FEATURE
software + preventive maintenance
page 36
PREVENTIVE MAINTENANCE
Boosts Tool Grinding Productivity,
Safety page 6
SOFTWARE FACILITATES
Hardware Investments
page 12
StuderGRIND Software Optimizes,
Documents, and Analyzes
All Aspects of Grinding...Offline
page 26
also in this issue . . .
THE UNSUNG HEROES
OF ENHANCED
PRODUCTIVTY page 3
INSPIRING FUTURE
ENGINEERS THROUGH
COMPETITION page 4
KEEPING PACE
IN A FAST-MOVING
INDUSTRY page 47
6
page
page
18
F E AT U R E S
6
Preventive Maintenance Boosts Tool Grinding
Productivity, Safety
Tips for maintaining your WALTER and EWAG machines.
12 Software Facilitates Hardware Investments
A look into financial software that helps streamline
the machine tool purchasing process.
14 Modular Coolant Supply System is Rigid and Reliable
Shop Tools introduces the Hirt-Line® articulated modular
coolant piping system.
16 Targeting Safety Gains Through Preventive Maintenance
page
26
Grinding wheel preventive maintenance safety tips from
Saint-Gobain.
18 Shop‘s Success Revolves Around Quality
and Precision Grinding
Shop‘s unique layout puts focus on quality control.
D E PA R T M E N T S
3
MY THOUGHTS
4
GRINDING IN MOTION
5
CAREER TRACK
24 A GLIMPSE INTO
44 IN THE ZONE
46 DIGITAL DIGEST
47 LAST THOUGHT
26 StuderGRIND Software Optimizes, Documents,
and Analyzes All Aspects of Grinding...Offline
Maximizing productivity, cost-efficiency and energy
management using grinding machine software.
32 Common Sense Maintenance Optimizes
Your Metrology Investment
Simple maintenance tips from Marposs to keep
running at peak efficiency.
34 Standards-based Data Systems Drive Energy Savings
MTConnect provides visibility to factories’ energy choices.
36 Proactive Planning Pays Off
Grinding software and OEM support help shop battle back.
42 A Little Grinding Fluid TLC Goes A Long Way
Tips on keeping grinding fluids in tip-top condition
from Blaser.
Grind/Software & PM Issue 2015
1
M Y
UNITED GRINDING
North America
UNITED GRINDING Group
International
510 Earl Blvd.
Miamisburg, OH 45342, USA
Tel +1-937-859-1975
Fax +1-937-859-1115
info@grinding.com
Körber Schleifring Machinery
(Shanghai) Co., Ltd.
1128, Tai Shun Road
Anting Town
Jiading District
Shanghai 201814, China
Tel +86-21-3958-7333
Fax +86-21-3958-7338
info@grinding.cn
Fredericksburg Branch Office
5160 Lad Land Drive
Fredericksburg, VA 22407, USA
Tel +1-540-898-3700
Fax +1-540-898-6819
info@grinding.com
United Grinding
Mexico S.A. de C.V.
Blvd. Bernardo Quintana No. 7001
Of. 1003
Querétaro, Qro. 76079, Mexico
Tel +52-1-555-509-7739
german.gordillo@grinding.com
CYLINDRICAL
Hans Ueltschi
Vice President, Sales
510 Earl Blvd.
Miamisburg, OH 45342, USA
Tel +1-937-859-1975
Fax +1-937-859-1115
hans.ueltschi@grinding.com
TOOL
Markus Stolmar
Vice President, Sales
5160 Lad Land Drive
Fredericksburg, VA 22407, USA
Tel +1-540-898-3700
Fax +1-540-898-6819
markus.stolmar@grinding.com
SURFACE & PROFILE
Larry Marchand
Vice President, Sales
510 Earl Blvd.
Miamisburg, OH 45342, USA
Tel +1-937-859-1975
Fax +1-937-859-1115
larry.marchand@grinding.com
CUSTOMER CARE
Joseph Szenay
Vice President, Customer Care
510 Earl Blvd.
Miamisburg, OH 45342, USA
Tel +1-937-847-1234
Fax +1-937-859-6915
joseph.szenay@grinding.com
the GRIND
Publisher
Ted Neckel
Director of Corporate Marketing
ted.neckel@grinding.com
Tel +1-937-847-1229
Layout & Design
dgs Marketing Engineers
© 2015.
Körber Schleifring Machinery
(Shanghai) Co., Ltd.
Beijing Branch Office
Room 202, Building 18
Tower B, Universal Business Park
No.10 Jiuxianqiao Road
Chaoyang District
Beijing 100015, China
Tel +86-10-8526-1040
Fax +86-10-6500-6579
info@grinding.cn
Körber Schleifring Machinery
(Shanghai) Co., Ltd.
Chongqing Branch Office
15-11 Building 4,
No.18 Jinshan Road,
Longxi Street, Yubei District,
Chongqing 401147, China
Tel +86-23-6370-3600
Fax +86-23-6374-1055
info@grinding.cn
Körber Schleifring Machinery
(Shanghai) Co., Ltd.
Guangzhou Branch Office
Room 2003, 20/F
Center Plaza Tower B
161 Linhexi Road
Tianhe District
Guangzhou 510620, China
Tel +86-20-3862-1241
Fax +86-20-3862-1270
info@grinding.cn
T H O U G H T S
The Unsung Heroes
OF ENHANCED PRODUCTIVITY
Manufacturers today are always looking for ways to accelerate production cycles
“Software allows our grinding
and reduce machine downtime. In this issue of The Grind, we highlight a couple
machines to handle diverse
of unsung heroes – software and preventive maintenance – that quietly enhance
productivity by making life easier for operators and keeping machines up and running.
At UNITED GRINDING North America, we have a long history of providing
high-precision, high-output grinding solutions that encompass both machine and
customer profiles — from
individual component to
large-batch production.”
software technologies. It is this fact that separates us from our competitors.
Software allows our grinding machines to handle diverse customer profiles —
from individual component to large-batch production. It’s ultimately what makes
grinding easier.
Our outstanding team of developers has designed unique software for a variety
of applications. In fact, in this issue, you’ll read about AcuTwist, a small shop in
Pennsylvania that attributes much of its growth and success to the use of our
HELITRONIC TOOL STUDIO CAD/CAM software. This cutting tool company has
grown from one machine in the owner’s garage into a successful business with
several employees using multiple WALTER grinding machines to design, program
and produce all types of specialty tools.
Throughout this issue, you’ll also find information on the importance of performing
routine, preventive maintenance. Each year, our service team makes significantly
more service calls to shops that don’t properly maintain their machines compared
with those that do. To help customers with this important aspect of their business,
we offer on-site preventive maintenance programs. In fact, we’re seeing increased
demand for these types of services and have plans to expand our offerings in
United Grinding GmbH
India Branch Office
No. 487 - D1 & D2A
4th Phase, KIADB Main Road
Peenya Industrial Area
Bangalore 560058, India
Tel +91-80-415-54-601
Fax +91-80-415-54-603
info.in@grinding.ch
the near future.
United Grinding GmbH
Moscow Office
1-j Kasatschij Pereulok 5/2,
Strojenije 1
119017 Moskau, Russia
Tel +7-495-956-93-58
Fax +7-495-956-93-59
info.ru@grinding.ch
has helped you grow your business, we’d love to hear
I hope you enjoy this issue of The Grind. At UNITED GRINDING North America,
we are committed to providing you with information that will help
you grow your business and bottom line. If you have ideas
for topics you’d like to see covered in our magazine
or have a story to tell about how our grinding technology
from you.
Terry Derrico
President and CEO,
United Grinding North America, Inc.
All Rights Reserved.
2
Grind/Software & PM Issue 2015
Grind/Software & PM Issue 2015
3
CAREER TRACK
Inspiring Future Engineers
THROUGH COMPETITION
Customer Support
UNITED GRINDING North America is
unique team brings together students
a specified area. Then, student drivers
Business for UNITED GRINDING continues to grow,
always looking forward and wants to
from David Crockett High School, which
remotely controlled their robots and
and with it comes the immediate need to expand the
ensure the future is filled with talented
has a strong vocational program, and
worked with other teams to earn points
company’s customer support teams — in particular
manufacturers and engineers. The
Daniel Boone High School, which excels
by placing as many totes on their scoring
applications engineers and field service engineers.
company has discovered that one sure
at computer programming, to capitalize
platforms as possible and capping those
At UNITED GRINDING, service and support are as equally
way to entice the best and brightest to
on the strengths of each school.
stacks with recycling containers. The
critical to a customer’s success as the advanced software
seek careers in science, technology,
The FIRST Robotics Competition is an
robots also had to properly dispose of
and grinding technology the company provides.
engineering and math is to get involved
with them early.
international high school competition in
which teams have six weeks to build a
pool noodles, representing litter. At the
end of the weekend, the Musket Alliance
Employee turnover at UNITED GRINDING is extremely
students to participate in co-ops, UNITED GRINDING
low — typically less than six percent. “This consistently
plans to participate in one to ensure its future customer
low rate is because, once on board, individuals realize that
support team is fully staffed with trained, well-educated
UNITED GRINDING is an amazingly rewarding and exciting
individuals. The company also conducts extensive candidate
place to work,” explained Christine Taylor SHRM-SCP,
searches within various associations (veterans and others)
SPHR, director of corporate human resources at United
and encourages those with transferrable skills resulting
Grinding North America, Inc. “Most job openings here
from extensive experience in industry-related positions to
result from those individuals that have advanced to other
consider being part of the customer support team at
positions within the company.”
UNITED GRINDING.
UNITED GRINDING applications engineers ensure today’s
Current Customer Support openings at UNITED GRINDING:
manufacturers get the right technology for their specific
• Applications Engineer, Cylindrical Products Group production needs, while field service engineers keep
(Miamisburg, Ohio)
that technology operating at its full potential. The current
• Field Service Engineer, Cylindrical Products Group
For a second consecutive year, UNITED
game-playing robot. The game changes
finished 15th out of 66 teams.
GRINDING North America sponsored
each year to keep the competition fresh
“Participating in this competition
the Musket Alliance, a robotics team
and on a level playing field. This year’s
was an incredible experience for
comprised of students from two rival
game, which kicked off on January 3,
these students, but it came with a
high schools in East Tennessee, for
took on a recycling theme.
significant price tag,” explained Bob
the FIRST™ Robotics Competition. This
After picking up the competition manual
Beals, applications engineer for United
and a standard set of parts to build their
robots, the Musket Alliance divided its 20
members into five teams — electrical,
CAD design and animation, programming,
mechanical and business — and got to
work. Each team managed its assigned
aspect of the robot build, including
purchasing additional parts and
Crockett High School and a member
of the Musket Alliance. “The students
from both of these schools appreciate
UNITED GRINDING for giving them
an opportunity to develop technical,
business and teamwork skills, and
The business team secured sponsors
Ted Neckel, director of corporate
and handled the logistics for team
marketing for United Grinding North
travel and robot transport.
America, Inc., reiterated the company’s
At the Palmetto regional competition
commitment to developing the future
competed on a playing field that was
26 feet by 27 feet. During one period,
the robots were required to operate
independently of their drivers to move
yellow totes and recycling containers into
Grind/Software & PM Issue 2015
son, Sawyer is a sophomore at David
materials to make specialized parts.
