German based high precision products solution providers for metal cutting, HAIMER will be giving live demonstration of its latest tool holding, clamping and balancing machines at the India’s largest die mould exhibition, Die Mould India 2016. The company is going to highlight its revolutionary tool holding devices, power clamp range of shrinking technologies and balancing machines along with other technologies.

The company will showcase:

Tool Holders
HAIMER offers the right clamping technology for every industry, application and typical machining operation. Take advantage of the innovative solutions from the technology leader for tool holders.

Shrinking Technology
For years, HAIMER has been the leading developer of inductive shrink fit technology for tool holders. Rely on our broad experience and use the world’s largest range of shrink fit equipment and coils. With the Power Clamp range, HAIMER provides its shrink-fit chucks with a comprehensive and well thought out range of devices of inductive shrink fit machines. By doing so, you profit from the fact that HAIMER perfectly coordinates shrink fit machines and chucks in its own production.

Balancing Machine
With the Tool Dynamic series HAIMER offers a universal machine concept for balancing tool holders, grinding wheels and other rotors. Increase your productivity with less unbalance in your production. With the Tool Dynamic balancing machine series, HAIMER offers a comprehensive solution for the balancing of tool holders, grinding wheels and big rotors with diameters up to 800 mm. Starting from the table and complementary machine TD 1002 to the automatic balancing machine TD 2010 Automatic, HAIMER has for every need the suitable balancing machine.

Getting machine investment ‘right from the start’ is the key to reducing payback times

Despite the significant investment that a new machine represents, the fact that around 70% of machines are purchased un-tooled means that many manufacturers are still missing opportunities to reduce payback times and improve the return-on-investment (ROI) from their capital outlay.

Achieving the best possible ROI requires recognition that a machine purchase is only one element of a successful installation. Carefully planned machine investment strategies should encompass both capital machine purchase and a detailed assessment of the best methods and tools for the chosen production task. Time taken as early as possible in the planning stage can pay huge dividends in terms of reducing the ‘total cost of acquisition in terms of a smooth installation, shorter run-off period, minimum business disruption, reduced cost-per-component and the earliest possible payback.

Indeed, in some cases early identification of the best approach and tooling solutions may even present the opportunity to further improve ROI through the purchase of less expensive machines than originally planned.

It is with these factors in mind that Sandvik Coromant developed and continues to evolve its ‘Machine Investment’ (MI) support services. Helping manufacturers to get their investment strategy ‘right from the start’, MI considers how OEMs, machine tool agents and tool manufacturers can all work together to deliver the best possible outcome for a given environment.

Close liaison
MI is a proven step-by-step approach designed to save time, trouble and money. It defines, both in technical and commercial terms, the end user’s needs and the new opportunities that investment can bring. A Sandvik Coromant team is created to work closely with the customer and the machine manufacturer to ensure that these requirements are realistic and are achieved. All key specialist players are involved at the earliest possible stage, including software, clamping and coolant suppliers.

With pre-investment collaboration between the expert parties, results will inevitably be better because difficulties are foreseen and taken into account. The focus is on priorities such as production costs and output, with discussions typically involving capacity objectives, process definition, choice of machining method, component machining costs, cycle times, tooling requirements, programming, workholding, process flexibility, quality, unmanned operating possibilities, predictable tool life and toolholding/changing.

Full project support
MI support covers evaluation of parts, processes and applications, and assists with time studies, cost-per-component and turnkey projects. It will also create a bespoke tooling package that matches machining requirements, provide on-site application support and customise a training programme to build peak performance for operators. Every aspect of the production process can be defined using the Sandvik Coromant Tool Investment Analyzer (a time study tool package), along with drawings, ROI and cycle time/set-up time calculations and a host of other tools. Manufacturers also have access to a payback calculator (www.payback-calculator.com) that can help to determine exactly how long it will take to pay back the investment.

Liaison with third parties takes place at all project stages through to final verification of the machine running in full production. Based on typical MI cases, manufacturers can start making profit from day one, can increase productivity by 15% or more, and can reduce payback time by 12-15 months.

