Some still think that tool presetters don’t make sense for job shops because their production quantities are too small. But short runs are precisely why job shops should be doing presetting offline. The more often a machining center is set up with new tools, the more savings tool presetters can deliver – and the most advanced tool presetting systems do more than ever before, in less time, between jobs. Take a look.
MORE EFFICIENT PRODUCTION THROUGH AUTOMATED TOOL PRESETTING
The UNO series of tool presetters combine optimum ergonomics with extensive technical equipment. “The diverse options ensure that the UNO series of individualization is unmatched in this price category,” explains Lothar Sommer, the managing director of DMG MORI Microset GmbH (Bielefeld, Germany). In addition to a touch display, RFID chip system and post processors as standard controls, the range of potential equipment now includes completely new options, such as the autofocus and automatic drive. The UNO autofocus differs from the manual UNO in that it automatically focuses the cutting edge to be measured. This option saves enormous time for tools with several cutting edges around the circumference.
The UNO automatic drive positions the cutting edges automatically. No special knowledge is required by the user because the machine carries out fully automatic measurement of complex tools with several cutting edges and steps at the press of a button.
This means the UNO automatic drive constitutes an additional worker in tool presetting. The same manual operation as used in the standard version is now possible with both equipment configurations if needed. The UNO autofocus and UNO automatic drive from DMG MORI Microset come with a comfort system cabinet and a 22 in touch display in their standard versions. The models of the UNO series are available in two sizes. The UNO 20|40 kicks off with a 400 mm traverse path in the Z-axis while the UNO 20|70 has a travel of 700 mm. Both versions are available as tabletop devices with a 19 in screen. There is a 22 in or 23 in touch display available as an option, as well as the comfort system cabinet. What is unique here is the possibility of measuring tools with diameters up to 100 mm with the snap gauge principle even with the standard version thanks to a traverse path of +200 mm to -50 mm in the X-axis. All conventional tool interfaces, such as HSK, Capto, VDI, KM or BMT, can be realized by adapting the spindle in addition to the SK 50 that comes with the standard version.
The inherently rigid bed with 3-point support not only ensures safe footing but highest flexibility in the workshop as well thanks to simple setup. The integrated infinite fine adjustment in both axes and the segment incident light for visual control of the cutting edge are also outstanding features included in the standard version. “You can only get this class of FEM-optimized and thermally stable grey cast iron construction from us,” adds Sommer. “The UNO sets new standards in the entry class of tool presetting. The release-by-touch operation in particular and the large touch display for even better handling of the Microvision software make work so much easier.” This high-performance software enables simple and operator-independent measuring in all equipment configurations.” Microvision offers intuitive operation for the user and with its helpful functions quickly achieves highly accurate measuring results. Accuracy is aided by a focusing window, which enables exact positioning even for highly complex tools. A thermal label printer, vacuum clamping, a second camera for setting the center of rotation and a multitude of other options round off the latest UNO series. Technical data includes:
- Max tool diameter mm 400
- Max tool dia snap gauge mm 100
- Max tool length, Z-axis mm 400/700
- Manual with autofocus
- CNC fully automatic with manual mode
- Infinite fine adjustment
- True running accuracy at spindle nose µm 2
- Repeat accuracy µm ± 2
- Precision spindle SK50
- Vacuum clamping
- Spindle brake
- 4 × 90 deg indexing for turning tools (e.g. VDI)
Rotational center measuring device
- Dial gauge
- Second camera
DMG MORI USA, 2400 Huntington Boulevard, Hoffman Estates, IL 60192, 847-593-5400, Fax: 847-593-5433, us.dmgmori.com.
AFFORDABLE BENCH TOP TOOL PRESETTER WITH CAMERA AND LCD TOUCH SCREEN
BIG Kaiser Precision Tooling Inc. (Hoffman Estates, IL) introduces a budget-friendly benchtop tool presetter equipped with a 5.7 in color LCD touch screen and camera. As an upgraded model of the popular DIASET, manufactured by Innotool (Austria), this vision-based camera version enables one-touch angle, radius, diameter and length measurements. An optional incident light allows for inspection of cutting edges for built-up edge, flank wear or fractures. The DIASET is built with a stable measuring column and base made out of mineral cast. This strong foundation ensures extreme rigidity and excellent temperature resistance for high repeatability and positioning accuracy of .0001 in. These impressive capabilities on an entry-level presetter are also supported by horizontal and vertical slides that smoothly move along hardened and precision ground guideways, both with pneumatic locking mechanisms and foot pedal control.
The high-precision rotating spindle allows a guaranteed accuracy of runout measurements to less than .0008 in TIR and is available with either integral ISO50 or ISO40 taper spindles. Reduction adapters are available for other common interfaces (ISO, HSK, KM, Polygon, etc.). Many combinations of max diameter/max length are available to perfectly suit your measuring needs – and budget. Additionally, two built-in USB ports for simultaneous external data saving and label printer connection, as well as internal storage of up to 99 reference points, means investing in the DIASET Camera Type will dramatically reduce the chance of human error in tool preparation. Leasing options are available and price quotes can be easily requested on the BIG Kaiser website.
PRESETTING AND BALANCING ON ONE MACHINE
Two of the biggest trends in today’s manufacturing world are presetting and balancing, so it is naturally a good idea to create a machine that does both. The TD Preset from Haimer USA, LLC (Villa Park, IL) is the only unit to combine Haimer balancing technology with Zoller measuring technology. As a manufacturer of tool holders, no one understands the importance of taper interface better than Haimer, and this knowledge is integrated into the modular spindle adapter system, which clamps just like a machine tool spindle, making measurements more accurate and ensuring repeatability. The modular design takes less than a minute to switch out any modern spindle interface. Since both presetting and balancing can now be done in one place, even more time is saved because the tool holder doesn’t have to be set up in two separate machines.