February 25-28, the Musket Alliance robot
4
Grinding North America, Inc., whose
make new friends.”
in Myrtle Beach, South Carolina on
And because most colleges require their engineering
leaders in the engineering field. “This is
a great program that fosters engineering
and technology skills in young people,
and inspires them through an exciting
competition. This is not only important to
the future success of UNITED GRINDING
North America, but to the success of our
industry as a whole.”
applications and service openings are challenging jobs,
and candidates must possess specific sets of skills
and experience. The positions also require a fair amount
of travel.
For those individuals with the basic electrical and mechanical
(Chicago, Elgin, Rockford, Milwaukee area)
• Sales Engineer, Spare Parts Sales
(Miamisburg, Ohio)
• Field Service Engineer, Tool Products Group EWAG (Chicago, Elgin, Rockford, Milwaukee area)
concepts and education, UNITED GRINDING will train them
• Automation Sales Engineer, Surface and Profile Products on its various technologies, further advancing the knowledge
Group (Miamisburg, Ohio)
and capabilities of those individuals. In fact, UNITED
• Regional Sales Manager, Tool Products Group
GRINDING has added new training programs and initiated
(California)
application and service engineer recruiting efforts at the
college level.
To apply, please email your resume to:
applicant@grinding.com
Grind/Software & PM Issue 2015
5
Wheel Mounting Issues
F E AT URE
To ensure consistent part accuracy, grinding wheel adapters
require periodic checking and replacement. The excellent
rigidity, runout, and repeatability of WALTER HELITRONIC
POWER machines result in part from the machines’ unique
compression-fit wheel adapters. A compression-fit adapter
features simultaneous contact on both the taper and the flat
end face. That rigid contact relies on tight tolerances of both
the adapter and the spindle nose geometry.
Wear of the mating surfaces results from repetitive elastic
deformation of the semi-hardened steel adapter
over the
hardened steel spindle nose. In addition, normal handling of
an adapter often causes nicks and other damage. Wear or
nicks may limit mating to only one surface, creating instability
that reduces spindle life, lowers grinding feedrates, decreases
wheel life, and produces inferior grinding finishes.
Consequently, it is essential to check adapters at least
quarterly. The best inspection method involves applying
machinists’ blue layout fluid to the machine’s spindle taper
and face, then mounting a wheel adapter. Upon release,
the adapter should indicate contact
on the front 30 percent
of the taper nose and show a full ring on the flat face. If
contact shows on more than 30 percent of the short taper
nose, or if contact on the flat face is incomplete, the adapter is
excessively worn. The loss of rigidity in the worn connection
may result in vibration and poor machining results. The
adapter should be discarded and replaced.
Preventive Maintenance
BOOSTS TOOL GRINDING PRODUCTIVITY, SAFETY
Another wheel-mount maintenance issue involves the
HSK wheel adapters on WALTER HELITRONIC VISION
and HELITRONIC DIAMOND machines. It is important to
accurately torque these adapters; using too little torque will fail
to secure the wheel, while too much torque will damage the
screw or the adapter. In mounting an HSK wheel adapter, the
small hole in the adapter is aligned with the red mark on the
spindle end and a torque wrench is used to tighten the hex
screw to 124 pound-inches (14 Newton-meters) torque.
It is important to not confuse the VISION/DIAMOND HSK
wheel adapters with the WALTER taper fit adapters used
on the HELITRONIC POWER series (POWER R, POWER
PRODUCTION, POWER DIAMOND, MINI POWER, etc.).
HELITRONIC POWER adapters use a different mounting
method and torque setting.
Air Quality Matters
An often-overlooked maintenance issue is the quality of the
compressed air supplied for the machine’s clamping systems,
pneumatic valves and air purges. The air must be clean and
dry. Machines typically have air separators to remove excess
moisture, but they are designed to work with air that meets
ISO8573-1 specifications, namely Class 3 for oil aerosols,
Class 5 for particulates and Class 4 for vapor pressure
dew point.
Air quality is crucial for dependable operation of key machine
systems. For example, the WALTER HELITRONIC POWER
PRODUCTION machine has air purges in the grinding spindle
and glass scales and uses air to operate the spindle lock,
tool clamping cylinder, coolant valve pneumatics and loader
pneumatics. Contaminated air eventually causes malfunctions
in these components, such as sticking valves or, in the case of
glass scales, inaccurate positioning of the axes.
Software Safety
Manufacturing software has become a make-or-break
component of the machining process. When functioning as
intended, software can facilitate unmatched productivity;
corrupted or otherwise defective software can totally shut
down an operation.
Protecting machine software from contamination by corrupted
data and viruses is crucial. Some problems are simply the
result of misguided good intentions. For example, the
popularity of familiar PC-based operating systems gives many
users the confidence to make software changes independent
of input from the machine or control manufacturer.
anufacturing machinery requires regular maintenance to achieve maximum
productivity, accuracy and reliability. It also is necessary to maintain and protect
the software systems that are crucial in the operation of modern machine tools.
Safety requirements must be met as well. Accordingly, UNITED GRINDING offers
the following tips for effective preventive maintenance procedures.
“To ensure consistent part accuracy,
grinding adapters require periodic
However, software modifications made without specific
instructions from UNITED GRINDING will void the machine
warranty and could cause serious machine damage or operator
injury due to uncontrolled machine motions.
checking and replacement.”
6
Grind/Software & PM Issue 2015
Grind/Software & PM Issue 2015
7
In general, users should not install software without guidance
from UNITED GRINDING. This includes anti-virus software
(see the next entry in this maintenance tips list), automatic
backup/restore software or video games. Users should not
install a network without consulting with UNITED GRINDING,
nor should they move files with Windows® Explorer or
perform any administrator functions in the machine’s operating
system. Making changes in PC software may seem simple,
but independently altering a machine operating system is not
worth the risk of damaging the machine or worse.
Going Anti-Viral
A key tactic in avoiding corruption of machine operating
software is keeping it isolated from sources of computer
viruses. Networking and file sharing provide tremendous
assistance in improving productivity, but they also introduce
the risk of spreading viruses. Viruses may degrade machine
performance and even lead to data loss.
To protect machines from computer viruses and limit the
damage if infected, the latest anti-virus software should be
installed on all PCs that are connected to the Internet. Going
a step further to install anti-virus software on every PC in the
facility, whether connected to the Internet or not, significantly
reduces the risk of potential contamination via shared media.
For the same reason, a virus-free PC should be used to
scan all portable media (memory sticks, CDs, etc.) before
connecting the media to a machine. Virus-free machine files
should be backed up regularly. Machine tools should not be
connected to the Internet except to obtain remote teleservice
from UNITED GRINDING.
The shutdown procedure
is somewhat different
for FANUC and Andron
(HMC) machines.
It is important to note that taking the above precautions
generally makes it unnecessary to install anti-virus software on
machine tools; such software is not recommended because it
may negatively affect machine performance.
“Spending $1,000 on your nozzles
saved us $100,000 a year!”
Aerospace bearing manufacturer
“The new manifold and nozzles allowed us to switch from plated to
brazed CBN wheels. The higher productivity and wheel life saves us $2.7
million per year.”
Maintaining Backup Power
Backup batteries are just that: a temporary safety net in the
event of main power failure. The batteries should not be used
to cover extended, anticipated outages such as holidays or
plant shutdowns. Batteries should be changed every year
even if their expected life is longer because unanticipated
circumstances can shorten battery life.
Orthopedic implant manufacturer
“The new nozzles reduced flow rate by
33% and dropped the part temperature
by 40°F. Wheel life between dressing
doubled.”
Automotive camshaft manufacturer
Trying is BELIEVING. Try a CoolGrind nozzle at no risk now.
Visit COOL-GRIND.COM or
call (860) 429-8822
8
Grind/Software & PM Issue 2015
Machine downtime is much more costly than replacing
batteries. Some machines and components have special
requirements or characteristics regarding backup power.
For example, Programmable Logic Controls (PLCs) use a
battery for power when the machine is turned off. The battery
protects the memory from losing the PLC program that
controls limit switches, motors, valves and much more. The uninterrupted power supply (UPS) in some WALTER
HELITRONIC POWER machines uses a battery to provide
enough electricity for a graceful control shutdown when the
external power source fails. The UPS does not, however,
provide enough electricity to run the machine. (Most “UPS
failures” are simply battery failures.) Battery power loss on a FANUC machine will require
re-measurement of the machine axes and resetting of
the zero points. That is a four-hour job, assuming a shop
is capable of doing it; if not, the expense of battery failure
will include that of a service visit.
It is crucial to maintain power to the machine while changing
the battery, and to replace both PC and CNC batteries at the
same time.
Proper Shutdown Procedures
In an issue related to machine power status, WALTER
HELITRONIC machines with the HMC 600 or FANUC control
run the Windows operating system and do not have a UPS.
With these, and all Windows-based operating systems, it is
critical to follow proper shutdown procedures. Shutting down
the machine at the main disconnect, without first shutting
down Windows, can corrupt the operating system and
Grind/Software & PM Issue 2015
9
could damage the hard drive. Years of tool development can
be lost as well if the data has not been backed up regularly.
The operator must wait until the appropriate Windows
shutdown screen appears before turning off the power to
any machine running the Windows operating system. This
applies to HELITRONIC machines with the HMC 500, HMC
600, or FANUC control, HELICHECK and HELI TOOLCHECK
machines, and most EWAG CNC machines.
The shutdown procedure is somewhat different for FANUC
and Andron (HMC) machines. When shutting down a FANUC
machine, the operator should click the WWM icon at the
bottom of the Windows shutdown screen and select “Close
all Windows” then select “Shut Down” when the option
appears. When another window opens, the operator should
select “Shut Down” (never “Restart”) then
“OK.” The screen
will read “Windows is Shutting Down.” When the screen
displays “It is now safe to turn off your computer,” the main
disconnect can be shut off. On the other hand, when shutting down an Andron (HMC)
machine, the operator should press the “Windows Key”
to open the Windows start up icons and select “CLOSE
WINDOWS.” When the option appears, the operator should
select “Shut Down.” Then, when another window opens, the
operator should select “Shut Down” (never “Restart”) then
“OK.” The main disconnect can be shut off when the screen
reads “No Signal.” extinguishing system supplier or make arrangements for
installation by a company technician. UNITED GRINDING can
also name potential local suppliers to service existing systems.
Door Lock Safety
All machine tools today have automatic safety locks to prevent
the door from being opened during operation. Some shops
operate machines with disabled lock safety switch circuits, but
this presents a serious safety hazard. It also should be noted
that, like door locks, the Axis Enable Foot Switch should never
be disabled.
Periodic Preventive Maintenance
Safety First: Fire Extinguishing Systems
Whenever oil coolant, dielectric or similar machining fluids are
in use, there is risk of fire. Many state and local regulations
require a fire extinguisher system anywhere oil coolant is in
use. The system must be charged and inspected onsite prior
to startup and re-inspected and certified on a regular basis
as required by law. To help shops fulfill these responsibilities,
UNITED GRINDING can provide the name of a local fire
UNITED GRINDING has developed scheduled preventive
maintenance programs to periodically inspect machines and
identify potential problems before they occur. The company
checks items such as belt tension, lube fluids and filters and
machine geometry, and reports in detail what components
need attention.