Up-front planning
From experience, Sandvik Coromant knows that if planning is not done correctly, the result will be extra costs for new tools and the loss of key people to other commitments. Also, the machine often becomes very busy, very quickly and it gets hard to find the time to address issues, which in turn leads to reactive ‘fire fighting’ rather than proactive planning.

By spending a little more time and effort in the beginning, those adopting sound MI practices will experience less surprises and frustrations, and come out ahead in the long run. This is about more than just equipping the machine – MI support relies on a unique combination of tools, tooling solutions, service and industry experience to help attain higher productivity, faster throughput, more rational tool management and reduced downtime. Sandvik Coromant MI specialists can turn talk into concrete financial data based on target production parameters. A specially developed interactive programme gives end users instant access to the direct and indirect benefits of smart machine tooling.

Capturing the benefits
For instance, at the heart of the smart tooling ethos is the Coromant Capto® toolholding system. Designed to rationalise the tool management process through the use of a single system for both turning and rotating tools, Coromant Capto provides high repeatability and maximum rigidity, facilitating the highest possible metal removal rates. No modifications are needed – standard tools can be used straight away. Tool changeover times are typically reduced from 10 minutes to just 60 seconds, which can mean a saving of circa €50,000 a year on a typical CNC lathe. Of course, Coromant Capto is just one innovation among approximately 2,000 new products introduced by Sandvik Coromant every year, all of which are designed to make customers more productive.

Without doubt, tooling has a big influence on ROI, as a few simple examples show. For instance, while milling is demonstrably better for roughing and semi-finishing operations than rival processes, even when the need for straightforward turning is required, turn-milling with an endmill or facemill may be a better solution with regard to metal removal rate. Similarly, drilling is usually most efficient using an indexable insert short-hole drill. However, when there is a variation in hole sizes along with limitations to tool magazine stations or spindle power for large diameters, the flexibility of an endmill producing holes by helical interpolation may well be the best way forward.

World of opportunity
Through MI support, machine shops quickly see a new world of opportunities based on providing the power to run a new machine to its full potential. After all, custom-matched cutting for specific operations can increase cutting data by an impressive 20%, which can mean a full 15% reduction in total component cost.

Of course, lower component costs are just one of many modern pressures facing the manufacturing fraternity. Others include global competition, reduced lead-times, high raw material prices and ever more complex designs and exotic materials. As a result – and regardless of the size of the company – those paying for a new machine should make sure it pays them back. MI from Sandvik Coromant offers a total package that is able to unleash the full potential of the investment, right from the start.

Start-up toolkits
Around 70 per cent of new machines are sold un-tooled by machine tool manufacturers, agents or distributors. With this in mind, it’s easy for machine shops to overlook the issue of tooling, a factor that can hamper the transition time from machine delivery to full production. To address this problem, Sandvik Coromant offers a range of start-up toolkits designed to get machines cutting metal and making a profit immediately.

In total, 66 different start-up toolkits are available for the most common turning centres, machining centres and sliding head lathes. Included in the kits is a selection of tools needed to commence machining on everyday workpiece metals such as cast iron, steel, aluminium and toolroom materials. A dedicated webpage at www.sandvik.coromant.com/startuptoolkits steers site visitors through the kit selection process.

Courtesy: Sandvik Coromant

Compared to conventional lathe chucks used for large clamping diameters, the weight with ROTA-S flex drops down to 60%. At an identical table load much heavier workpieces can be machined, and due to the low height enough space remains for the workpiece and the tools. On the other hand, for machining smaller workpieces the extended guideways can be easily disassembled, so that the workpiece accessibility has been considerably improved compared to a clamping application with conventional large chucks. A special lubrication system ensures for permanently high clamping forces of both variants. Dirt seals prevent chips and dust from entering the workpiece. The ROTA-S flex can be easily assembled on a machine table, and by using the optimized jaw quick-change system, retrofitting can be done within seconds. The chuck clamps small parts as reliably as large ones, and thereby ensures maximum operator’s safety. The clever clamping solution is available in the sizes 700, 1000, and 1200 for ROTA-S plus, and the manual chuck ROTA-S plus 2.0 is available in sizes 315, 400, and 500. Depending on the size, the chuck (without top jaws) weighs 170 kg, 360 kg, or 490 kg. The ROTA-S flex can be combined with numerous chuck jaws from the 1,200 types of the world’s largest standard chuck jaw program from SCHUNK.

