Please tell us something about Colibri Spindles…
Established in 2003, Colibri started by manufacturing air-bearing dicing spindles, and although we continue to supply high quality spindle solutions for the semiconductor industry, the company shifted its focus to a highly innovative technology we developed in the mid-2000’s – the HSM Jet Spindle – a compact, coolant-driven, high speed auxiliary spindle for milling and turning operations.

Colibri’s tagline says, ‘The Metalworking Innovators’.  Tell us more about some of the innovative technologies from Colibri?
The HSM Jet Spindle’s coolant-driven technology is in and of itself quite an innovation; utilizing the CNC machine’s own cutting fluid supply as a power source to drive the spindle. Along with that, we have added a wireless real-time RPM monitoring system built-in to the spindle, for greater accuracy than ever before.

Colibri is also engaged in the development of new complimentary IOT applications and accessories; anticipating the future of ‘smart’ factory operations. Our SmartHUB device monitoring system, mounted inside the CNC machine, receives wireless real-time data from the spindle and interfaces with machine PLC to display all that information via Colibri’s special software platform on a tablet that can be viewed   wherever you go.

What kind of partnerships/tie-ups do you have with companies like ISCAR, TaeguTec, Ingersoll, Tungaloy, DMG MORI, and others?
Colibri can boast strategic alliances with some of the world’s most respected names in the metal machining industry. We are very proud that the HSM Jet Spindle is among the leading technologies being offered by IMC group members; ISCAR, TaeguTec, Ingersoll and Tungaloy, plus other industry leaders such as EWS, Index-Traub, DMG MORI, Fukuda and more; as an innovative solution to their customers.

Tell us about your widely accepted technologies like SPINJET and Typhoon?
The HSM Jet Spindle (trade names SPINJET/Typhoon) offers a high speed machining solution using small diameter tools for a wide range of semi-finishing and finishing machining applications such as milling, drilling, thread milling, engraving, chamfering/deburring and fine radial grinding. It’s easily adapted to existing CNC machines – with no installation or external power feeds. The compact unit is a truly ‘plug & play’ device that easily fits on the ATC or tool magazine.

The Jet Spindle uses the machine’s existing coolant or cutting fluid supply as a pressurized energy source rotating a turbine in the range of 40,000 to 60,000 RPMs. The coolant is delivered directly to the cutting edge,which greatly improves chip evacuation, surface finish and helps prolong tool life.The monitoring of the spindle’s rotational speed in real-time optimizes cutting conditions for all-around machining efficiency.

Can you please tell us something about your R&D activities?
Colibri’s R&D department is a very busy place. We have recently expanded our HSM Jet Spindle line to include a special high-pressure coolant driven model we call the JETiger, that can handle up to 80bar. We have also introduced angle-head Jet Spindles, with both fixed and adjustable configurations.  In addition, 2017 will be a very exciting year for Colibri, as we are scheduled to launch a number of new products based on the coolant-driven HSM Jet Spindle technology, but for a far wider range of machine types and applications.

Coming to cutting tool technologies, what are the recent technological developments?
Probably the most significant would be hybrid machining – using both additive and subtract machining processes. Additive manufacturing is not a replacement for CNC machining; which will continue to provide the fastest and most precise way to manufacture a broad range metal parts. But because additive methods can achieve intricate and enclosed geometries that CNC machining cannot, both methods can be employed to complement each other in the particular manufacturing process they are best suited for. In the long run, this hybrid approach should result in increased productivity, improved quality and higher profits.

How can your technologies impact customer’s business and productivity?
Colibri’s exclusive spindle technology has had a proven impact on our customer’s bottom line. Utilizing both coolant power and high speed, greatly enhances performance by significantly cutting down on machining time, improving surface quality and extending tool life. Our in-the-field- tests, numerous case studies and customer testimonials concur; the HSM Jet Spindle really does impact profitability.

How has the industry evolved over the years?
We can already see evidence that the Industry has made great strides by implementing sophisticated robotic systems; enabling greater productivity and reliable lights-out manufacturing.  The next few years will see the dawning of the Industry 4.0 age, as more factory operations become connected and interconnected. Every industry segment will be geared towards integrating and implementing the 4.0 concept. Company goals will revolve around reducing data waste and improving manufacturing processes – from pre- to post-machining, using connected technology and high level machining know-how.

What kind of demand you see in India compare to western or more developed world?
In the past few decades we have seen significant and steady growth in the demand for cutting tools in India’s manufacturing sector. India has posted growth in the automotive arena and both the heavy and light engineering sectors.  We see the India market as a microcosm of the world that includes both highly advanced multi-national companies determined to further improve their production process and also local companies, striving to climb up the technology ladder and establish a stable business.

Your future plans for India…
Our plan is to develop relations with a strong strategic partner in India. Ideally, it would be a company with well-established connections in the local metal machining industry and a highly skilled sales and tech team, who are dedicated to elevating their customers to the next level; utilizing innovative technologies such as the HSM Jet Spindle.

By Nishant Kashyap

Ace in the Hole
Also on display at India’s largest tool show was the SpadeRush which made its exhibition debut at IMTEX.

As one of the newest TaeguTec launches on display, the SpadeRush is another marvel of metal-cutting engineering due to the new line’s high productivity head changeable drills for large diameter hole-making.

