CNC universal tool grinder new technology

In recent years, the tool industry is gradually shifted from mass production standard tool mode to small batch production of many varieties of special tools mode conversion. How fast and stable user needs a special tool to the market has become an important issue placed in front of the tool manufacturers. Industry-leading is 20 years ago, began the development of CNC tool grinder is headquartered in Melbourne, Australia, ANCA (green cards, site group: official Chinese name of the company now for Ocamar) Pty.Ltd. 

The tool grinder Anka production five types: the TX7 production, regrinding RGT type, thread processing TapX the SBG-type blade processing, stamping tools PGX type. Here are the best-performing TX7 tool grinder. 
Anka developed 5-axis + 4-axis controlled CNC TX7 universal tool grinder bed resin concrete developed by the company, its excellent damping performance equivalent to nine times the cast iron bed. Wide space of the machine according to the three-dimensional CAD design, the front of the spindle close to the mechanical center position of the rotating column, are able to achieve high precision grinding spindle structure in arbitrary radius, and the basic parameters of the machine are shown in Table 1.

Table 1 TX7 machine parameters

Maximum tool length	300mm (maximum cutting edge length 250 mm)
Tool diameter	200mm
Maximum tool weight	25kg
Wheel spindle motor power	18kW (24HP) (built-in motor)
Grinding wheel spindle	Big-plusBT40
Wheel component count	2
Machine weight	7500kg

Figure 1 CNC universal tool grinder TX7 +

To operate, high production efficiency TX7 main function is as follows: 

• All axes are used to directly drive 

NC tools in general grinding wheel spindle or linear motion axis by means of a belt driven by the motor shaft gear. The green card spindle, linear motion and rotary axes completely direct drive, in addition to all belts and gears. Anka's leading position in this field. 

· MPG-feed 

Using the manual pulse generator, fast and secure program detects operator of NC-controlled action. The use of this feature, the operator can perform simple input, output and fast setup program, thus shortening the adjustment time. 

· Automatic grinding wheel replacement 

The two sets of wheels (each consisting of four wheels and cooling device) can be replaced at the same time in the 4s. To improve accuracy, the grinding wheel spindle Showa Seiko mechanical clamping system. Each wheel can be adjusted to the coolant conduit, and the completion of the new wheel and the adjustment of the cooling fluid conduit in 2min. 

· Big Plus grinding wheel clamping system 

Patented product - Big Plus wheel clamping system using Showa Seiko machinery company, cone and end face contact on both sides, so as to ensure a high precision. Accurate clamping of the grinding wheel assembly to improve the accuracy and performance of the tool. In this way, both fully improve the processing capacity of the grinding wheel itself and prolong the life of the grinding wheel. 

· High-speed workpiece axis 

The high-speed the workpiece shaft (3000r/min) once installed will be able to cylindrical grinding, one-time installation manufacturing step drill. The axis of the workpiece can also be installed performance correction device for efficient, high-precision correction processing. Optional correction device can be maintained in the long processing consistency in the quality of the punch and die. 

Toolroom software 

Green card as a leader of the NC tool grinder software technology, the software market iGrind, iBurr, iProfile, CIM 3D and iFlute, for two reasons: the versatility and flexibility of its software technology has enduring. 

· To improve the machining accuracy of the function 

Green card company to develop and bring to market many products to achieve better machining accuracy, here are two cases. 

* IView tool measuring system (see Figure 2)

Figure 2 iView system use cases

The contour of high precision grinding Christmas tree cutter tool. Anka developed sophisticated iView high-speed cameras can be measured in the clamping state, can be installed on any X-rated CNC tool grinder and accurate determination of the tool in a matter of minutes. iViewcamera and software programs combination of the following determination: the contour of the tool (end mill, ball end mill, R fillet end mills), tool diameter, given angle in 3:00, 3:00 given radius.

Figure 3 iView screen display

The characteristics of the the iView high-speed camera can not be removed from the grinder tool Determination will need to be amended for the cycle times longer tool or measurement tool regrinding effect is very obvious. In addition, it can be simple determination of 5 μ m with a tolerance band is displayed on the screen (see Figure 3). iView with the preservation of the measurement data transmitted automatically create reports and print functions. Precise measurements and iView camera installation tool grinding state, thus ensuring a high-precision measurement. 300 times using high-precision camera can be determined to 2 mu m. 

