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hp tooling 2020 #1

  • Text
  • High precision
  • Harnischcom
  • Tooling
  • Carbide
  • Milling
  • Additive
  • Processes
  • Solutions
  • Grindtec
  • Materials
  • Manufacturing
  • Machining
  • Grinding
The journal of hp tooling is an english, global publication on all aspects of high precision tools, accessories and their applications.

materials & tools A wide

materials & tools A wide product range Dressing tools and digital solutions KAPP NILES, as a manufacturer of gear and profile grinding machines, offers highly developed technologies with various tool concepts adapted to the respective task. The product range in the tool sector includes dressing tools for dressing vitri fied bonded grinding tools and non-dressable grinding tools with CBN- and diamond coating. Dressing tools can be used for the following processes: KAPP NILES offers dressing rolls in galvanic positive and nega tive versions for the generating grinding. These are used for flexible, workpiece-bonded or topological dressing of vitrified bonded corundum grinding worms. Diamond profile rolls with or without head dressing device For the profile grinding process KAPP NILES offers diamond form rolls in sintered design. In addition to the economical version with natural diamond, the durable version with set CVD diamond plates is also used. The diamond form rolls can be reground several times and are characterised by a long tool life. Diamond dressing gears are available for gear honing. These bring the correct tooth geometry quickly and accurately into the corresponding honing ring and guarantee the quality desired at the component. In addition to the dressing tools, CBN and diamond grinding tools have been part of the product range for over 40 years. KAPP NILES manufactures non-dressable, electroplated single-layer CBN and diamond tools for finishing Multi-groove diamond full profile rolls of gears and profiles. The tools are characterised by long tool life, accuracy and regrindable bodies and are among the top products worldwide. They are used when the highest demands are placed on quality, performance and economy. The CBN coating can be renewed more than 50 times, thus contributing to the conservation of resources. On request, tools can be equipped with RFID chips, which enables integration into a tool data management system such as KN assist. Provision of set-up and tool data via RFID technology As well as constant optimisation of machining times, the reduction of set-up and non-productive periods also always play an important role in a flexible production environment. In addition to machine concepts with optimised set-up times, KAPP NILES offers intelligent components. KN extender For set-up processes the technological data of components and tools is made available to the controller by using RFID technology, which enable an identification without any contact between antennas and RFID chips in the machine. In order to correctly identify the components, the operator is guided through intuitive step by step menu navigation, thus reducing the possibility for faulty inputs. 22 no. 1, 2020, March

materials & tools The key advantages of RFID technology are that it prevents incorrect component installation, it automatically reads and transfers component data, it prevents incorrect entries, which results in shortening of the overall input time, as well as preventing downtimes due to incorrect component installation. Tool data management and digital workbench KAPP NILES has developed its own platform called KN assist which contains a tool data management system among other features. Exchangeable, intelligent components with all geometric and process-related data can be managed and clearly displayed outside of the machine within the tool data management system. All tool data is therefore stored centrally in a single location and is retrieved from there. KN assist also provides supportive functions for the setup process. This means that essential assembly and disassembly operations for multi-part-tooling can be carried out by the operator in advance. This results in shorter preparation times for the subsequent grinding project. Furthermore, information is provided to the intelligent components which, together with the RFID technology, optimises the set-up process. CBN grinding worms KN assist, together with the KN extender (computer assembly for workshops, which equips workbenches with digital functionalities), manages the customer’s operation, labelling and management of all components outside of the machine. Besides the identification of components by RFID, optical component recognition is also possible. The system is designed to also manage components without RFID or a QR code/DMC identification. GrindTec 2020, hall 3, booth 3001 information: www.kapp-niles.com With additive manufacturing to more productivity If the weight of PCD tools is reduced, as a rule significantly higher cutting data can be used. Along with design freedom, the possibility of weight optimisation is one of the crucial advantages offered by 3D printing. Due to the specially developed structures inside the tool, which cannot be manufactured conventionally, the weight can be reduced significantly. New bell tool with low weight, long tool life and best cutting data An example of how MAPAL uses this advantage of 3D printing in practice is the new bell tools with brazed PCD inserts. Bell tools are used for the external machining of hose connections, among other applications. These connections, for example on turbochargers, must satisfy com - plex contour requirements. Manufacturing must be cor re - spondingly precise. Existing processes are also subject to continuous improvement so that manufacturing is costeffective and reliable in series production. MAPAL has therefore optimised the existing, conventionally manufactured bell tool. Using the selective laser melting process, the inside of the tool has been modified - instead of solid material there is now a specially designed honeycomb structure. As a consequence, the tool is 30 % lighter and the tool life is increased by approx. 40 % due to the damping effect. It is therefore possible to machine faster; the machining quality remains at the same high level. MAPAL is presenting a new bell tool with low weight, long tool life and best cutting data The honeycomb structure inside the tool can be realised thanks to additive manufacturing In total the machining time has been reduced by 50 %. Furthermore, the cooling channel design has also been optimised. The new bell tool is of hybrid design. Using selective laser melting, the new tool geometry is printed on a highly precise tool body with a HSK-63 connection. The additively manufactured part is subsequently machined conventionally. Then the PCD inserts are brazed in place and cut to shape using a laser. information: www.mapal.com no. 1, 2020, March 23

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