Both Zoller Pilot 3.0 image processing software and Haimer balancing software are easy to use on the included touch screen monitor. Some of Zoller’s main presetting features include a repeatable measuring accuracy of ±2 microns to measure height and diameter, automatic cutting edge shape detection and a maximum contour function that detects and measures the cutting edge contour produced when rotating the tool by 360 deg, thus showing the tool holder assembly’s TIR. The Haimer balancing machine uses hard-bearing technology and force sensors to measure unbalance with a repeatable accuracy of ±0.5 gmm. After measuring, the automatic indexing shows exactly where the unbalance on a tool holder assembly is. The software then provides the option to correct the unbalance using either set screws, balancing rings or by removing material through drilling or milling. A balanced tool holder assembly provides not only better surface finish, but a drastic improvement on both cutting tool and machine tool spindle life.
The TD Preset uses an external PC running on Windows that stores more than 5,000 different tools, so a shop doesn’t have to reprogram anything when measuring multiple assemblies. The extended hood on the machine enables a maximum measurable length of 15.70 in and maximum diameter of 14.20 in. The spindle itself can hold up to 66 lb.
TOOL MEASUREMENT, INSPECTION, PROFILING
Parlec, Inc. (Fairport, NY), a worldwide leader in toolholding and presetting solutions, announces its latest presetting innovation, the Origin TMM. This compact tool measurement and inspection system weighs only 140 lb and is capable of handling a range of tasks. “The Origin offers excellence in design, engineering and manufacturing, and its video measuring technology capabilities is second to none,” said Matt Ricotta, the director of product marketing for Parlec. “For under $10,000, the Origin presetter is truly unlike anything in its class.” The Origin offers a measuring length of 508 mm (20 in) and a measuring diameter of 254 cm (10 in). Other features include surface illumination, .001 mm fine adjustment, rapid quick-positioning handle with electronic breaking, and a 19 in widescreen monitor with 70X video magnification. The spindle is fit for 40 taper or 50 taper (CAT, BT, ISO and SK). Additional adapters for other connections are available.
Parlec also offers the Apex Profile Inspection Machine, a fully automated, ultra-precise, profile measurement system designed to measure profiles of form cutting tools and grinding wheels. “The Apex is an ideal alternative to three-dimensional inspection machines. It will help inspect and qualify the most difficult geometric profiles using existing DXF drawings,” notes Matt Ricotta. The Apex offers a measuring height of 420 mm (16.5 in) and a measuring diameter of 400 mm (15.75 in). Other features include ParleVision® Imaging technology, a completely enclosed measuring environment to minimize environmental influences, and dual 19 in widescreen monitors with 70X video magnification. The user friendly software design of Apex can complete inspections in an easy three-step process. With a single import of DXF drawings, inspections are performed and repeated with the click of a button, accelerating and enhancing the process to reduce scrap and improve production efficiencies.
Parlec, Inc., 101 Perinton Parkway, Fairport, NY 14450-9182, 585-425-4400, Fax: 585-425-7542, www.parlec.com.
MEASURE AND PRESET TOOLS WITH ONE CLICK
Measure the tool, preset it and, at the push of a button, start with production. This doesn’t just sound easy, it is easy. EZset tool presetters from EZset LLC (Ann Arbor, MI) are known for their ease of use, speed and precision. No shop wants to produce a huge amount of waste, and presetting tools with these presetters and their multiple software functions increases shop production productivity by reducing the number of wasted work pieces. One software function is EZmax, which enables the determination and measurement of the actual maximum contour of cutting edges at circumference. With a fast and precise contour focus of all cutting edges, the maximum Z and X value is determined. After the measurement, the maximum corner radius and the two maximum cutting edge angles can be output at a click.
Typing the wrong data into the CNC machine often results in high waste and lost money, but using EZset tool presetters with ImageController 2 and 3 makes control-specific data output and transfer easy. The measured actual data is transferred to the CNC machine with only one click. The tools are measured and preset, the machine is selected and the actual tool data is transferred, depending on the settings, directly via network, serial interface or USB stick. Typing errors through manual input are excluded. Software functions that can be added include EZjob setup sheet management for creating workpiece-related setup sheets, and the EZedit editing of output formats after the measurement. As business grows more competitive, every shop has to produce more and more economically. To be faster than your competitor, EZset presetters not only provide precise measuring results, they collect them very fast in an easy-to-operate way. The user gets up to five measuring results in only a few seconds without any tool data entry: vertical measure, horizontal measure, radius and two angles.
There are four EZset tool presetters that come in different sizes: EZgo and EZset with ImageController 1, 2 and 3. The EZgo with ImageController basic, the smallest EZset device, is an entry-level tool presetter with extremely simple operation and precise measuring results. Gently pressing a button engages the unique EZclick function for standard measuring of length, diameter, radial and axial run-out. The EZset with ImageController 3 is the top of the range and comes with integrated tool management in a graphics library. Tool cutting edges can be visualized with Autofocus and 40-fold magnification. The EZset with ImageController3 offers modern, user-friendly, configurable IC3 image processing software. The user interface features state-of-the-art technology inside an easy, innovative and highly precise touch and slide function. For a detailed traceability, it measures, saves and documents tool cutting edges within seconds.
Amid Challenges, Majority of Metalformers Predict Little Change in Economic Activity
U.S and Canadian incoming orders expected to remain steady, according to the latest barometer reading from the Precision Metalforming Association.
U.S. Manufacturing Grows in September –– PMI Dips 0.6% to 55.4
The Institute for Supply Management reports that among the six biggest industries, food, beverage & tobacco remains the best-performing sector, with fabricated metal and chemical products growing strongly.