* Fine-tuning chuck system (MACS) 

MACS (patent pending) is a green card company to design high-precision collet system. It can be corrected and the elimination of axial and radial runout control the beating of 50mm at 3 mu m or less, automatic and manual feeding beating control minimum. The range of diameters can be clamped for 2 to 27mm, and TX7 corrector with. 

* Automatic loading and unloading 

In order to increase productivity, TX7 configure the following for optional automatic loading and unloading device, the device is designed in the back of the machine, optional fitted. 

- Individual trays loaded automatically 

Tray capacity: tool diameter 25mm above 40, the tool diameter 3 ~ 16mm 220. Pallet load cycle time of loading for 16s. Machine automatic production of software can be a different shape of the grinding tool. 

- 5 trays loaded automatically 

Basic parameters and leaflets trays automatically loaded the same. The tray capacity of 1100. 

- Automatic loading robot 

Load cycle time of 10s, is characterized by a humane system of procedures, clean design and anthropomorphic principle. 

The TX7 of unique applications 

1) Christmas tree cutter grinding 

When processing Christmas tree cutter eccentric groove, different spiral groove requires a different profile shape of the grinding wheel. How to reach the spiral required on the contour of processing difficulties.

Figure 4 Christmas tree cutter

To meet this requirement, the green card has developed a special application software and processing procedures, the use of standard R-shaped grinding wheel, eccentric groove profile shape along the spiral groove processing. 

The software determination of the shape of the groove-shaped cross-section profile were measured to determine accurately the groove of the profile shape processing in order to determine the exact location of the processing sites. The handler for each groove was measured to ensure the accuracy of each surface. The profile shape from the DXF file import, wheel components must be properly selected. Shape of the grinding wheel, in particular, is the accurate determination of the radius of the arc is very important.

Figure 5 Determination of groove shape contour of instances

2) High-speed Mogou "FASTgrind" grinding technology 

Has been high-speed steel drill bit to use aluminum oxide or CBN grinding wheel, with more than one machine production, from raw materials to complete the production process of the drill is semi-automatic and manual control, drill varieties change, the machine reset difficult, cumbersome, and more than special machine investment cost of products greatly improved, so only a handful of companies can be equipped. 

To solve this problem, green cards and Dorset high bein (Sain-Gobain) to develop a production of high-speed steel drill bit "FASTgrind" new grinding technology, the advantages of less investment, strong adaptability. This highly efficient high-speed steel drill bit and tap grinding technology is not only used in mass production.

The Figure 6 speed Mogou FASTgrind technology

The grinding technology "FASTgrind" is the Aulos Wheel "on the basis of production by the ANCA TX7 CNC tool grinder and NortonAbrasives. In the past, only the CBN grinding wheel CNC grinder to meet the production of high-speed steel drill bit grinding wheel is very difficult to correct. In feed rate, a lot of CNC grinding machine also had problems. Dorset high bein Aulos wheel, high-performance model developed for these defects CBN grinding wheel. The patented long shape of the wheel than ceramic abrasive greatly increasing the flexibility of the grinding, the side with the groove allows the wheel to far more than the CBN grinding wheel speed machining grooves. The TX7 with Norton Aulos wheel combination of a conventional manner not super-short period of time was adjusted to become possible. (End)

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Note die sharpening and repair

1 edge wear and burr measurement 

Field habits determined by hand stamping burr size and determine the sharpening timing, the error is too large. Of course, the degree of edge wear and edge blunt only by detecting stamping burr height and thickness, burr distribution uniformity of size, shape and position accuracy and blanking plane quality stamping, the master edge wear, edge change blunt, identify the timing of sharpening. 

General stamping burr height micrometer available. To improve measurement accuracy, each measured three last consecutive punching punch and die member, and each mold accessories is measured at least 3 to 5 points, averaged. For complex shape and thin materials and small size, precision stamping, available tools, microscopes, the optical projector precision measurement. 

