At the GrindingHub, May 17-20, at Messe Stuttgart, ANCA will be showcasing its technology portfolio, which enables customers to increase capacity, improve profit margins and gain efficiencies.

Choosing which technology to invest in should be guided by business objectives, working with existing goals, processes, data and insights.

In-process OD measurement CPX

The CPX In-Process OD Measurement System is a quality control system that monitors and controls the OD of ground blanks within a batch production.

Batch grinding on a CPX with high material removal rates and within tight tolerances is a core function of the machine. The DO measurement system goes a step further by using the SPC function that comes standard with the DO measurement software. SPC is user defined and tolerances as well as Cp and CpK values ​​are constantly monitored, controlled and reported to the user.

The outer diameter measuring system is permanently mounted inside the machine and is only called upon when necessary, depending on the defined tolerances and the measuring frequency. Precise in-process measurement and compensation is applied to maintain the outer diameter of the blank at the nominal diameter.

The system has the ability to handle multiple diameters in a single setup, making it suitable for complex blank geometries/shapes and longer batches, the company says.

GOALS

ANCA’s Integrated Manufacturing System (AIMS) is the future of optimized cutting tool production through streamlined manufacturing and connectivity.

Industry 4.0 technology views a plant as one machine, rather than separating it into many different elements of design, blank preparation, grinding, laser marking, washing, packaging and shipping.

AIMS is a modular solution that can be deployed in stages allowing a gradual and smooth transition from traditional manufacturing to automated and integrated manufacturing.

An AIMS manufacturing cell will be on display at the GrindingHub, demonstrating a fully automatic tool manufacturing process starting from the pallet with blanks and ending with pallets with ground tools.

The GrindingHub demo includes the following components:

• Automatic adjustment – preparation station, it is a main operator interface. Jobs scheduled for production are uploaded via the AIMS server to the AutoSet station and are prepared for production here, pallets are loaded with blanks for further automatic processing
• Automatic extraction – AMR (Autonomous Mobile Robot) responsible for material transfer between processes replacing operators carrying pallets or individual tools between machines/processes. The AutoFetch robot will transfer complete pallets with blanks to the respective grinder, pick an individual tool from a grinder for out-of-process measurement and compensation, then pick a pallet of finished tools and transfer it to the finished goods area
• MX7 linear grinder equipped with the AutoLine Advanced loader (Robomate 2 loader with AIMS kit installed), allowing to accept pallets presented by the AutoFetch
• Zoller Genie with Zoller AutoLine Advanced responsible for the out-of-process measurement of individual tools in a production batch. The measured values ​​are transferred to the respective mill and the compensation of the milling parameters takes place on the basis of the individual tolerance settings of the customers.

AutoMarkX laser marking

AutoMarkX is a stand-alone automatic laser marking station replacing laborious manual processes.

It is AIMS Ready, which means it can be used as a stand-alone machine but can be easily integrated into your unmanned AIMS manufacturing cell with automatic pallet transfer using the AutoFetch robot.

The AutoMarkX eliminates the need for manual laser marking which is repetitive and laborious work that could be automated and therefore save you money. By avoiding manual handling, tool quality is protected by eliminating the risk of chipping.

AutoMarkX accepts up to two full tool palettes, which means you can mark a large number of tools without human intervention. Flexible marking means that the message can be engraved on just one side of the shank or on opposite sides of the shank as well as the end of the tool. The last option is particularly useful for applications where a unique tool identification code (eg Datamatrix) needs to be engraved on the tool. Codes like Datamatrix are usually etched on the shank where they are likely to be exposed to excessive surface wear, making them unreadable. The end of the tool is the best place to burn this type of code to overcome this problem.

Automated small batch and regrinding

ANCA has developed the LaserUltra closed-loop barcode and measurement reader interfaced with the iGrind and the end customer’s ERP system. This system will be demonstrated on the FX7 linear platform. The demonstration will highlight how to set up a resharpening tool using a barcode reader and a QR code, how to easily make adjustments in our ANCA software, what inputs are possible in an ERP system, the configuration of RFID to allow automation of mixed diameters and the actual grinding process. The FX7 Linear machine will also feature Pop-Up Steady, AutoStick, Auto Wheel Qualification and iView.

The standalone MX7 Linear with RoboMate Loader will demonstrate ANCA’s solution for automatic grinding and loading of indexable inserts. The machine and feeder will be installed with grippers, grippers, pallets and an exchange station specifically for the manufacture of special inserts. Accessories installed on the machine include the 4-station Auto Stick, Auto Wheel Qualifier, and LaserUltra.

Equip yourself to ski

Driven by the electrification of the automotive industry and the general rise of e-mobility, the demand for trimming cutters has grown by 30% year-on-year. The GCX Linear offers a complete solution for customers to tap into this rapidly developing market, including the ability to produce countersinks, shapers and regrinding hobs. It offers advanced stand-alone software to design and optimize the tool, seamlessly interfaced with the gear tool package in ANCA’s renowned ToolRoom software. The machine is built for precision with features including all axes with LinX linear motors and an improved headstock. GCX Linear has also added a series of technologies: AEMS dressing, MTC on grinding spindle and dressing spindle, integrated gear tool measurement and direct compensation – setting the new standard for producing beveling tools that achieve class highest DIN AA quality.

Due to the novelty of the bevel tool, many gear measuring machines still lack the correct mathematical model to assess the quality of the cutter. A world leader in solving the problem of quality control, ANCA has developed the world’s first integrated gear tool measuring system, which enables grinding-measuring-compensation entirely performed in-machine, as the only practical solution in a closed loop.

At the GrindingHub, the GCX Linear will demonstrate the bevel cutter production process aided by the industry’s first integrated gear-driven tool measurement system.

New tool room

In addition to demonstrations of ANCA’s ToolRoom and CIM3D software, visitors can preview the next version of the RN35.

ToolRoom RN35 focuses on improving productivity and cycle time, especially machine running costs. New process optimization features reduce cycle time, which in turn provides higher quality tools and longer wheel life. This includes automated reduction of air grinding time and deviations calculated based on tool simulation models.

Some of the major improvements include

• Feed optimization – Integration of the Q-Prime function in the ToolRoom software to obtain a constant material removal rate (MRR) based on the specifications of the wheel manufacturers. This is done by calculating and controlling non-constant feedrate, if any, to achieve better cycle time and longer wheel life.
• Reduced airtime – Automated airtime reduction by optimizing deviations based on tool simulation models and wheel shapes.
• Statistical Process Control (SPC) – Helps control your production process during high-volume manufacturing by monitoring variations due to wheel wear and other process-controlled activities. Process capability data can be displayed graphically or stored for future QC or later evaluation purposes. It also helps customers control critical tool dimensions like diameter by updating grinding wheels at regular intervals.
• Profile spline – Used to control and maintain the hook/rake angle along the path of the cutting edge on a given profile. Increases cutting performance and tool life with an even hook/rake angle along the edge.