The SCHUNK manual chuck ROTA-S flex weighs up to 60% less than conventional lathe chucks, and covers a particularly large clamping range.

SCHUNK ROTA-S flex allows clamping of different workpiece sizes. The versatile manual chuck can be modified in no time.

With the multi-tooth guided SCHUNK EGN and EZN mechatronic grippers, SCHUNK transfers the unique features of the original pneumatic SCHUNK PGN-plus and PZN-plus universal grippers to the world of mechatronic based gripping. The electrically driven and energy-efficient SCHUNK EGN and EZN 2-finger parallel or 3-finger centric grippers combine the range of options and robustness of their pneumatic model with the variability, intelligence, and sensitivity of mechatronic gripping modules. The most unique exterior feature is the SCHUNK patented, multi-tooth guidance, which minimizes wear and guide play, and ensures high stability and loading capacity of the guideways. Brushless servo motor is used as a drive, and its rotation is translated into a stroke movement through a spindle nut. A resolver, which is directly connected to the motor, continuously queries the position of the servo motor, and allows exact positioning of the gripper fingers. Control is carried out by a SCHUNK ECM controller, which is equipped with standard plug connector technology by Profibus or CAN bus. It allows simple commissioning and parametrization by a PC and rotary encoding switch. Finger position, gripping force, acceleration, and speed can be regulated and controlled during the ongoing handling process. Since the gripper fingers can be pre-positioned, short cycle times can be shortened or the impulse force during the gripping process can be reduced. Combined with the SCHUNK FMS force measuring system, sensitive parts can be gently handled.

A vast option program transforms the 24-V-DC modules into a multi-functional unit, which can be also used in demanding environments. This includes the direct attachable protection protection cover which guards against fluids and dust, compensation units for compensating angle errors, force-measuring jaws, and jaw quick-change systems. For tool-free wiring with the controller, pre-assembled drag or robot cable sets in various lengths up to 20 m are available. A DNC coating ensures optimal conductivity, and reliable protection of the electronic components. With standard threads for protective conductors, personal safety is ensured. Combined with the SCHUNK ECM controller, and the SCHUNK ECS safety module, the EGN and EZN transform to a certified safety gripping system according to DIN EN ISO 13849 without any conversion. Equipped with the functions SLS, SOS, and STO they meet performance level d and SIL 3, providing safe human-machine collaboration in confined spaces. The mechatronic SCHUNK EGN 2-finger parallel gripper is available in three sizes with gripping forces of 400 N, 720 N, and 1,000 N, and a maximum stroke of 8 mm, 10 mm, and 16 mm. The SCHUNK EZN 3-finger centric gripper is offered in two sizes with gripping forces of 500 N and 800 N, and a maximum stroke of 6 mm or 10 mm.

Mechatronic universal gripper: A vast program of accessorires transforms the SCHUNK EGN and EZN to multi-purpose units for different environments and fields of application.

SCHUNK KONTEC KSC 125 scores with high precision, and process reliability. A pre-clamped and scope-free center bearing (ball bearing) and a particularly adjusted slide ensure a repeat accuracy of +/- 0.01 mm, and allow precise machining of the first and second side of the clamping system. An integrated chip flow and a specially protected spindle ensure maximum process reliability. The centric vise is also suitable for automated machine loading: it can be used in every pallet storage system as an affordable solution. In order to minimize set-up times, it can be combined with the SCHUNK VERO-S quick-change pallet system. The all-rounder is available with a jaw width of 125 with two base body lengths of 160 or 300 mm, and a clamping force of 35 kN. The clamping width amounts up to 303 mm, depending on the system jaw and base body length.

The SCHUNK KONTEC KSC centric vise allows different set-ups. This all-rounder is available in unit size 125 now.