2 metal stamping size and shape and position accuracy measurements 

After repeated sharpening, the die size will change. In particular, the majority of> 3 to 6 mm material thickness of plate and slab material blanking part blanking die, smooth consideration by the die hole punch to shirk the workpiece or waste, on the small conical recess mold hole, to prevent workpiece or scrap gathered and plug in the die. The die edge the wall pour out material, after grinding the upper surface of the horizontal size will inevitably produce an increment. Excessive gain in order to avoid repeated sharpening its size exceeds the allowable value, leaving out of the stamping size unqualified.Therefore, before sharpening should refer to the values ​​given are calculated and measured stamping after grinding size, to stamping size qualified so far. 

Inaccurate positioning device or gauge pin wear, rotating, feeding into the distance deviation increase. For continuous blanking part, often be caused by stamping inside and outside round concentricity error is too large, dividing the incision problems such as uneven cloth, it is in the repair test mode requires special attention. 

Measurement tryout stamping presses the normal operation for some time, punching a certain number of stamping. Measurement of hedge pieces should first observe the red section quality to determine the uniformity of the gap. Then detect the burr height and uniformity of last crossed detected size and shape and position accuracy. 

3 clearance measurement 

Accurate determination of the new system and overhaul or repair to all kinds of die clearance inspection and molding, one of the primary means of repair mode quality, die fitter and punching to adjust the basic skills of the workers. 

Plasticine indentation and fill the mold cavity is in a case where there is no practical and accurate clearance measurement instrument, more economical, accurate and reliable clearance measuring method. With a uniform thickness that is greater than twice the stamping material thickness does not exceed 5 mm plasticine, relying on manual clamping gently closed state to meet the design and then gently mold to remove the plasticine, observation and measurement to stay in plasticine on the upper and lower mold indentation, you can get the exact gap value. For blanking die, indentation on the mold can be controlled just pressed into the plasticine 0.8 to 1.5mm position; forming die majority should be embossed in the clamping state. However, stretching, flanging and the like of the mold, but also due to the simultaneous detection of the mouth portion of the fillet radius of the die size and uniformity, so when the platen punch into the die 2 to 3 times the material thickness of the punch member is appropriate. 

4 die installation and commissioning of 

Installation and adjust the die must be particularly careful. Because die especially large and medium-sized die, not only very expensive, but also the weight trace difficult to move, personal safety should always be the first place. Unlimited digital device, die, in particular, nor die guide mechanism between the upper and lower mold should be added to a mat board. Clean up in the press table to be tested mold clamping state placed in the appropriate position of the press countertops. Selected ram stroke press process documents and die design requirements in the mold onto the table before the raised bottom dead center position and raised to 10 ~ 15mm larger than the mold is closed, by adjusting the slider rod, mobile mold, to ensure that the handle is aligned with the handle hole and appropriate die height. General blanking die first fixed lower mold (do not tighten) and then fixed on the mode (tightening), platen T-bolts are advised to use the appropriate torque wrench to tighten (mold) to ensure that the same bolts with consistent and ideal pre-clamping force. Manual winding the tight thread appears due to physical, gender, texture error caused by the preload is too large or too small, can be effectively prevented the same thread PRELOAD ranging, causing lateral displacement of the upper and lower molds, the gap change the stamping process, the nibbles stripping blade mouth, such as failure occurs. Tryout before the mold to conduct a comprehensive lubrication and normal production of the materials used in air travel to start the die 3-5 recognition mold functioning properly and try red. Adjust and control the punch into the die depth, check and verify the die-oriented, feeding, shirk, lateral pressure and suppress institutions and device performance and operational flexibility, and then appropriately adjusted so as to achieve the best technical condition. Small, medium and large die trial red 3,5,10 discontinued beginning of the seizure, red 10, 15, 30, qualified try for re-examination. Crossed detection, red cut surface and burr inspection ORCHID Dimensions are in line with the shape and position accuracy requirements before delivery of production. 

5 standard prefabricated parts and reserves 

For die standard components should focus on prefabricated and leave some reserves for selection at any time in the process of manufacturing and repair die. In particular, the main working parts, including: a variety of round punch side of the blade, scrap cutter, and a variety of templates, die handle, mold, lateral pressure device before backgauge device ...... should full range of specifications reserve 3 to 5 sets or more, commonly used sizes, should be more reserve.

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