Available as a standard drill in 3xD and 5xD for a diameter range of 26-41 mm, the SpadeRush’s unique clamping technology enables customers to quickly change drill heads without removing the clamping screw from the holder – an important feature that greatly reduces tool setting times and also machining downtime.

Furthermore, the asymmetrical base design of TaeguTec’s SpadeRush means error proof insert mounting, high tolerance, improved tool accuracy as well as repeatability, and an excellent surface finish.

Typhoon Power
Held another tool that garnered much interest was the Typhoon, which deploys high-spindle speeds without having to invest in replacing the company’s machines.

TaeguTec’s revolutionary new technology used in the Typhoon facilitates high-speed machining on existing set-ups enabling increased efficiency, accuracy and improves the quality of the workpiece while saving significantly on cost and time.

High-speed machining remains unexplored in the industry owing to reasons of high cost and set-up, but TaeguTec’s Typhoon opens up big possibilities of high-speed finishing on several existing good, low-medium spindle-speed, high-rigidity machines.

The Typhoon system uses the existing machine’s coolant supply, reaching rotation speeds of up to 40,000 RPM while the main machine spindle remains idle.

This unique coolant-driven high-speed machining spindle is recommended when high RPMs are required on standard CNC machines.

The Typhoon combines roughing applications using regular tools at regular parameters and low diameter finishing applications at high RPMs. The Typhoon can be mounted on tool magazines without any special adaptation and can be handled by ATC, greatly improving the flexibility and efficiency of the existing machine in the process.

Quad Rushing
TaeguTec’s QuadRush was also on display and is an extremely popular and productive product line for grooving, parting, lateral turning and chamfer machining. The line’s unique features include a four cutting edge insert line allowing excellent performance and repeatability.

With the line having now expanded into external threading applications, the unique, multi-corner four cutting edge insert, known for high accuracy and surface quality, are available in 60 degrees and 55 degrees partial profiles. What’s more, all QuadRush threading inserts are compatible with QuadRush standard cartridges and holders.

The TaeguTec products and solutions were exceptionally well received at the exhibition and kept the salespeople and engineers busy for the entire duration of the seven days that included a weekend and a national holiday.

“The overwhelming response and interest from our customers and visitors augurs well for the times to come,” said Mr. Krishnan.

Machine shops looking for the power of Mother Nature in order to transform their limited RPM machines into speedy F-1 style workhorses at a fraction of the cost can now look no further than TaeguTec’s newest offering.

The Typhoon, TaeguTec’s revolutionary high-speed jet spindle, was developed for applications that need high RPMs for small diameter tools on slow RPM machines.

The new tool is designed to be used for high-speed machining in milling, holemaking and grinding applications.

The system works by utilizing the machine tool’s existing coolant supply, driven by a high-pressure pump as an energy source, to rotate a built-in turbine at speeds of up to 40,000 RPMs.

The Typhoon does not replace the existing machine’s spindle, hence saving the manufacturer thousands of dollars in upgrades or replacement. Instead, it improves the existing low RPM spindle machine’s performance, surface finish and tool life capabilities and increases productivity.

To save on energy use, the machine spindle is idle while the Typhoon performs its operation.

The Typhoon’s incredible precision offers excellent surface quality due to its optimized machining conditions and its plug and play feature makes it an easy product to install on existing machines with no modification required.

Another important feature of TaeguTec’s Typhoon is that it extends the cutting tool’s life, a feature that is made possible due to the optimal cutting conditions and strong coolant jet flow.

Its features include a direct wireless rotation speed display system that monitors the actual cutting rotation speed during the machining process, a 2.4 GHz frequency transmitter, direct wireless rotation speed monitoring of up to 5 meters and a wireless LED display that enables the reading of the Typhoon’s RPM in real time.

The Typhoon is available in three versions, each one covering specific ranges of diameters and speeds for a wide range of workpiece materials and machine tools.

TaeguTec’s newest high-speed jet spindle is designed for applications requiring shanks of up to 6 millimeter and cutting diameters up to 3.5mm. It is specifically adapted to workshops where CNC machines have a spindle capacity lower than 15,000 RPMs and through coolant with a minimum.

During several product tests, TaeguTec’s Typhoon considerably improved the performance of limited RPM machines. While performing a test that required the milling and profiling of an electrolytic copper workpiece, TaeguTec’s Typhoon reduced the machining time by 58 percent and also reduced the spindle wear.

In another product that involved the milling of a turbine part made with a SAE 303 workpiece, the Typhoon increased tool life by 300 percent and reduced the machining time by over 27 hours.

In the case of milling a mold made from V2 material, the Typhoon was able to reduce the total machining time from over 13 hours to just over 5 hours and saved 50 percent of the time used during the polishing process.

While performing thread milling tests on a SAE 4340 workpiece, the Typhoon continued its hot streak by reducing the machining time per part by 85 percent which in turn increased the tool life by as much as 200 percent.

Overall, TaeguTec’s Typhoon is an ideal solution for the growing demand in finish and semi-finish operations on a wide range of processed materials in the die and mold industries as well as high-precision machining in the aerospace and medical industries.

This newest high-speed jet spindle by one of Asia’s largest metalworking manufacturers, boosts productivity by significantly widening the application range on medium and large machine tools, increases efficiency, minimizes set-up time and decreases machining time all of which reduce the overall cost.