Scheduled preventive maintenance as a planned expense
will reduce or eliminate the cost of unexpected service calls,
while reinforcing productivity. Machines can run continuously
when needed, and downtime can be scheduled at the shop’s
convenience. Regularly scheduled preventive maintenance
ensures a proactive approach to machine performance
and production, maximizes machine uptime and provides
organized maintenance records.
Careful attention to machine tool mechanical, software
and safety issues will pay multiple benefits in terms of the
productivity, responsiveness and, ultimately, the profitability
of any manufacturing operation.
Learn more
www.grinding.com
When the coolant becomes a Liquid Tool.
PRECISION
SPEED
POWER
O Grinding Spindle repair and service
on all makes and models.
O Grinding Arbor and accessory sales.
O Quality and Expertise that only an
*Grinding wheel not included
OEM spindle manufacturer can provide.
O Over 75 years of excellence at your service.
« The right product – correctly applied,
and I guarantee a higher feed rate. »
Rico Pollak Head of Grinding Technology
O Contact us today to start your FISCHER experience.
Blaser Swisslube AG
3415 Hasle-Rüegsau, Switzerland
10
Grind/Software & PM Issue 2015
Phone +41 34 460 01 01
contact@blaser.com
FISCHER USA, Inc. | Racine WI | www.fischerspindle.com | info-fusa@fischerspindle.com | T 800 333 6173 | F 262 632 6730
Grind/Software & PM Issue 2015
11
“The financial software available
F E AT URE
through NMTFC can help justify the
purchase of the equipment that will
produce high-quality parts faster
and more consistently, while at the
same time optimizing operational
efficiency and uptime.”
United Grinding North America, Inc. recently named National Machine Tool
Financial Corporation (NMTFC) as a financial service provider. A First Midwest
Bank Company, NMTFC offers a wide variety of financial software programs that
guide shops in the selection and financing of machines that will provide maximum
investment returns as well as improved part-making productivity.
Software Facilitates
Hardware Investments
anufacturing software enables machine tools to produce high-quality
parts quickly and consistently while optimizing operational efficiency
and uptime, resulting in increased profits, steady cash flow and strong
business growth.
Scott Brossard, CMTSE,
National Machine Tool Financial
Corporation
12
Grind/Software & PM Issue 2015
Similarly, financial software provides a variety of benefits in the machine tool
purchasing process. Use of financial software can help a business justify and
manage the significant investment required for a machine tool. Software
packages have been developed to determine what is affordable, what type
of financing is optimal and whether it is best to pay cash or let the machine
generate the revenues for machine payments.
Basic financial software includes tools called ROI calculators. With one type
of ROI calculator, users enter information into an Excel®-format spreadsheet
to compare the financial benefits of a potential new machine versus their
existing machine and process. Another ROI calculator permits comparisons of
a variety of possible new machines and processes. The calculator projects the
additional profits generated and estimated payback time of the investment in
new equipment. Often, these calculations point out that a lower selling price does
not necessarily lead to quicker payback, increased profits or higher satisfaction.
Machine tool manufacturers and distributor sales teams themselves use ROI
calculations to justify the solutions they suggest to potential customers.
A monthly payment calculator is another widely used financial software tool.
Users enter the amount to be financed, the length of the loan and the finance
rate, and the software calculates the monthly payments. Payments can be broken
down further into cost per hour for 1, 2 and 3 shift operation. Although these data
do not fully represent the total cost of machine ownership and operation, they
provide a reliable indicator of the fundamental costs of owning the machine and
accessories that will produce the work in the most profitable way.
A tax savings calculator previews the potential savings associated with tax code
options such Section 179 and Bonus Depreciation. The machine buyer enters the
price of the equipment, and the financial software quickly determines possible
tax benefits under the current tax code. NMTFC updates the calculator to reflect
yearly changes in the code, and the calculator is provided in an Excel format so it
can be stored on a computer for quick accessibility. While not considered to be
a formal interpretation of tax law, the calculations provide basic information that
can be useful in consulting with an accountant or other tax professional to confirm
eligibility for tax incentives and benefits.
In the credit evaluation process, NMTFC utilizes an in-house “spread
software” to quickly calculate many of the factors that go into financing
approval. The information involved includes the customer’s trends in revenues
and costs, company liquidity, cash flow, debt to tangible net worth ratios and
EBITDA (earnings before interest,
taxes, depreciation and amortization).
The software completes the analysis
in minutes. This information helps
NMTFC understand the customer’s
financial ability to handle the payments
and makes the approval process easier
and quicker. Once the information is
analyzed, it allows NMTFC to function
as a consultant to the customer, and
help in the decision process if needed.
Since 1986, NMTFC has provided
financing solutions that have helped
thousands of companies obtain the
equipment and financing arrangement
that suits them best. Many solutions are
creatively structured to accommodate
specific customers equipment needs
and financial situations. As partners
with United Grinding North America,
Inc. to provide financing solutions, the
role of NMTFC is simple: to make the
purchase of the UNITED GRINDING
equipment easier for its customers.
With benefits parallel to those of
manufacturing software, the financial
software available through NMTFC
can help justify the purchase of
the equipment that will produce
high quality parts faster and more
consistently, while at the same time
optimizing operational efficiency and
uptime. And, as with manufacturing
software, the results are maximum
profits, steady cash flow, and strong
business growth.
Learn more
www.netlease.com
Grind/Software & PM Issue 2015
13
F E AT URE
“Coolant is one of the most important things in a shop, but
people consider it a necessary evil. Just because the coolant
is on doesn’t mean it is helping. It has to be in the right spot.”
Modular Coolant Supply System is Rigid and Reliable
NITED GRINDING provides state-of-the-art machines
that maximize grinding productivity and efficiency.
The company recognizes that its machines achieve top
performance when complemented by equally advanced
ancillary systems and accessories.
Among the critical elements of the grinding process are coolant
supply systems. Sufficient, consistent and accurate coolant
delivery prevents heat-related damage to the workpiece and
grinding wheel as well as flushes away swarf and provides
lubricity. Interruption or misdirection of coolant flow can
severely compromise workpiece surface finish and wheel life.
A coolant system’s final delivery components can be a source
of supply problems. Plastic coolant piping and nozzles or light
metal tubing may shift out of position due to the pressure of the
coolant flow itself. Corrosion, heat and abrasion may also affect
the tubing arrangement. Tubing elements can kink or break.
As a result, UNITED GRINDING now offers an articulated
modular coolant piping system for its STUDER cylindrical
14
Grind/Software & PM Issue 2015
grinders that provides unfailing rigidity when assembled but can
easily be custom-configured to match any grinding application.
The Swiss-made Hirt-Line® coolant delivery system consists
of a series of threaded stainless-steel elements that screw and
lock together and extend from the machine’s coolant source to
the nozzle that ultimately directs coolant flow.
The U.S. importer of the Hirt-Line system is Shop Tools, Inc.,
Colorado’s largest independent distributor. Shop Tools
introduced the Hirt-Line system at IMTS 2014, after which
UNITED GRINDING began to offer the system to its customers.
Shop Tools representative Tim Young said, “Coolant is one of
the most important things in a shop, but people consider it a
necessary evil. Just because the coolant is on doesn’t mean
it is helping. It has to be in the right spot.”
The Hirt-Line system comes in 5.8-mm and 11-mm I.D. sizes.
Basic components consist of machine connection adapters with
a choice of thread configurations; screw-together pipe elements
in lengths ranging from 21 mm to 1,000 mm; ball connectors
to create curved piping; a variety of movable and fixed elbows
including angle, star, T and Y choices; and a wide selection of
round and flat nozzles. The system also features accessories
such as ball valves, plugs and manifold blocks.
The pipe elements have wrench flats that permit them to be
locked together and resist movement against coolant pressures
as high as 1,500 psi. Components can be configured to produce
180-degree curves if desired, and will not kink or break. Their
tough 303 stainless steel composition provides high resistance
to impact, corrosion and wear. Hirt-Line continually develops
new components for the system and also has the capability to
produce special designs for particularly challenging applications.
Users can tailor coolant flow to the exact part locations and
wheel widths involved, in many cases positively affecting
grinding wheel and dressing tool life.
In the past, custom-fabricated nozzles and tubing arrangements
have worked well in some applications. However, production
downtime and increased expense resulted when a nozzle broke
or wore out and needed to be remade. The modular nature of
the Hirt-Line system enables it to be configured for nearly any
application, but also guarantees the availability of parts for quick,
cost-effective replacement or modification for new applications.
The Hirt-Line system has proved to be excellent for use in
high-volume manufacturing where machines are dedicated
to longer-term production of a single part or a family of similar
parts, situations where changeover is minimal and reliable
performance is a top priority. Currently, typical users are Tier 1
and 2 suppliers in the automotive and aerospace industries that
are employing the system on STUDER S41 and S33 machines
in multi-shift grinding of similar parts using high-pressure coolant.
Young said the extensive selection of elements allows
assembly of a nearly infinite number of setup combinations.
“You can plumb coolant and get it where you need to have
it. You are only limited by your imagination,” he said, “It’s
kind of like an Erector Set for big boys.”
Learn more
www.shoptools.com
Grind/Software & PM Issue 2015
15
F E AT URE
C
THE RING TEST
45º
1. Maintenance of the Grinding Wheel
Ordinarily, one does not think of grinding wheels in terms
of maintenance. First, they are consumable products, and
second, they have no moving parts. But, because grinding
wheels often have a lifespan of up to several years, it is
important to know how to maintain them properly.
45º
C
45º
That grinding machines come with safety guards is not
coincidental. Consider that most precision grinding wheels
operate at speeds of around 100 mph or 45 m/s. The energy
inside a spinning grinding wheel is extremely powerful, and if a
grinding wheel breaks while in motion, that energy is released
in a split second with potentially catastrophic results.
45º
One of the most important PM considerations with respect
to the grinding process is the inspection of the grinding
wheel. Damage to the wheel can weaken it significantly,
making it susceptible to breakage during use. The following
two inspection steps should always be taken prior to using a
wheel, even if it has been mounted and used before.
“TAP”
HERE
45º
45º
FLOOR
Light Wheels
Suspend from hole by
small pin or finger.
Heavy Wheels
Support on clean hard floor.
Targeting Safety Gains
Through Preventive Maintenance
reventive Maintenance (PM) is essential to sustaining
long-term product quality. Regular and thorough
PM routines keep machines churning out good parts
at target rates with minimal unplanned downtime.
Ethan Weikleenget,
Senior Product Safety Engineer,
Saint-Gobain Abrasives, Worcester, MA
In addition to product quality, workplace safety also improves
as a result of effective preventive maintenance, because when
machines function according to their intended design, fewer
hazards exist. But even greater safety gains are achieved by
intentionally incorporating safety checks into PM activities.
The following addresses two important preventive maintenance
components that contribute greatly to safety in the context of
the grinding process.
16
Grind/Software & PM Issue 2015
The Ring Test
This simple test applies to most precision abrasive wheels.
To perform this test, hang the wheel from the index finger
(heavy wheels can be stood vertically on the floor) and tap
it with a hard, non-metallic object in the upper-right and
upper-left quadrants. An undamaged wheel will emit a clear
ringing sound, but a cracked wheel will produce a ‘thud.’
Then, rotate the wheel 45 degrees and repeat the process
until all quadrants have been inspected.
