 employees. We are the largest local OEM service support, and the grand opening of our new facility greatly enhances our capabilities for the local market.”

Website

Schuler’s Digital Suite

 

About Schuler Groupwww.schulergroup.com

Schuler offers customized cutting-edge technology in all areas of forming—from the networked press to press shop planning. In addition to presses, Schuler’s products include automation, dies, process know-how, and service for the entire metalworking industry. Schuler’s Digital Suite brings together solutions for networking forming technology and is continuously being developed to further improve line productivity and availability. Schuler customers include automotive manufacturers and suppliers, as well as companies in the forging, household appliance, and electrical industries. Schuler presses are minting coins for more than 180 countries. Founded in 1839 at the Göppingen, Germany headquarters, Schuler has approximately 5,000 employees at production sites in Europe, China and the Americas, as well as service companies in more than 40 countries. The company is part of the international technology group ANDRITZ.

Schuler’s global portfolio of world-renowned brands include BCN (Bliss Clearing Niagara) Technical Services, Müller Weingarten, Beutler, Umformtechnik Erfurt, SMG Pressen, Hydrap Pressen, Wilkins & Mitchell, Bêché, Spiertz Presses, Farina Presse, Liebergeld, Peltzer & Ehlers, Schleicher, and Sovema Group.

 

About Schuler North Americawww.schulergroup.com

Schuler North America (Schuler), headquartered in Canton, Michigan, is the North American subsidiary of Schuler Group. Schuler provides new equipment, spare parts, and a portfolio of lifecycle services for all press systems—including preventative maintenance, press shop design and optimization, turnkey installations, retrofits for existing systems, and localized production and service. Schuler’s best-in-class position in the metalworking and materials industry serves automotive manufacturers and tier suppliers, as well as home appliance, electronics, forging, and other industries.

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Schuler’s Digital Suite provides manufacturers with a fully networked press shop for optimized production.

Schuler Presents the Press Shop of the Future

Schuler North America unveils digitalization and modernization best practices with an industry workshop and grand opening of new facility.

Schuler North America, subsidiary of Schuler Group GmbH, will host a Digitalization & Modernization Workshop on February 23, 2023. The workshop is also the grand opening of Schuler’s Michigan Ave Service Facility in Canton, Michigan.

Schuler will identify the press shop of the future and highlight key technologies that maximize overall equipment effectiveness (OEE), implement digitalization practices, and conduct smart press shop practices. Attendees will learn how the press shop of the future reshapes costs, output, and carbon footprint.

“Topics, and marketing buzz words, such as IIoT and digitalization have oversaturated the market,” states Telvi Zanin, VP of Service at Schuler North America. “Our Digitalization & Modernization Workshop provides the valued ‘how-to’ ingredient and is designed to help attendees build their own state-of-the-art press shop of the future.”

Schuler’s Digitalization & Modernization Workshop is a full, one-day event with various sessions that provide innovative and practical solutions for making press shops smarter. Session topics include:

  • The Press Shop of the Future
  • Optimize Shop Floor Operations
  • Protect Dies & Prevent Damages with VDP
  • Press Shop Planning with Cloud Solutions
  • Shop Floor Tour
  • Get Proactive with Service Agreements
  • Future Products
  • Cocktail Reception

The workshop also serves as the grand opening of Schuler’s Michigan Ave Service Facility. The facility is 32,000 sq. ft. and is equipped with a 50-ton crane, in-house press pit for rebuilds and assembly, specialized equipment, and full-time field service and engineering support hub.

“The Digitalization & Modernization Workshop is an opportunity to inform the market about Schuler’s Digital Suite solutions and how manufacturers can create a fully networked press shop. Concurrently, our new facility exemplifies Schuler’s capabilities to the local market,” explains Kevin McAllister, President of Schuler North America. “The Michigan Ave Service Facility enables reduced turnaround time for repairs, press rebuilds, and modernization projects. We created a convenient space for customer shipments, follow-ups, reviews, and buy-offs.”

The workshop and grand opening will begin with an on-site press conference and conclude with a cocktail reception for guests to meet with Schuler’s presenters and team of qualified experts.


Website

Schuler’s Digital Suite
Schuler Service
Schuler Modernization

About Schuler Groupwww.schulergroup.com

Schuler offers customized cutting-edge technology in all areas of forming—from the networked press to press shop planning. In addition to presses, Schuler’s products include automation, dies, process know-how, and service for the entire metalworking industry. Schuler’s Digital Suite brings together solutions for networking forming technology and is continuously being developed to further improve line productivity and availability. Schuler customers include automotive manufacturers and suppliers, as well as companies in the forging, household appliance, and electrical industries. Schuler presses are minting coins for more than 180 countries. Founded in 1839 at the Göppingen, Germany headquarters, Schuler has approximately 5,000 employees at production sites in Europe, China and the Americas, as well as service companies in more than 40 countries. The company is part of the international technology group ANDRITZ. 

