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CNC tool grinder keeps tools coming
Cutter is sharp when it comes to cutting economy
Keeping up with the demand for end mills in
a busy economy is a full-time job, and increasingly, tool companies are looking into CNC
tool grinders to help them stay competitive. At Melin Tool Co., Inc., a $6 million,
60-year-old manufacturer of carbide- and cobalt-based HSS end mills, most of the tools are
produced for distributor sales, striving end users from automotive, aircraft, and tool/die
and mold making industries. Accuracy and timely delivery are key requirements for its
customers.
The MGX CNC tool and cutter grinder features a bual spindle system, permitting the
use of up to six grinding wheels.
Melin grinds out more than 1,500 end mills daily, seven days a week. Maybe that's why
it was necessary for the company to purchase a third tool and cutter grinder; another MGX
CNC grinder from ANCA, Inc., Farmington Hills, MI.
"With the materials and machine we use, we feel we can provide a higher quality
end mill than most other sources," says Mike Wochna, Melin president. "We enjoy
a low turnover among our employees, many of whom have been with use for years and have
come up from a manual tool grinder. They add the skill and judgment necessary."
About 10 years ago, the company decided it had to change the way it did things, and
began looking into CNC cutter grinders. According to Wochna, customers wanted the tools
made on a CNC grinder because they wanted to resharpen them on a CNC grinder. Melin also
cited the need for production consistency, plus the cost of previous assembly line-style
manufacturing methods was relatively high.
Today, for most of its smaller tools, Melin runs three MGX CNC tool and cutter
grinders. It was the first U.S. customer for the MGX and it took delivery of its third in
mid-2000. The compact, dual-spindle grinder is a high-productivity precision tool grinder
for tools up to 1Ž2创 diameter shank and lengths up to 6创, including burrs and
router bits.
"We took one of the first machines to improve our production quality and turnover,
and the new one really fits into what we do now--two spindles for production versatility
and an auto loader that allows us to more easily handle end mills typical for
us--1Ž2创 and less," says Wochna. "Changeover is simple and quick, and
its precision on small tools makes it a good fit. We grind tools to 0.020创 diameter to
tolerances of 0.0004创. A 0.025创 diameter tool off by 0.001创 is a big difference,
where on a larger tool this isn't as much of a factor."
With an integrated robotic loader and tool change times of less than 5 seconds, the MGX
is effective for high-volume precision tool grinding. Pallet loading with up to 280 tools
per pallet permits extended unmanned operation. The loader system uses gripper and arms to
pick up, transfer, and place the tool in the collet; the loader always knows where the
tools are. Its main benefit to Melin is that a tool blank is always ready to be loaded, so
change time is quick.
It features nine machine axes--five traditional rotary and linear axes and four soft
axes. Using the CNC's power, the four soft axes provide the versatility of a 9-axis
machine with the mechanical simplicity of a 5-axis machine.
The machine's offset dual spindle design can be used to provide up to six grinding
wheels in a single cycle with minimal interference or repositioning. Spindle can be setup
with high speed and low speed wheel packs for production versatility. Each spindle can
deliver up to 11 hp at up to 10,000 rpm for high stock removal rates. A 20,000 rpm spindle
is optional for polishing or grinding with small wheels.
The machine's Precision Collet Assembly and precision adjustable pop-up steady rest
means runout as low as 0.000 008创 to 0.000 016创 (2 to 4 microns) in a production
environment is typical and setup times in as little as 10 minutes. Ultra precision collets
are easy to change while maintaining tolerances.
Included with the MGX is a labor-saving automated laoder.
It can be programmed to produce any combination of tools from a single pallet of
blanks, making the MGX efficient even in small batch runs. Because it is a Windows
NT-based system, the ANCA control system makes it easy for operators to use the ANCA
ToolRoom software to their advantage. ToolRoom permits new part development simply by
entering the parameters of the new tool into the CNC, avoiding trial and error machining.
This helps avoid or reduce the number of compensations made after the first tool is made
and measured.
CIMulator 3D provides an off-line tool development environment that enables the design
of new tooling and the required manufacturing process without disrupting production. Setup
time for tools is reduced, and production can begin more quickly. Available as an offline
workstation, CIMulator 3D can also run on the CNC to simulate tool production programs
before grinding.
A variety of ANCA tooling components.
The quick setup and changeover the MGX provides was important to Melin because of the
short runs it produces; 50 to 75 pieces per run, with three to four runs a day. The shop
operates 21 hours a day with 12 ANCA grinders on the floor.
Other advantages include its small footprint, rapid setup with a probe that detects
tool position in the machine prior to cycle start, easily upgradeable software,
transferable machine to machine, and an auto loader that helps increase production per
hour.
For more information from ANCA, Inc., Farmington Hills, MI, Circle 349 or
visit http://www.OneRS.net/102mf-349
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