The One-Minute Free Spin Test
Prior to grinding with a newly mounted wheel, bring the
grinding wheel up to operating speed and allow it to run for
one full minute before grinding. During that time, be sure
that no one stands within the wheel’s plane of rotation. If the
wheel is critically damaged, this test will cause it to fail in a
controlled environment.
Implementing these two simple tests as regular PM
inspections will reduce the likelihood of a wheel breakage
and thus enhance the safety of the grinding process.
2. Maintenance of the Mounting Flanges
Throughout the world, Saint-Gobain is perhaps best known
as a producer of glass. Our glass is featured in many famous
structures, including the Grand Canyon Skywalk, a U-shaped
bridge that overhangs the edge of the Grand Canyon by
70 feet. The glass floor panels afford tourists an incredible
view of the river below.
While glass can safely support the weight of the tourists,
the designers wisely selected steel over glass to support the
entire one-million-pound structure. Why? Glass is strong but
brittle, and this brittle composition makes it very sensitive to
concentrated loads.
Vitrified grinding wheels are made of glass; therefore, they
are also strong yet brittle. As a result, concentrated forces
can cause the wheels to break, which could lead to
disastrous consequences.
The condition of flanges (i.e. wheel mounting equipment) is of
critical importance because irregularities in the bearing surface
will magnify stresses on the wheel. Combined with the normal
stresses of rotation and grinding, these additional mounting
stresses can cause the wheel to crack and eventually break.
When it comes to mounting, good equipment must be
coupled with good procedures. Even pristine flanges can
cause problems if clamped down excessively.
Please reference the aforementioned national safety
standard, ANSI B7.1-2010, for complete design and condition
requirements for mounting flanges.
While inspecting the wheel is an important preventive safety
measure, it is not necessarily a proactive one. Proactive
safety with abrasive products is accomplished through proper
use, which includes but is not limited to storage, handling,
mounting, guarding, balancing, dressing, cooling and grinding.
A safe and robust grinding operation employs regular checks
and redundant safeguards to ensure that wheels are correctly
used and maintained.
In closing, the application of sound preventive maintenance
principles to grinding wheels and equipment bolsters the
overall safety of a grinding process. Through the inspection
of wheels, equipment and operating procedures, potential
hazards are avoided and processes can run productively
and safely.
(For details about these aspects of grinding wheel use, please
refer to ANSI B7.1-2010 or www.nortonindustrial.com/safety.)
Learn more
www.saint-gobain-northamerica.com
Grind/Software & PM Issue 2015
17
F EATU RE
Shop‘s Success
Revolves Around
Quality and
Precision Grinding
Precision tolerances as close as 0.0002" are the norm because quality is at the heart of everything Hommer does.
Shop’s unique layout puts
focus on quality control.
18
Grind/Software & PM Issue 2015
ommer Tool & Mfg., Inc., a leading North American
manufacturer of custom mold-ready components, follows
a unique formula when it comes to precision and quality.
Everything in the company’s 24,000 square-foot facility
in Arlington Heights, Illinois, literally revolves around
part quality, with the shop floor laid out in a hub-and-spoke
plan that puts quality control in the center of its 11 machining
departments. This strategy, along with a transition from
manual to automatic O.D. grinding, has catapulted Hommer
to performance excellence, helping the company succeed
in delivering perfect parts and impeccable service.
When creating molds for small parts, injection moldmakers
depend on the highest quality components. For some
Grind/Software & PM Issue 2015
19
Hommer creates precision components out of all types of materials, including S7, H13, D2, M2 420, copper and MoldMAX®.
industries, such as medical device or pharmaceutical, precision is everything. But as
any moldmaker will attest, it doesn’t happen by accident. Instead, precision tolerances
result from a commitment to quality and high-performance grinding technology.
At Hommer, precision tolerances as close as 0.0002" total tolerance are the norm
because quality is at the heart of everything they do. Every workstation in the
spotlessly clean, temperature-controlled shop is equipped with tenth-indicating
micrometers and high-accuracy drop indicators. A barcode tracking system maintains
complete traceability for each and every process. The company only hires the
most highly-skilled people capable of programming, setting up and operating the
machines, and has a detailed process for cultivating those skills in-house.
When James “JR” Hommer Jr. stepped into a leadership role and assumed
complete responsibility of the business about 15 years ago, he quickly saw that
customer needs were changing. At the time, Hommer’s business model was
to manufacture simpler round components for the injection molding market,
but customers were beginning to ask for more complex parts. Because their CNC
20
Grind/Software & PM Issue 2015
Highly skilled employees are capable of programming, setting up and operating the machines.
O.D. grinding at the time was basic, the company was limited to manufacturing
simpler pieces that were 1" or less in diameter and 12" or less in length.
“As a growth strategy and strategic plan, my first major move was to hire a marketing
manager,” explained Hommer. “Then, out of the blue, I received a promotional mailer
from a manufacturer of automated grinding machines, which put that kind of machine
on my radar.”
After researching the options available from the various manufacturers of grinding
solutions, Hommer honed in on UNITED GRINDING’s STUDER cylindrical grinders.
The shop now has several STUDER machines, the recent ones being an S40 and
an S33.
As a most significant benefit to Hommer, the S33’s turret wheelhead features
two O.D.-wheel spindles and provides one-degree increment automatic-indexing
capability when needed for the shop’s complex parts. The highly versatile S33 with
measuring functionality sports a center height of 6.9" and distance between centers
of 25.6", with a maximum workpiece weight between centers of 176 lbs.
The company chose STUDER
because the programming is
superior and consistent across
all machines.
Grind/Software & PM Issue 2015
21
Also known for its versatility, Hommer’s
S40 machine offers a grinding length
up to 63" and a fast direct drive of the
infinite B-axis, a functionality that has
opened the door to many new business
opportunities for the shop.
Hommer produces cavity
components, custom cores,
rotating cores, custom core pins,
thin wall ejector sleeves and
complete stack-up tooling ranging
from a .250" to 3" in diameter.
The STUDER grinders enabled
Hommer to change its focus from
manufacturing commodity parts to
more complex parts that are larger in
diameter, longer in length and achieve
the precise tolerances customers
need. The new capabilities coupled
with an increase in communication
with customers have helped Hommer
triple its business and become a niche
provider of cavity components, custom
cores, rotating cores, custom core
pins, thin-wall ejector sleeves and
complete stack-up tooling.
The shop creates the precision
components out of all types of
materials, including S7, H13, D2, M2,
420, copper and MoldMAX®, and most
range from a quarter of an inch to
three inches in diameter, although they
have done some that are 12" to 13" in
diameter. The bulk of Hommer’s pieces
require an average of 15 operations,
beginning with soft-state chipmaking
operations, including cutoff, gundrilling,
turning and milling. After the parts
are heat treated, they hit the hard side
of the house for centerless grinding,
CNC O.D. grinding, CNC I.D. grinding,
form grinding, surface grinding, honing,
hard turning, hard milling, wire and
sinker EDM, etc., all the way to final
inspection.
As business grew, the company added
a new STUDER about every two
years. “I initially selected the STUDER
because the programming was
superior,” explained Hommer, “and it’s
the same across all machines. That’s
a huge benefit to us because our lot
sizes are small — averaging around 32
pieces — and our cycle times are short
— around three to five minutes. We
do about four changeovers per shift,
and the simple setups and mechanical
processes on the STUDERs allow us
to set up in a half hour or less.”
22
Grind/Software & PM Issue 2015
Hommer admits, however, that he doesn’t make the
purchases lightly. “The capital investment for a STUDER is
significant, so I do a lot of due diligence before making the
decision,” he said.
The O.D. grinding department consists of five STUDER machines
– two S40s, one S31, a basic S33 and an S33 with B axis.
To illustrate, he shared that prior to acquiring the shop’s
second S40, Hommer completed a scheduling project that
analyzed each facet of the business. The results clearly
identified O.D. grinding as a capacity constraint, so the
company changed some scheduling processes and evaluated
its machining capabilities. In doing so, the staff recognized
that one of the STUDERs, an S33 with a fixed head, was
not helping the company keep up with the growing demand
for more complex parts. The machine did straight O.D.s,
but could not achieve features such as angles, longitudinal
positioning multiple diameters or out-of-round grinding.
Hommer replaced it with the S40, which took the O.D.
grinding department from a capacity of 150 to 250 hours
per week. This move right-sized Hommer for the workload
at the time, but offered no room for growth.
This is when Hommer added its newer S33 with a B axis
and automatic indexing. Today, Hommer’s O.D. grinding
department consists of five STUDER machines: the first
S40 purchased, a second S40, an S31, a basic S33 and the
S33 with B axis. The department’s capacity is now about
350 hours per week and includes two shifts that complete
over 2,000 unique details per year. In fact, 93 percent of
Hommer’s jobs involve parts the company has never made
before and most likely will never make again.
“One advantage I have over someone just now entering the
market for complex, custom parts is that I have invested
in these machines over time and have the skilled labor to
operate them,” said Hommer. “It would be very difficult
for a shop to invest in all of this equipment at once.”
Another key to Hommer’s success is the understanding
that the company can’t run its operations by exception.
Rick Frankowitch, operations manager at Hommer, explained
that customers hold Hommer to an extremely high standard
and don’t want any variability in the tool. After all, these
customers need to be able to guarantee millions of parts
for their molds, so Hommer can’t deviate when it comes
to quality.
“We can’t tell employees that one customer’s part has
to be perfect, but another customer’s doesn’t,” shared
Frankowitch. “When our clients need perfect component
parts, they turn to us because they know we’ll give them
the perfect component that can deliver every single time.”
While Hommer is often more expensive than the
competition, customers are willing to pay the higher price
point because the company consistently produces parts
that are true to the print specifications. Each step of the
company’s production process involves precision tolerances,
exacting workmanship and rigorous quality control systems
that begin with the first piece and span the entire process to
final inspection. Clearly the commitment to quality pays off.
“I had a customer pay our company the ultimate
compliment,” Frankowitch said with a smile, “he said
he wastes a lot of time checking perfect parts.”
Learn more
www.grinding.com
Grind/Software & PM Issue 2015
23
A
G L I MPSE
INTO
Mitchell’s Life
Field Service Manager Applies Improvement
Processes at Work and in Life
Outside of my work
at UNITED GRINDING,
I am an imaginative illustrator
have always been fascinated by complexity in the world around me. Or maybe
it’s more accurate to say that I have always been intrigued by the challenge
of finding a way to simplify difficult or overwhelming things. So, when asked
by executive management to spearhead a PuLs project that would help us
improve across the company, I jumped at the opportunity.
PuLs stands for precision and passion. It’s our philosophy and training program
at UNITED GRINDING, and it is designed to improve processes and procedures
throughout the company. It teaches us how to define and analyze problem areas
and gives us good tools that take the emotion out of situations and force us to focus
on the facts. Really, PuLs is so much more than a program; it defines our culture of
always looking for better, more efficient ways of doing things.
I have been leading a team charged with improving our customer order care
process — one of six target areas we believe can have huge impact on our
business. Our team identified several problems with our current process and
worked through detailed statistical analysis to find the causes of the problems.
Then, we developed new processes and procedures for correction that involve
creating a new training program for our technical engineers and a budget for
rolling it out.
