Reduced tool measurement times
Reduced tool measurement times
By inspecting multi-diameter or complex form tools with a state-of-the- art Walter Heli Toolcheck automatic, non-contact tool measuring machine from Korber Schleifring UK of Honiley near Kenilworth, cutting tool manufacturer PJ Tooling reports that it has reduced tool measurement times to a fraction of what they used to be.
Based in Warlock, PJ Tooling has carved a strong market niche in the manufacture of bespoke cutting tools. These include round shank milling, reaming and form tools as well as more traditional dovetail, flat form tools and special inserts for cam automatics and transfer machines – all made to specific customer requirements. These can be manufactured from solid or brazed insert carbide, HSS or indexable insert carbide. Typical batch sizes vary from one-offs to 50-off.
Serving industries such as aerospace, fluid power, pneumatics, automotive and instrumentation, the company employs 21 people.
Helping PJ Tooling meet its healthy order book are three Walter Helitronic Power CMC five-axis tool and cutter grinders, all purchased within the past seven years. However, with such enhanced manufacturing prowess, the company soon realised the inspection process could benefit from similar advancements in technology.
“For batches of step reamers and more complex forms such as fir-tree root cutters, inspection was very labour intensive, occupying projector set-ups for long periods with results that were totally reliant on consistent method and application between operators using the equipment. Tools that were taking between 15 and 20min to 100 per cent inspect between centres on a profile projector are now done in minutes,” explains managing director Mark Webb.
He says that Walter was the natural choice for an automatic, non-contact tool measuring machine simply because of compatibility with the existing five- axis capacity, familiarity with the operating software and the technical support provided on the Walter machines over previous years.
As well as inspecting finished tools, operatives also use the Heli Toolcheck to set-up and monitor the first tool being loaded to the Helitronic Powers, thus ensuring initial accuracy. It is planned that within the near future the Heli Toolcheck will be “linked” to the Helitronic Power machines to permit even greater process efficiency.
According to PJ Tooling, another benefit of the Heli Toolcheck is its ability to scan a sample tool sent in by a customer, extrapolate the data and generate a detail drawing from this. This is extremely useful as customers often do not have detailed tool drawings but may have cutters from subcontractors or their own toolrooms that merely need replicating.
“To emulate proven geometry, flute shapes and compound clearances on forms is almost impossible without the right equipment; however, the Heli Toolcheck means this is now a valuable extra service we can provide our customers” confirms Mark. “Overall the new machine has enhanced the effectiveness of our labour time and it is one of the contributing reasons why 2006 was one of the best trading years in our history” he concludes.
Details available from: Korber Schleifring UK. Tel: +44 (0)1926485047;E-mail: neil.whittingham@walter-machines.de;web site: www.walter-machines.com
