ADVANCED MANUFACTURING NOW Jose Alvarenga
New Toolholder Technology Improves Effi ciency a T
raditionally in high-volume thread production, productivity can be limited by machine tool spindle rotational speeds and feeds. Synchronous spindles often do not achieve the programmed rotational speeds above a certain spindle feed. Especially when using small cutting tool diameters, the programmed cutting speed may not be achieved without decreasing tool life and increasing cycle times.
Additional machining challenges include high energy con- sumption. Typically more than half of the energy consumed by a machining center is required for the cooling system, and high speed rigid tapping operations can also be a contributor to energy consumption. Today, these challenges have been answered with in- novative toolholding solutions. For example, new toolholder technology incorporating transmission gearing is capable of keeping up with the programmed spindle speeds, featuring an integrated transmission of 1:4.412 to optimize thread production on CNC machines with synchronous spindles. Combining the integrated transmission with minimum- length compensation offers a way to effi ciently work with high cutting speeds and a relatively low synchronous machine tool speed, compensating for synchronization er- rors during the threading process. The results are signifi cant time and money savings, particularly in high production tap- ping operations. This technology makes it possible to run machine spindles in a non-critical energy saving RPM range during thread production. Additionally, up to 40% time savings can be achieved due to signifi cantly shortened thread production cycles resulting from the combined fast acceleration and cutting speeds facilitated by the integrated transmission. The time savings substantially increases the number of tapped holes achieved in a given operation and is especially effective in
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AdvancedManufacturing.org | January 2015
high-production tapping. Tool life and thread surface quality are both optimized. In one example, in order to compensate for projecting edges and taps of different lengths, three tapping attach- ments were being used in the manufacture of gearboxes. The larger the projecting edges, the more rotational speed had to be reduced. A SpeedSynchro toolholder from Emuge Corp. (West Boylston, MA) was substituted for the three tapping attachments, making use of a short tool extension to maintain rotational speed. Also, to save costs, shorter, less expensive DIN taps can now be used. The Softsynchro minimum length compensation capability has improved the quality of the threads by compensating any synchroniza- tion errors of the machine and ensuring an even load on the cutting edges of the taps. At the same time SpeedSynchro guarantees a consistent depth of threads as well as reduced cycle times and a decrease in required maintenance.
New toolholder technology incorporating transmission gearing is capable of keeping up with the programmed spindle speeds.
In another application example comparing a standard
Synchro cycle with SpeedSynchro, new SpeedSynchro tool- holder technology resulted in a 39% time savings and 1750 fewer production hours when forming 29,000 threads per day in a six-day-a-week production schedule. In addition to the right toolholder, to produce optimal
threading results, selecting the right tap or thread mill for the high production application-at-hand is critical. The impor- tance of paying close attention and examining your applica- tion’s needs, and then taking the time to get advice from cutting tools experts is vital for success.
Tap Holder Product Manager Emuge Corp.
www.emuge.com MODERN MANUFACTURING PROCESSES, SOLUTIONS & STRATEGIES
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