Learning these skills has given me a tremendous opportunity to really make a
difference at UNITED GRINDING. They have also come in handy outside of work.
As a volunteer assistant coach for my 10-year-old son’s basketball team,
24
Grind/Software & PM Issue 2015
The Centerville Hustle, I decided to apply the same principles
used in the PuLs project to help the other coaches and
players improve.
and sculptor and create
I record statistics during games — shots attempted and
made, fouls, free throws, steals and rebounds — then use
some of PuLs‘ data analysis tools which have revealed some
interesting and actionable information. For example, the data
clearly shows that our team is not a very good three point
shooting team. It also shows where our “sweet spots” are for
making high percentage shots.
of colored telephone wire.
Presenting this information to the other coaches and the boys
in an easy-to-understand manner has helped us better teach
the boys how to make good shot choices, and the results have
been good. The team has won most of its games and now sits
at the top of the league standings.
characters. I also create
I look forward to continuing to learn and grow with
UNITED GRINDING. Being a leader of a PuLs initiative
has given me opportunities to make a difference for
our company, our customers and a great group of boys
learning how to play a great sport as a team.
museums and several art
one-of-a-kind sculptures out
My sculptures are of sports,
science fiction, military,
warrior and comic book
commercial pieces. My
art has been featured in
and craft shows across
the United States.
Grind/Software & PM Issue 2015
25
F E AT URE
StuderGRIND Software Optimizes, Documents, and Analyzes All Aspects of Grinding...Offline
Tom Vieira,
Application Manager,
Cylindrical Division,
United Grinding North America, Inc.
Erhard Kämpf,
Section Manager, Form and Thread,
Fritz Studer AG
26
Grind/Software & PM Issue 2015
eliable production is the primary goal of every metalworking operation.
As a result, most shops choose grinding parameters aimed at guaranteeing
that their processes will produce the desired part size, tolerances and
surface finish time after time. Experienced shop owners and machine
operators tend to apply conservative cutting conditions and stay with them.
While the safest approach may seem like the best approach, it does not allow
shops to take full advantage of the capabilities of advanced grinding machinery and
tooling and thereby misses opportunities to maximize productivity, cost-efficiency
and energy management.
With typical on-machine grinding software packages, the operator enters information
regarding the workpiece material, desired part dimensions, machine tool capabilities
and tooling available. The software then determines
appropriate feeds and speeds for a specific grinding cycle.
The offline StuderGRIND software package provides a much
more comprehensive approach. StuderGRIND provides
workpiece-oriented programming as well as data collection,
storage and analysis. With its StuderTechnology grinding
support module, the software represents a powerful tool that
minimizes grinding times and optimizes all aspects of the
overall process. The software also compiles and analyzes cost
and time data for use in documentation and creation of quotes.
An optional selection of cycle-specific software modules
provides the capability to perform and optimize processes
such as dressing, contour grinding and threading.
Because it operates offline from the grinding machine on an
external PC, StuderGRIND delivers all of the above benefits
while the grinding machine continues to produce parts.
StuderTechnology
The StuderTechnology module of StuderGRIND calculates
process parameters, on the basis of the latest advances in
grinding technology in combination with over a century of
cylindrical grinding experience and know-how from Fritz
Studer AG. The software considers approximately 300
machine factors and utilizes a database with integrated
grinding knowledge that can be supplemented with data
from a shop’s own experience. The software analyzes
the most important process-relevant variables — such
Grind/Software & PM Issue 2015
27
ground via the StuderTechnology
module of StuderGRIND were
process
consistently within tolerance.
A comparison between a program
Programmers and operators with
conventionally and one generated
extensive grinding experience can
by the StuderTechnology module of
nearly always produce parts that exceed
StuderGRIND illustrates the benefits of
required specifications. However, the way
the module’s capabilities.
based on expert knowledge and created
to maximum productivity and profitability
in manufacturing is to reliably produce,
The comparison test involved three
but not unnecessarily exceed, part
operations of internal and external
requirements in the shortest amount
grinding on a flange. The required surface
of time.
roughness was Ra 0.3 and specified
roundness variation was less than
1 µm. Parts programmed, simulated and
Efficiency
Optimized
StuderTechnology
Experienced Operator
ground via the StuderTechnology module
of StuderGRIND were consistently
within tolerance and showed only minor
variations in values.
Quality
parameters
Parts programmed, simulated and
Conventional Expertise
and StuderTechnology
The same parts were also machined
time, on the other hand, was longer.
consumed more than one hour of shop
with a program created conventionally,
Nevertheless, overall processing time
time. When that additional time is
based on expert experience. Surface
(adding programming and grinding time) of
added to overall processing time, the
roughness was consistently better than
the StuderTechnology programmed parts
StuderTechnology-generated program
required, while roundness was better
was shorter than that of the conventionally
was 66 percent quicker than the
than specified for some parts and out
programmed parts. As part volume
conventional program when one unit
of specification for others. Exceeding
increased, the StuderTechnology overall
is machined, 40 percent faster with a
surface roughness requirements
time advantage grew. For one unit, the
10-unit run, and 26 percent faster when
resulted in longer sparking out times
total time was 8 percent faster, growing
grinding 100 parts.
that considerably lengthened the actual
to 22 percent with 10 units and 24 percent
grinding time for the part.
when grinding 100 units.
The automatically generated
StuderTechnology program immediately
Actual grinding time for the
The conventionally generated program
produced parts that met specifications
StuderTechnology programmed
was optimized to lower grinding times,
in less time overall. No optimization
operation was 26 percent faster than
bring surface roughness closer to
was needed. And, the StuderTechnology
the time for the conventional program.
specifications and produce consistent
software provided full documentation
The StuderTechnology programming
roundness. The optimization process
of the process parameters.
and variables
CyClotron ProduCts, InC.
Leaders in Filtration Systems
Cyclotron Products, Inc. offers a complete line of filtration systems
designed to remove solid particles from water soluble and synthetic
industrial fluids using the most economical and efficient methods.
Use of the simulation significantly reduces the amount of
time spent setting up and test running a grinding process.
In addition to calculating machining time, the software
determines total production time and data such as unit costs,
enabling accurate calculation of job quotes.
Enviromentally Responsible
NIC FILTRAT
LO
N
IO
ON
LE
StuderTechnology is part of a complete CAM system
that integrates optional expansion modules for dressing,
form grinding and other specialized grinding applications.
Implementation of the expansion modules can eliminate the
need for special machines to complete specific operations.
Users choose individual optional modules based on the
IR
A Complete CAM System
STUDER pioneered “pictogramming” graphic language for
use in programming the grinding process. Expanding that
visual resource, StuderGRIND software permits the creation
of an entire virtual machine that enables a user to work with
images of the workpiece, grinding wheel and all components
of the process such as dressing devices. The comprehensive
Efficient
•Morepartsperdressingcycle.
•Lessmachinedowntime.
•Eliminatesamountof
liquid waste.
•Consistentcoolantaeration
eliminates bacteria problems.
•Closertoleranceson
critical parts.
ENV
Virtual Machine Simulation
Economical
•Extendscoolantlife.
•Upto30%longer
grinding wheel life.
•Nopurchaseof
replaceable filter media.
•Lowmaintenancecosts.
•Smallfootprint.
MEN
SIB
Data analysis includes automatic calculation of process
parameters that essentially eliminates the need for further
optimization efforts and can result in reductions of 25 to
50 percent in production time (see above sidebar). Beyond
determining grinding feed and speed, the software analyzes
and optimizes associated time-consuming activities including
setup, programming and documentation.
visual overview facilitates the creation of setup plans and tool
lists. Programs can be simulated and checked for collisions
throughout the entire work envelope. The software calculates
all process data individually and automatically for each
operation and supplies a full graphic simulation.
CY
C
as workpiece material and heat treatment/hardness as well as
grinding wheel and cooling lubricant specifications — for each
operational step.
TALLY RES
PO
N
Cyclonic filtration benefits the environment as
no disposable media is used in the process.
This saves petroleum, preserves countless trees,
and eliminates the associated environmental
impact created by the disposal of spent filter media.
Contact us to discuss all of your filtration needs. (262)898-0710•Fax(262)898-0748•1509RapidsDrive•Racine,WI53404
Visit our website: www.cyclotronproducts.com
28
Grind/Software & PM Issue 2015
Grind/Software & PM Issue 2015
29
future proof
Operation-Specific
Expansion Modules for
StuderGRIND software
Implementation of the optional expansion
modules for StuderGRIND often can eliminate
the need to acquire special machines for
specific operations. Choice of individual
optional modules depends on the features
and capabilities of the machine in use and
the particular work a shop performs.
StuderDress
Because reprofiling a grinding wheel is time
consuming and requires shutdown of
part-producing operations, optimizing
the dressing process provides a great
opportunity for reducing overall production
time. StuderDress offers an innovative
strategy for the profiling of new wheels
and the reprofiling of used wheels. The
strategy incorporates an optimized number
of cutting passes, including roughing cycles
designed to eliminate unnecessary traverse
movements and save time. Depending on the
wheel profile, StuderDress enables a wheel
to be dressed 3 to 10 times faster than with
conventional methods. The module also
permits setting of T-points at any location
and angular positions on the tool to facilitate
programming drawing.
StuderContour
Peel grinding is a highly efficient method
for high-precision production of longitudinal
contours. The StuderContour module
of StuderGRIND employs peel grinding
techniques to enable rotationally symmetrical
shaft parts such as drills, taps and drawing
tools to be roughed from solid. Wheel
travel paths are chosen to result in the
shortest passes possible and to maximize
consistency of grinding wheel performance.
A sophisticated correction function allows
deflection, cylindricity and straightness to be
ground quickly and accurately on parts with
a critical diameter/length ratio in respect to
dimension, form and position. The module
30
Grind/Software & PM Issue 2015
StuderTechnology
Grinding technology support
software simulation, cost
and time analysis.
StuderDress
Efficient profiling and
reprofiling of grinding
wheels.
StuderGRIND
Workpiece-oriented
programming and data
storage. Cycle specific
visualization of the grinding
tool in relation to the
workpiece.
StuderThread
This thread software turns
a universal machine into
a thread grinding machine.
StuderFormHSM
StuderContour
Peel grinding with automatic
definition of cutting passes,
convex/concave grinding
applications, contour grinding.
StuderPunch
Highly automated and highly
flexible solution for grinding
of punches.
contains predefined step tool programs as
well as full simulation capabilities.
StuderPunch
The StuderPunch module represents a
highly automated and flexible solution for
grinding of punches. Designed for individual
components and small-batch production
runs, StuderPunch is applicable on universal
grinding machines and on production
machines specially adapted for the process.
A shop can store accumulated grinding
knowledge in software memory for use in
production jobs that will repeat at future
times. Software-supported machining
strategies provide highly efficient material
removal and result in lower grinding tool
costs due to reduced tool wear. The module
is fully automated for streamlined
production of families of die and press punch
components. The software databank stores
numerous die/punch cross sections and
geometries in the DXF format.
StuderThread
StuderThread software expands the
capabilities of a universal cylindrical grinder
to give it the functionality of a thread
grinding machine. Partial operations such as
thread grinding can be carried out in-house,
saving time and cost. The software provides
Highly efficient software
for out-of-round grinding,
simple programming of
forms and polygons.
