Tool presetting had already been identified as a way of increasing machine tool utilisation and was carried out to a point, but the solution in place relied on the transfer of data via a printed sticker which was then manually inputted into the machine, taking up valuable time and with the potential for errors being made during the input process.
The installation of an Amon Ra-TW presetter from Nikken has taken productivity and efficiency to the next level, with increases in performance and accuracy being apparent from the outset. All tool building and setting is carried out in the pit crew area of the workshop, where the Amon Ra-TW is the primary piece of equipment in use.
The pit crew is responsible for building up a dedicated tool set for each job that is manufactured, and do so in the background whilst the machine tools are running to minimise the amount of downtime between batches of components, maximising productivity.
The Amon Ra-TW has the ability to transfer data directly to machine tools or a central file system – Seiki Systems in the case at Produmax – so that tool data can be downloaded with the offline CNC programs from a single source.
Having a dedicated resource to prepare all tool sets for 13 machine tools, in metric and imperial units, now means that each job in production has a guaranteed tool file accompanying the tool set and CNC program. The production team is now confident that jobs can be run without any errors due to manual intervention or data entry mistakes.
Production has seen a significant benefit from having tools more accurately set. Some components have features where machining with two different cutting tools meet – and where previously there may have been a distinct line where the two operations join, there is now a perfect blend between the surfaces.
This is possible because the presetter allows for the precise measurement of the position of the longest flute on an endmill, ensuring highpoints are set with absolute consistency. This has dramatically reduced any instances of rework, particularly where there is a demand for components to have a machined finish and cannot be polished to remove any imperfections.
In addition to tool presetting, the tool inspection facility of the Amon Ra-TW has enabled the monitoring of tool wear and the establishment of agreed wear figures to define tool end-of-life. Where before the level of wear on a cutting tool was subject to opinion and interpretation, there is now a definitive figure that has been formulated as a point where a cutting tool is no longer fit for purpose, enabling better management of cutting tool replacement and effectively eliminating scrap due to tool degradation.
The additional feature of being able to read in tool .dxf files is also invaluable for making comparisons between physical tools and engineering drawings.
Produmax now has a robust process in place to manage the tooling sets of 13 machine tools producing complex precision components. The introduction of the Amon Ra-TW has eliminated on-machine tool setting for 13 milling machines, with roll-out to all turning centres planned in the future.
Nikken www.nikken-world.com
Produmax www.produmax.co.uk