Schuler’s global portfolio of world-renowned brands include BCN (Bliss Clearing Niagara) Technical Services, Müller Weingarten, Beutler, Umformtechnik Erfurt, SMG Pressen, Hydrap Pressen, Wilkins & Mitchell, Bêché, Spiertz Presses, Farina Presse, Liebergeld, Peltzer & Ehlers, Schleicher, and Sovema Group.

 

About Schuler North Americawww.schulergroup.com

Schuler North America (Schuler), headquartered in Canton, Michigan, is the North American subsidiary of Schuler Group. Schuler provides new equipment, spare parts, and a portfolio of lifecycle services for all press systems—including preventative maintenance, press shop design and optimization, turnkey installations, retrofits for existing systems, and localized production and service. Schuler’s best-in-class position in the metalworking and materials industry serves automotive manufacturers and tier suppliers, as well as home appliance, electronics, forging, and other industries.

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Smart and Economical Laser Blanking Solutions

The technology offers maximum flexibility, efficiency and part quality, as well as material savings of up to one million USD per year 

Canton, Michigan, July 27, 2022 – A blanking line is usually made up of a coil line, an uncoiler, a threading unit, leveler, roll feed, the cutting area and the stacking unit. This holds true with laser blanking lines, but the material is cut by a laser cell instead of a shear or press. Justine Fonteyne, Schuler’s Area Sales Manager of the Americas, has recently explained the technology’s multiple advantages in an online seminar. 

There has been a rising interest for laser blanking lines, given the die-free blanking capabilities. Schuler has sold 15 worldwide, including five in North America. With the frequent changeover of new car models, vehicle manufactures are happy to avoid investing in expensive dies – especially new players within the EV market, for which ramp-up production may be slower. “And die change time costs production time,” Fonteyne underlined. Additionally, no dies equate to no die storage or maintenance, and less initial infrastructure investment as no heavy press foundation or loop pit is required. Apart from that, no noise or vibration is emitted. 

Schuler’s Justine Fonteyne explained the various advantages of laser blanking technology in an online seminar.

Overall equipment efficiency of up to 80 percent 

Because of Schuler’s Dynamic Flow Technology (DFT), Schuler’s laser blanking lines are also much faster than conventional stop and go laser cutting systems like flatbed lasers. The material runs continuously without the need to stop-and-start before cutting. The output can reach 45 parts per minute, depending on the geometry of the blank. Due to no die changes, the overall equipment efficiency (OEE) is up to 80 percent. 

“Depending on the part mix, Laser Blanking can be the cheapest way of blanking,” Fonteyne stated. “Due to digital nesting solutions, the technology has much greater material utilization.” In contrast to conventional lines, the parts can be designed independently from die restrictions. Also separation strips can be avoided with edge-to-edge nesting. Improvements in material utilization of an outer body part mix of approximately 1 percent quickly add up to material savings of up to one million USD per year.  

No wear of dies and presses 

Schuler’s laser blanking lines produce homogenous cutting edges with hardly any burr. “This is relevant for aluminum because the flitter in the die is reduced to almost zero,” Fonteyne explained. The rising number of high-strength steel pose further challenges to conventional lines regarding the wear of dies and presses, but the lasers are not affected by this at all. Schuler offers workshops for part simulation and optimization as well as business calculation. 

Fonteyne provided insight into Schuler’s Track & Trace solution that has already been implemented at the Smart Press Shop in Germany, a joint venture between Schuler and Porsche. “Being the first station for the material in the press shop, we start the tracking of the production data here,” said Fonteyne. “The production data is connected to every part and can be tracked easily and continuously. For example, data pertaining to the thickness of a blank or the amount of oil distributed can be transmitted to the press line in order to achieve a perfect forming process. 

Watch the complete video of the online seminar here: https://youtu.be/oC59OzaCW0c 

 
Listen to Carla Bailo, President & CEO of the Center for Automotive Research (CAR), and Justine Fonteyne discuss laser blanking via CAR’s podcast: https://anchor.fm/the-car-podcast/episodes/Laser-blanking—featuring-Justine-Fonteyne-of-Schuler-Group-GmbH-e1krdmp/a-a8799jm 

Internet 

laserblanking.schulergroup.com 


About the Schuler Group – www.schulergroup.com 

Schuler offers customized cutting-edge technology in all areas of forming—from the networked press to press shop planning. In addition to presses, our products include automation, dies, process know-how and service for the entire metalworking industry. Schuler’s Digital Suite brings together solutions for networking forming technology and is continuously being developed to further improve line productivity and availability. Our customers include automotive manufacturers and suppliers, as well as companies in the forging, household appliance and electrical industries. Presses from the Schuler Group mint coins for more than 180 countries. Founded in 1839 at our headquarters in Göppingen, Germany, Schuler has approx. 5 000 employees at production sites in Europe, China and the Americas, as well as service companies in more than 40 countries. The company is part of the international technology group ANDRITZ. 

For further information on Schuler Inc., North America, please contact: 

Jaime Bartholomai, Marketing & Communications Manager 
Schuler Incorporated 
7145 Commerce Blvd. 
Canton, MI 48187 USA 
Jaime.Bartholomai@schulergroup.com 

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