StuderForm
Software for simple
out-of-round applications.
immediate access to most common thread
types. In addition, free-form thread profiles
can be produced at any time, as can preset
and other thread geometries. The software
enables regrinding of pre-machined threads
via an active probe for prepositioning the
workpiece. Cylindrical diameters and threads
can then be ground in a single clamping.
StuderFormHSM and StuderForm
Grinding of noncircular contours, forms and
polygons presents a significant challenge for
grinding machines, tooling and the personnel
who program the processes. StuderFormHSM
(High Speed Machining) is highly efficient
software for out-of-round grinding that
enables manufacturers to perform noncircular
form grinding and meet customer demands
for accurate production of complex contours.
High path precision and simple operation in
dynamic operations facilitate both individual
component and large batch production.
StuderFormHSM controls the axial drives
directly and can thus handle highly dynamic
process specifications.
features and capabilities of the machine in use and the specific
work performed in the shop (see sidebar at left).
StuderGRIND with StuderTechnology and optional expansion
modules permits fast setups and quick adaptation to changing
parts, offering value for companies that manufacture small
lots or single parts. On the other hand, the software’s ability
to store prior programs and incorporate ongoing changes
makes it an excellent tool for high-volume shops when parts in
production are subject to engineering changes.
Non-production Time Savings
Although many manufacturers concentrate nearly exclusively
on reducing actual grinding time, reductions in time and effort
spent on non-production activities such as programming,
setup, optimization and documentation can have an
equal or greater effect on productivity and profitability.
StuderTechnology’s wide range of analytical tools determines
where steps in the overall process can be modified and made
more efficient.
The benefits provided by StuderGRIND software combine to
significantly reduce the total cost of ownership of the grinding
system, ensuring that buyers achieve maximum return on
their investment in a premium STUDER grinder.
Automatic Quality and Speed
STUDER compares the advantages provided by StuderGRIND
software to those of modern photographic cameras. Where in
the past extensive photographic knowledge and technical skill
were required to maximize photographic quality and speed,
today’s cameras feature software that seamlessly automates
exposure, focus and image processing. A person with
basic knowledge of camera operation can create top-quality
photographs. Through its advanced software, STUDER
aims to make processing of the majority of standard grinding
applications equally as automatic and easy. And just as
photographic automation is continually evolving and updated,
STUDER modifies, improves and upgrades its grinding
software to make it “future-proof.”
With regard to larger global issues, StuderGRIND software
possesses BluePlus features developed in recognition of the
VDMA German mechanical engineering trade association’s
Blue Competence initiatives to enhance manufacturing energy
efficiency and sustainability. Companies that participate in the
initiative’s policies are permitted to badge their machines with
the Blue Competence logo. BluePlus represents STUDER’s
effort to make its grinding systems more energy efficient and
economical. Key to that effort is software that monitors 16
channels of machine operation and determines how to best
utilize and conserve energy.
Overall Grinding Support
Offline StuderGRIND software combines a century of
grinding machine and process development with present-day
technology and manufacturing systems. Overall, the software
and the STUDER cylindrical grinders it supports enable a shop
to maximize its productivity, profitability and participation in
environmental progress.
Learn more
www.grinding.com
As an alternative, the StuderForm module
is a simplified version of the software that
expedites the grinding of cams and polygons
in standard small-batch production.
Grind/Software & PM Issue 2015
31
F E AT URE
2.Clean Up Your Act. Precision equipment and dirt don’t
mix. Modern gauges are tough and designed for the
manufacturing environment, but dirt is relentless and the
less of it a gauge has to deal with the longer it will last.
A routine preventive maintenance program can
ensure that wide range in-process measuring heads
such as the Unimar gauge maintain the accuracy
typical of ultra high-performance comparators,
even under the most severe operating conditions.
If you READ THE MANUAL, you‘ll probably find a list of
cleaning Do’s and Don’ts. They’re based on the manufacturer’s
real-world experience and should be followed.
Once gauges are clean, devote some attention to the filters
on the electronics boxes. Hot electronics tend to die quickly,
and a clogged filter on a heat exchanger is a sure way to
speed up the process. Failing electronics can also produce
erratic results that lead to scrap parts and, in extreme cases,
mechanical damage.
The new generation P7up electronic
amplifier for connecting to Marposs
measuring heads and other devices
represents an economical, practical
and reliable solution for highly complex
applications involving in-process
workpiece monitoring on grinding
machines. The unit has been designed
as a direct, pin-to-pin replacement for
previous generation amplifiers.
3.Lubrication Is Not Optional. Not everything requires
lubrication, but equipment that does won’t function for
long without it. If you READ THE MANUAL, it will tell you
what needs to be lubricated and the lubricant to use. Here
again, the manufacturer’s recommendations are based on
real-world applications and ought to be followed. In most
cases, “Just as Good” probably isn’t.
4.Calibrate, Calibrate, Calibrate. Your gauges are subject
to age, accident and operator error, as well as normal wear
and tear. It’s unreasonable to expect them to perform well
without periodic calibration. READ THE MANUAL to find out
how to set up a calibration procedure and schedule. Then,
follow it. Even the world’s best metrology systems aren’t
worth much without proper calibration.
Common Sense Maintenance
Optimizes Your Metrology Investment
Simple maintenance
tips to keep running
at peak efficiency.
By Frank Powell,
Product Manager, Grinder Products,
Marposs Corporation
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Grind/Software & PM Issue 2015
odern metrology hardware is incredibly durable and
reliable, but it requires regular maintenance to get the
maximum value from your investment. The program
doesn’t have to be complicated; most of it is just
common sense.
Here are some simple tips to keep your metrology hardware
running at peak efficiency.
1.READ THE MANUAL. This is capitalized because it’s seldom
done. Every piece of metrology hardware comes from the
manufacturer with a manual containing recommended
maintenance procedures. Those procedures are based
on the manufacturer’s experience with thousands of
installations. Following them exactly will extend the life of
your equipment and minimize your total cost of ownership.
The basic maintenance items outlined above should be tracked
to ensure they‘re done regularly and provide insight into the
impact of age on your system’s performance.
Here are a few things to look for when you’re dealing with older
hardware.
1.Inconsistent readings and calibration problems are often
caused by worn contacts. Given enough time and cycles,
even carbide or diamond will wear to the point at which the
contacts must be replaced.
2.Dirt, coolants and other fluids are relentless and can
infiltrate sealed components over time. You should schedule
a detailed inspection of areas not subject to routine cleaning,
especially if they’re sealed.
3.Threaded connections are subjected to normal vibration
and thermal cycling and eventually will loosen and should
be checked periodically. A loose fitting is also a pathway for
contaminant infiltration. If a fitting is loose, you should detail
check the attached devices.
4.Cables are the Achilles’ heel of a metrology system.
They’re routinely cut, pinched, abraded, attacked by
chemicals and otherwise damaged. Synthetic coolants are
a major cause of cable damage. If you use them, you need
to increase the frequency of cable inspections.
Maintenance alone won’t save your system.
Good maintenance will extend the life of your metrology
system, but it won’t make it last forever. You need to be aware
that changing technology and increasingly strict environmental
regulations are combining to make whole categories of spare
parts scarce or even unobtainable.
For example, the gas plasma displays that were state-of-the-art
a few years ago are listed as environmental hazards today.
They aren’t even available as like-for-like replacement parts.
With the new RoHS standards, this trend is likely to escalate
and will impact many components that are vital to older
systems. Your maintenance records will indicate which
components should be stockpiled while they’re still available,
and which equipment you should consider replacing before
the parts are discontinued.
Good metrology systems aren’t cheap. A well-planned, regular
maintenance program will maximize their life and help smooth the
transition when it’s time to change. It’s never too soon to start.
Learn more
www.marposs.com
Grind/Software & PM Issue 2015
33
The brightest future for energy
savings, and indeed for
productivity, comes when
modern high-efficiency machine
tools, MTConnect and the
best software available are
combined.
MTConnect makes it
easier to get data off new
or old machines, helping
to identify the equipment
and processes that are
most energy intensive.
MTConnect on new machines
or as a retrofit serves up
machine tool data in a format
that is predictable, consistent
and easy for modern computer
systems to digest.
Standards-based Data Systems
Drive Energy Savings
By Russ Waddell,
MTConnect Product Manager,
The Association For Manufacturing Technology
hen it comes to manufacturing, smart energy use
is just like many other cost-saving best practices.
The easiest steps are usually obvious: don’t leave
the lights on and HVAC running all night without
a third shift on; cover up heated open tanks for
processes, like chroming or anodizing; minimize the open
door load/unload times for furnaces, etc. With modern
sensors and computer controls, standards like MTConnect
can give visibility to other energy choices that are not so
obvious but can have major financial implications.
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Grind/Software & PM Issue 2015
The technology available for an energy-efficient factory
of the future reaches across hardware, software and
systems engineering. For machine tools, that means optimal
component selection with subsystems like hydraulics,
chillers and coolant, each chosen for the lowest possible
energy consumption while maintaining high performance.
Software comes into the picture to manage when each
subsystem is active, and again when material removal
processes are optimized at the CAM or CNC level. Process
optimization on individual machines, with reduced scrap rates
and lowered setup times, then feeds into a Manufacturing
Execution System (MES) or Enterprise Resource Planning
(ERP) System to cover an entire facility or multiple facilities.
This top-to-bottom approach is the most effective way to
manage energy consumption.
Of course, most facilities don’t have the luxury of planning
from the ground up with energy use in mind. Brand new
machines installed into an existing system can save huge
amounts of energy, but outdated or non-existent energy
management tools and policies can make it difficult to
actually identify these savings. Hidden energy savings will
still help the bottom line when energy bills are lower at
the end of the month, but better monitoring avoids leaving
money on the table. In particular, local, state and federal
energy savings grants and tax breaks can’t be fully taken
advantage of without some additional detail and metrics
on energy savings.
MTConnect on new machines or as a retrofit serves up
machine tool data in a format that is predictable, consistent
and easy for modern computer systems to digest. For
single machines or cells, proprietary data formats don’t
create much difficulty. But as an energy strategy moves
from one machine or cell to a full department, factory or
multiple factories, translating data across brands or types
of equipment gets expensive quickly.
Because MTConnect data is standardized, the software
options for collection, recording, storage, compilation
and analysis extend beyond just industrial solutions.
The manpower saved on both the shop floor and the back
office from better software can be put to use spotting
energy savings opportunities, productivity chokepoints
and generally improving the bottom line. Higher level
systemwide tasks are still better performed by a human,
which means the same changes taken into consideration
for the sake of energy savings also translate to better
resource allocation across the factory floor.
A systemwide view is important here because gains are
relative. Like productivity gains, absolute energy savings
from a machine almost always come from buying newer,
better machines or components. With only older equipment
in a shop, optimizing production between comparatively
energy efficient and inefficient equipment can show big
savings. That kind of optimization is already commonplace
for maximizing capacity and delivery times; energy use is
just another factor to consider. MTConnect makes it easier
to get data off new or old machines, helping to identify the
equipment and processes that are most energy intensive.
With energy policies in place, new equipment can slot into
place and increase the overall system efficiency.
