techview
Technology for High-Production Tapping
T
raditionally in high-volume thread production, pro- ductivity can be limited by machine tool spindle rota- tional speeds and feeds. Synchronous spindles often
do not achieve the programmed rotational speeds, especially when using small cutting tool diameters. The programmed cutting speed may also result in increased tool and energy costs due to tool failure. While more than half of the energy consumed by a machining center is required for the cooling system, high-speed rigid tapping operations can contribute a signifi cant amount to the overall energy consumption. Today, these challenges have been answered with in- novative toolholding solutions. Emuge’s new technology, the Speedsynchro Tool Holder, 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, compensat- ing for synchronization errors during the threading process. The results are signifi cant time and money savings, particu- larly in high-production tapping operations. This technology makes it possible to run machine spindles in a noncritical, energy saving rpm range during thread production, increase overall tool life due to an Emuge-patented minimal length compensation, and lower cooling costs with an optional Minimal Quantity Lubrication (MQL) implementation, all of which can be used to show considerable cost savings in the competitive automotive industry. Additionally, up to 40% time savings can be achieved due
to signifi cantly shortened thread-production cycles result- ing from the combined fast acceleration and cutting speeds facilitated by an integrated transmission. The time savings substantially increases the number of tapped holes achieved in a given operation and is especially effective in high-production tapping. Tool life and thread surface quality are both optimized. Exact thread depths can be achieved since the toolholder does not reverse direction of rotation. It supports a maximum
Jose Alvarenga
Tap Holder Product Manager Emuge Corp. West Boylston, MA
spindle speed of 2000 rpm and a maximum tapping speed of 8824 rpm.
In one example, in order to compensate for projecting edges and taps of different lengths, three tapping attach- ments were being used in the manufacturing of gearboxes. The larger the projecting edges, the more rotational speed had to be reduced. A Speedsynchro toolholder was substitut- ed for the three tapping attachments, making use of a short tool extension to maintain rotational speed. The minimum length compensation capability improved the quality of the threads by compensating any synchronization errors of the machine and ensuring an even load on the cutting edges of the taps. At the same time the toolholder guaranteed a con- sistent depth of threads as well as reduced cycle times and a decrease in required maintenance.
This toolholder technology
makes it possible to run machine spindles in a noncritical, energy saving rpm range during thread production
In another application example, comparing a standard
Synchro cycle with the Speedsynchro toolholder 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. After 500,000 threads, there was little or no wear in the holder components, allowing the holder to run for another half a million threads without a set maintenance schedule.
In addition to the right toolholder, selecting the right tap
or thread mill for the high-production application at hand is critical to produce optimal results. The importance of paying close attention and examining your application’s needs and then taking the time to get advice from cutting tools experts is vital for success.
39 — Motorized Vehicle Manufacturing 2015
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