EMO Milano Premieres for productive tool grinding and automated manufacturing

Editor: Alexander Stark

Germany — In the cutting tool industry, the trend is moving away from standard tools towards more complex geometries that are specially adapted to the specific application. In order for manufacturers to be able to produce these special tools economically, smart solutions are required. Anca will be presenting the technology, software and automation that enables tool manufacturers to design multiple tool types and grind them in one batch at EMO Milano 2021 on stand F10 G09 in Hall 2.

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The CPX Linear for blank preparation complements Anca's machine program.
The CPX Linear for blank preparation complements Anca's machine program.
(Source: Anca)

In order to compete successfully in the fiercely competitive market, tool manufacturers are striving for increased productivity, higher accuracy and more stable processes. In particular, the demand for automation, Industry 4.0 and technologies that can digitally connect all aspects of production is constantly growing. That is why Anca is working on a new solution: AIMS (Anca Integrated Manufacturing System). AIMS is an overarching platform. At the forefront is a management software suite under which all the hardware needed to grind, measure and machine complex cutting tools is gathered.

A new component of this is the new Automark X laser marking system, which Anca will present at EMO Milano. The automatic stand-alone laser marking station replaces manual and time-consuming marking work. As a result, Automark X simplifies the tooling process and increases productivity, the company explains. Automark X operates in a fully automatic mode when required, without the need for human intervention. This allows the operator to load the pallets with tools and attend to value-added tasks. In addition, the large variety of possible tool sizes ensures maximum variant diversity and cost-effectiveness.

The advantages of Automark X at a glance:

  • Automatic solution that replaces labour-intensive tasks.
  • Seamless integration into the ERP system and AIMS.
  • Cost-effective laser marking solution with small ROI.

Anca's new Automark X laser marking system replaces manual and time-consuming marking of tools with an automated process, increasing productivity.
Anca's new Automark X laser marking system replaces manual and time-consuming marking of tools with an automated process, increasing productivity.
(Source: Anca)

Opportunities offered by electromobility

In 2017, automotive manufacturing accounted for approximately 12 percent of cutting tool consumption. However, electromobility and the associated changes in manufacturing will have a significant impact. In the production of electric vehicles, the required machining time is significantly reduced compared to traditional combustion engines - by an estimated 50-75 percent. With electric vehicles, the demands on gear manufacturing have also changed drastically. For example, the high motor revolutions of up to 20,000 rpm means that a higher gear ratio is required to reduce the speed for efficient use in automobiles. In addition, the complex planetary gear systems are more prevalent in the new electric transmissions. The internal gears used in these transmissions are produced using the hobbing or skiving process. This requires new types of skiving cutters. This is where Anca technology opens up new options for tool manufacturers.

The GCX Linear combines all the necessary technological developments for the production of complex skiving cutters and impact bits for power skiving.
The GCX Linear combines all the necessary technological developments for the production of complex skiving cutters and impact bits for power skiving.
(Source: Anca)

Driven by the unprecedented growth rate of 28 to 36 percent in electric vehicles, solid carbide skiving cutters used in high-speed skiving processes are in high demand. Stable and repeatable production of the complex geometries requires a number of technology and process developments. ANCA combines these features in its GCX linear grinding machine, setting new standards for the production of peeling cutters. At EMO, interested visitors can experience the complete solution for the production of solid carbide skiving cutters up close and convince themselves of the top quality of the tools produced.

The GCX Linear is based on Anca's proven, high-quality CNC grinding machine platform. It has tailor-made functions to perform all operations for skiving cutters and impact chisels in a single clamping. With in-process profile measurement and direct path compensation, Anca offers a practical closed-loop production solution.

Advantages of the GCX Linear at a glance:

  • LinX linear motor technology on X, Y and Z axes.
  • In-process dressing with acoustic emission monitoring system (AEMS) and supervised machine learning algorithm.
  • Motor Temperature Control (MTC) minimises machine warm-up time and ensures optimum thermal stability during grinding.
  • Industry-leading in-process profile and distance measurement with analogue probe.
  • Direct path compensation without wheel dressing.
  • Comprehensive software package including design, simulation, grinding, dressing, measuring and compensation.

CPX Linear for perfect tool blanks

Another EMO highlight is the CPX Linear. With a surface finish of less than 0.2 µm (0.000008 in) RA and a concentricity of less than 2 µm, this four-axis grinding machine for the production of tool blanks complements Anca's machine range. The CPX Linear has a large working range and powerful grinding spindles and thus achieves maximum precision and productivity in the machining of blanks. Thanks to the Pinchpeel grinding method, it offers the same strength, rigidity and thermal stability.

Advantages of the CPX Linear at a glance:

  • AR300 loader.
  • Premierplus collet adapter.
  • Top-mounted retaining clamp.
  • Tailstock (to support long blanks).

FX7 Linear: a wide range of options for increased productivity

For toolmakers who need greater flexibility, increased spindle performance and/or the increased automation capacity of a robot, the FX7 Linear offers the ideal solution. A wide range of options, such as a 6-position wheel changer for automatic loading of wheel packs and coolant distributors, as well as robot loading options with a maximum loading capacity of 840 tools, ensure increased productivity and accuracy. At EMO, visitors will have the opportunity to see the features of the grinding machine in person.

Advantages of the FX7 Linear at a glance:

  • Linear motors on X and Y axis.
  • AMD5x control for faster processing.
  • HSK40F taper offers increased rigidity and accuracy for improved tool surface results.

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