Manufacturers already have a huge head start in sensor,
control and automation technology, and also have established
options for energy management systems. As software
options in both industry and consumer sectors expand, the
expectations for interfaces, software, ease of use, capabilities
and pricing will start to shift as industrial buyers continue to
seek the best available options. The brightest future for energy
savings, and indeed for productivity, comes when modern
high-efficiency machine tools, MTConnect, and the best
software available are combined.
For now, it’s important to look at existing energy policies
and how they relate to purchasing decisions. In many
cases, there is not even a price premium for machine tool
efficiency. MTConnect and other data connectivity features
and options, whether new or retrofit, may also be important
but underappreciated foundations for better energy visibility
and efficiency. And lastly, there’s no reason not to set the
bar high when it comes to energy. Advances in machine
technology, interconnectivity and software mean the future
of efficiency is looking bright.
Learn more
www.mtconnect.org
Grind/Software & PM Issue 2015
35
F E AT URE
“Between our HELITRONICS,
we run programs for more
than 80 specialty tools and over
100 standard tool programs.”
“As his TOOL STUDIO expertise grew,
Young discovered that the software enabled him
to produce unique geometries beyond those
Proactive Planning Pays Off
produced using PC-based programming.”
Grinding Software and OEM Support Help Shop Battle Back
With expertise in CNC tool
grinders and TOOL STUDIO,
Marcus Young created a
business that was an
immediate success.
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Grind/Software & PM Issue 2015
aunched in Kersey, Pennsylvania, in 1989, AcuTwist is the brainchild of
owner Marcus Young. At the time, he was managing an internal machine
shop at a specialty subcontractor that did a lot of production drilling in powder
metal parts for automotive and outdoor equipment applications. Most of the
holes were under 0.438" in diameter with depths typically five to 10 times
diameter. The shop used carbide and high-speed steel drills and would go through
about 100 drills per day, mostly because of poor drill performance.
The tiny shop was an almost immediate success, quickly
picking up several customers after it became apparent that
Young’s regrinding expertise resulted in drills with much
longer life than standard tools. “I realized that by tweaking
the geometry just a bit we could get longer tool life, cut
rounder and straighter holes and reduce the size of burrs on
the exits of through holes,” he explained.
According to Young, finding drills that cut to size and held required tolerances
was difficult, so the shop resharpened its own drills to size. However, the process
lacked repeatability, which prompted Young to propose the purchase of a better
resharpening system. The owners of the company were unwilling to make the
investment. So Young took a leap of faith, secured a loan, acquired the equipment
and opened AcuTwist for business in his garage with one manual tool grinder and
a desire to succeed.
Business increased, and Young hired a couple of
employees — including his now long-time shop supervisor
Travis Papa — and purchased another manual grinder. All
along, Young followed the evolution of CNC tool grinders
and was well aware of their capabilities and how they could
benefit his shop. So in 1998, Young made another significant
leap of faith and purchased AcuTwist’s first CNC tool grinder
— a WALTER HELITRONIC MINI POWER. He then acquired
a WALTER HELITRONIC POWER grinder and eventually a
second HELITRONIC POWER — all from United Grinding
North America, Inc. — and moved the shop to its current
location in Ridgway, Pennsylvania.
WALTER tool grinders feature patented 3D gantry designs
that provide the highest possible rigidity and precision.
Their grinding spindles ride on massive cross slides
within enclosed backwalls, while large C axes under their
workheads allow complete grinding of highly complex
tool geometries in single setups. This C-axis design also
eliminates the need for rotary spindle axes and further
enhances overall machine rigidity.
Grind/Software & PM Issue 2015
37
“With TOOL STUDIO, Young gains
programming flexibility combined
with very simple operation via
the program’s wizard, which
walks users step-by-step through
programming of even the most
complex tool geometries.”
38
Grind/Software & PM Issue 2015
programming flexibility
unique geometries
AcuTwist kept growing, and Young continued to learn and
capitalize on the capabilities of his first WALTER CNC tool
grinder. The shop had expanded its offerings beyond that
of just resharpening to include generating a wide variety
of tool geometries such as step drills, drill/reamer
combination tools, form tools and other specialty tools.
To keep pace with increased demand, Young acquired the
second WALTER HELITRONIC POWER CNC tool-grinding
machine at this time.
Because he had never produced a tool on a CNC grinder,
Young — from the start — relied heavily on WALTER’s
tool-grinding software when it came to generating tool
geometries and developing machine programs. He progressed
from the standard software to CyberGrind software and
most recently to the advanced TOOL STUDIO grinding
software. With TOOL STUDIO, Young gains programming
flexibility combined with very simple operation via the
program’s wizard, which walks users step-by-step through
programming of even the most complex tool geometries.
With minimal input of geometry data from users, the
wizard function fills in the blanks from its database for rapid
programming of drills, cutters, step tools, form tools and
other rotary tools.
As his TOOL STUDIO expertise grew, Young discovered
that the software enabled him to produce unique geometries
beyond those produced using PC-based programming.
“With TOOL STUDIO, I can put two drill points together on
the same tool,” said Young, “and use as many as six wheels
to generate it. Between our HELITRONICS, we run programs
for more than 80 specialty tools and over 100 standard
tool programs.”
That flexibility allows the company to develop multiple tool
geometries tailored especially for machining of powder metal
components — a tough job given the hard particles and
other challenges that material presents. “In one application,
we developed a drill/reamer for a Tier 1 automotive supplier
that produces P/M parts,” Young said. “Now, we produce
that tool in six different sizes for processing timing gears,
transmission gears, bearing caps and other P/M drivetrain
components. And, tolerances for these parts are often in the
micron range.”
According to Young, his shop actually got its start producing
specials — a significant portion of its current business —
when a customer in the tool and die industry needed a form
tool to machine a helical electrode for its sinker EDM.
“They didn’t even have a drawing and simply sent over the
tool profile via a DXF file,” commented Young. “It was a
small cutter with its largest diameter measuring only 0.125".
But what made it a challenge was that we had to match
more than 20 points on the profile, which we successfully
accomplished with our WALTER grinders.”
Now, AcuTwist produces all types of specialty tools, mainly
from carbide blanks ranging in diameter from 0.157" to
0.875" with lengths up to 6". A tapered end mill with an
angular tolerance of +/-0.05 degrees over a 1.500" length,
for instance, is now nothing out of the ordinary for the small
shop that started out resharpening drills.
Grind/Software & PM Issue 2015
39
Specialist for CNC rotary tables
www.lehmann-rotary-tables.com
“Our HELITRONICS allow us to keep
pace and continue to meet and
exceed those customer needs.”
“One of the things the flood taught us is that grinders make good anchors,”
he said. “But really, it taught us to back up files, programs, everything.”
To increase output and boost unattended operations,
AcuTwist’s HELITRONIC POWER grinders feature WALTER
ECO Loader Plus and thermal compensation software
that together allow the shop to run overnight in addition to
the 10 to 12 hours the machines run during the day. The
compensation software measures and adjusts for machine
growth to ensure consistent grinding precision, while the
ECO Loader Plus lets AcuTwist load over 80 tools. Mounted
directly on the machines’ workheads, the ECO Loaders take
up zero floor space.
we cleaned and dried them out, they were again fully
operational.”
According to Young, UNITED GRINDING technicians —
through hours of over-the-phone support — helped the
shop get its machines back up and running. The shop’s
coolant supplier also stepped up to quickly deliver barrels
of AcuTwist’s preferred coolant.
In May 2014, AcuTwist suffered an unexpected blow when
the nearby Clarion River overflowed its banks and flooded
the shop. “Within hours everything was sitting in three
feet of water, including our WALTER grinders,” recalled
Young. “Adding to the deluge, the floodwaters mixed
with several hundred gallons of stored synthetic grinding
coolant, while machine motors and other vital components
were completely submerged. Three of the five servomotors
on each grinder were submerged, but amazingly, after
Only a few months removed from the disaster, Young is
able to joke about it and take what lessons he can from the
event. “One of the things the flood taught us is that grinders
make good anchors,” he said. “But really, it taught us to back
up files, programs, everything. I had backed up accounting
information the night before, and it was stored on a thumb
drive I had in my pocket. The drive got soaked, but that
data was intact. But we lost a lot of blueprints, both from
customers and ones we generated.”
40
Grind/Software & PM Issue 2015
rapid turnarounds
The combination of Young’s expertise and advanced CNC
tool-grinding machine technology resulted in steady growth
for AcuTwist, with the exception of the Great Recession of
2008 and 2009. But to say business has always progressed
swimmingly might cause Young to disagree.
“Even customers pitched in to help,” said Young. “One of
our biggest customers called and wanted to know how they
could assist us and offered space in their plant for one of our
machines so we could continue to meet orders. The hard
work from UNITED GRINDING, our suppliers and customers
had AcuTwist operational again within three weeks after the
flood and saved us a lot of aggravation and cost.”
Since then, AcuTwist has tried to go paperless whenever
possible and employs multiple data backup strategies,
including clouds and an external hard drive. The company
also began purchasing tablets, which operators use on
the shop floor to access prints and other job data. The
information from these tablets is then uploaded into the
WALTER grinders.
An event like the flood might have deterred some shops, but
it didn’t prevent AcuTwist from moving forward. According to
Young, the company’s business model is a bit different than
many larger tool-grinding companies, and he aims to keep it
that way.
“Our niche is rapid turnarounds on relatively small quantities
of special tools — anywhere from one to 200 pieces.
Plus, we often get projects with turnaround times of a couple
of hours,” said Young. “And our HELITRONICS allow us
to keep pace and continue to meet and exceed those
customer needs.”
Learn more
www.grinding.com
New generation 500:
• Modular design: 4 basic modules – over 170 variations
• Up to 111 min-1 – clamp and release quickly –
short cycle time
• High degree of accuracy: concentricity, geometry
and positioning
• Compact and rigid construction – high spindle
clamping torque
• Fully impervious to IP67 as standard – IP68 optional
(waterproof in bath)
• Large workpiece clamp range
• Competitive prices
General importer for North America
Rotec Tools Ltd.
5 Schuman Road, Millwood, NY 10546
Phone: (914) 941-7311
Fax: (914) 941-0226
Email: info@rotectools.com
www.rotectools.com
Wanted: local representatives
Grind/Software & PM Issue 2015
41
F E AT URE
emulsion. Mixing temperature
(concentrate and water) of a minimum
+50°F to a maximum +86°F is
recommended. Properly filling the
machine the first time makes future top
offs much easier and encourages long
fluid and sump life.
Concentration monitoring
A Little Grinding Fluid TLC Goes a Long Way
ith proper use and a little maintenance, grinding fluid becomes
a Liquid Tool that ensures maximum machine performance and
improves surface finish and productivity. However, only fluid that is
kept in tip-top condition at all times can deliver such benefits, and to
get the longest working life out of that fluid, shops should take some
simple preventive maintenance measures.
Basically, fluids fall into two categories — neat oils and water-miscible cutting fluids.
Each has a different composition, and therefore needs to be handled and maintained
differently.
Neat oils are very high quality oils, which go from the drum into the machine sump
Rico Pollack,
Head of Grinding Technology,
Blaser Swisslube
without the addition of water. As a result, filtration for neat oil products is essential.
Good filtration helps keep the product clean and stable for quality grinding results.
Neat oil products have the potential to remain stable over many years, which allows
for increased return on investment.
Water-miscible fluids are
high-technology products. These
fluids require the addition of water and
must be maintained on a regular basis
to actively monitor the microbiological
components.
Water and mixing concentrate
It all begins with properly filling the
grinding machine with fluid. Grinding
fluid emulsion is mainly comprised
of water, and water quality (chloride
content, hardness and pH) varies
widely by region and country. Poor
water quality can have negative effects
on the coolant, machine parts and
components. Chloride content should
be as low as possible to avoid issues
caused by corrosion.
A mixing device can be used to achieve
a finely dispersed, homogeneous
42
Grind/Software & PM Issue 2015
Concentration is an important
consideration when it comes to fluid
life and should be kept within the
recommended range. Therefore, it is
important to consult your fluid supplier’s
recommended optimal range prior
to mixing. Maintaining the proper
concentration range has significant
impact on the overall performance of
the emulsion. Too-high concentration
will have a negative impact on the
foaming behavior of the fluid, whereas
too-low concentration will adversely
affect performance and stability.
Topping off
Water evaporates over time, so it is
important to top off fluids regularly to
keep the sump in proper working order.
Naturally occurring minerals in water
do not evaporate; rather, they remain in
the emulsion. As a result, to effectively
manage emulsion hardness, it is best to
use water that is de-mineralized or has
been treated by reverse osmosis.
pH value
pH value indicates the microbiology
condition of the coolant during use.
As pH value decreases, chances for
bacterial growth increase. If the pH
value drops below the minimum limit,
corrective measures should be taken,
including involving a coolant consultant
who can help restore proper values.
Tramp oil filtration
Efficient filtration and regular removal
of the tramp oil with a skimmer are
important steps to keep the fluid
emulsion in optimal condition, which in
the long run will help prolong sump life.
When it comes to fluid, a little TLC goes
a long way. Regular fluid maintenance
promotes long sump life, which in turn
reduces coolant disposal and eliminates
the need to purchase expensive
additives.
About Blaser
Blaser Swisslube develops and
produces specialized grinding fluids for
the metalworking industry to improve
surface finish, enhance material removal
rates, prolong wheel life and to fulfill
other machine-specific demands. The
company has broad experience in
regards to usage and maintenance of
coolants for more than 40 years. The
company‘s in-house Technology Center
at its headquarters in Hasle-Ruegsau,
Switzerland enables Blaser specialists
to test newly developed coolants and
to recreate the versatile machining
operations of its customers and partners
in a realistic way. Blaser Swisslube’s goal
is to help improve its customers’ grinding
processes and thus to optimize their
productivity and economic efficiency as
well as surface quality. The right fluid,
correctly used and monitored, becomes
a Liquid Tool.
Learn more
www.blaser.com
Grind/Software & PM Issue 2015
43
T HE
In the
ZONE
I N
Z ONE
HELICHECK 3D Non-Contact CNC Measuring
Machine Creates 3D Models for Analysis
of Cutting Tools and Production Parts
The WALTER HELICHECK 3D non-contact CNC measuring
machine employs a transmitted light camera and a laser sensor to
scan and digitize cutting tools and production parts, creating
3D models that users can save, process, analyze and measure.
The machine’s 3D Tool Analyzer software enables users to lay
freely selectable planes at any position on the 3D model. The
software then automatically analyzes the planes and provides
exact measurements of tool parameters such as core diameter,
rake angles and spiral pitch, even with variable lead. Working
with the 3D model enables users to perform analyses offline at a
separate station.
Additionally, WALTER’s new 3D Matcher software allows users
to overlay two 3D models within a graphical user interface
and perform a color-coded comparison. Matching the models
provides an instant evaluation of product quality and indicates
deviations from desired values.
F E AT U R E S A N D B E N E F I T S
• X-, Y-, Z-axis travels: 270 mm, 455 mm, 325 mm
• A axis: 360 degrees
• Length measuring capability E1 value:
E1 = (1.8 + L/300) μm
• Position resolution linear axes: 0.02 μm
• Measurement value resolution: 0.25 μm
• Maximum backlight diameter: 295 mm
• Maximum laser diameter: 80 mm
• Digitizes cutting tools and production
parts quickly
• Slider control permits free choice
of cross-section slices
CAD/CAM software for
fully automated CNC design
and production on
HELITRONIC machines.
• Performs runout compensation
• No coding necessary for laser scan
• Straightforward software requires no
further programming
• Software fully embedded in current software
overlay (Easy Check)
• Solid granite base offers high thermal stability
and excellent damping properties
• Width x depth x height: 1,117 mm x 1,390 mm
x 2,012 mm
Provides 3D models
using a transmitted light camera
and laser sensor.
HELITRONIC TOOL STUDIO CAD/CAM Software
Facilitates Design, Programming, Simulation
and Production of Tools and Production Parts
WALTER HELITRONIC TOOL STUDIO CAD/CAM software
makes possible fully automated CNC design and production
of extremely complex geometries in one clamping on grinding
machines from the HELITRONIC range.
F E AT U R E S A N D B E N E F I T S
Integrated wizard technology incorporates the WALTER
knowledge database to minimize the level of data entry
required. Standard license versions offer nearly unlimited
possibilities for tool geometry settings and provide pre-defined
features and functionalities for specific tool styles.
• 3D tool simulation featured throughout the entire
design/creation process
Service functions such as automatic warm up and opening of
operations help maximize productivity. An advanced license
option permits creation of user-defined tools as well as
modification and adaptation of individual designs. The software
ensures economic efficiency in batch sizes ranging from a
single part to large-scale production.
• User-controlled view permits focus on relevant data
• Combine operations to produce tools of varying complexity
• Click-and-edit enables immediate geometry modifications
• Feedrate optimizer can produce time savings up to 30 percent
• Automatic scaling allows simple resizing
• Grinding time calculations include data for entire operation,
individual steps and machine movement
• Options facilitate production of step tools, burrs
• Dressing and wheel shape options tailor wheel conditions to desired
tool profiles
• Tool and wheel data interface with WALTER measuring machines
eliminates double data entry
• Advanced tool measuring interface similar to an optical comparator
• Compatible with Windows® XP and Windows 7 on PCs and laptops
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D I GITAL
L A S T
DIG EST
T H O U G H T
t UNITED GRINDING one of our top priorities is to ensure that our
customers receive the best possible performance and service life from
our grinding machines. After all, we work in an industry that is constantly
evolving, so much so that what was a complex part five years ago is now
a standard design. Therefore, in order for our customers to stay ahead of
the manufacturing curve, we must develop intuitive technologies and dedicated
support initiatives that address their current and future needs.
ocial media is a great tool for increasing visibility of your company, strengthening your
brand and even attracting top-level talent to fill open positions. It gives you a unique
opportunity to connect with your audience on a personal level, but to be effective, your
social media strategy must include creating content that is best suited for the various
platforms you’re using. Follow these rules to deliver messages that are on target.
Know your audience
Create your voice
The key to creating and engaging a strong following
Your company’s social media is an extension of
is to really understand who your audience is, what
your other marketing efforts and must support
they want to know and how they like to hear it.
your company’s brand. Whether your company
Remember, your audience is made up of many
is known as serious and thoughtful or edgy and
different types of people — current and potential
direct, your content should be in line with the voice
customers, media, industry thought leaders,
used throughout your other marketing materials.
Technology
In terms of technology, consider our WALTER machines. These tool grinders
employ exclusive HELITRONIC TOOL STUDIO software with an innovative 3D
modeling interface that makes it easy to change the geometrical features of a
cutting tool in just a few mouse clicks. Customers simply click on the feature
they want to edit, and every window in the graphical user interface will display
information relating to that feature.
The TOOL STUDIO software also features wizard input assistance to make
standard cutting tool creation quick and easy. Furthermore, customers can
easily manipulate the software to produce several of the highly-specialized flute
combinations and profiles used in modern machining centers.
employees and even your competitors.
Choose your tone
Decide what platforms fit your audiences
The tone you use when writing content defines
Use of social media varies by age and profession.
your attitude toward the reader or the subject matter.
To catch the attention of various target audiences,
Sometimes it’s appropriate to choose a serious,
deliver your content where it can be consumed.
factual tone. Examples include the introduction
There are many different social media channels
of a new product or announcement of a change
available from Facebook and Twitter to LinkedIn
in leadership by your company. Other situations
and Google+, and each has a slightly different
may call for a more lighthearted, playful tone, such
user profile. Choose the channel for your message
as when promoting a contest or company event.
depending on the audience you want to reach.
Choose your tone wisely.
Deliver relevant content
Be professional
Connect with your followers by providing content
Every post or tweet is a reflection of your company.
that is relevant and valuable. It’s less about corporate
While writing for social media is much less formal
speak than about speaking directly to the challenges
than most other forms of marketing writing, it’s still
they face and giving them solutions. Keep in mind
important to be professional. Use correct grammar
that Twitter limits the length of your tweets to 140
and spelling. Never post anything negative, and
characters, so be concise. And remember to include
remember to thank your followers often.
photos or videos when possible.
We continuously update the software so our customers always have the
competitive advantage when it comes to new grinding applications. In fact, our
latest version of TOOL STUDIO works on equipment made as far back as 1997.
However, some hardware upgrades may be required to accommodate this more
powerful software.
Support
When it comes to support, we work hard to make sure that our customers have
the means and know-how to properly sustain their machines. This involves
everything from ways to safeguard manufacturing data to operator training to
creating a regular preventive maintenance schedule.
...in order for our customers to stay ahead of the manufacturing
curve, we must develop intuitive technologies and dedicated
support initiatives that address their current and future needs.
By Simon Manns, Applications Manager
Tool and Measurement Division,
United Grinding North America, Inc.
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47
L AST
T HOUG H T
continued
Every new WALTER and EWAG machine’s hard drive is
imaged prior to shipment. For WALTER machines, a copy is
also shipped to the customer. However, as these machines
undergo several software updates and accumulate databases
full of tool information, it becomes critical for customers
to create additional image backups and save them to an
external hard drive. After all, when companies have years
invested in developing cutting tools, it can be extremely
difficult to recover data without a proper backup procedure
in place.
We also recommend that our customers view regular
machine maintenance as a form of backup in that it helps
prevent hours of downtime. For example, by sticking
to a maintenance schedule where employees replace
filters, check fluid levels and change the grinding oil at
the manufacturer’s recommended intervals, it is possible
to boost the performance and overall service longevity of
a machine.
Finally, there is training. Everyone agrees they need it, but
not everyone allots the time for it. This is an unfortunate
scenario because too many managers consider it a luxury,
when it is actually a competitive and strategic advantage.
After all, not only do trained employees have the means to
reach their full potential, they can also bolster a company’s
productivity levels.
Consider the fact that it is much better to have an employee
attend a week’s worth of training as opposed to aimlessly
attempting to perform a task over and over again due to a
lack of knowledge. And we can help make training on our
machines easy and convenient via a wide range of courses,
from general grinding to specialized classes.
The bottom line is that the industry is going to keep moving
forward, and we do our very best to help our customers
keep pace by continually reevaluating our processes to
ensure they have the means to succeed today and well into
the future.
When it comes to support, we work hard to make sure that
our customers have the means and know-how to properly
sustain their machines. This involves everything from ways to
safeguard manufacturing data to operator training to creating
a regular preventive maintenance schedule.
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Grind/Software & PM Issue 2015