Tool measuring completes automatic loop for tooling solutions

Citation

(2009), "Tool measuring completes automatic loop for tooling solutions", Aircraft Engineering and Aerospace Technology, Vol. 81 No. 5. https://doi.org/10.1108/aeat.2009.12781eab.005

Tool measuring completes automatic loop for tooling solutions

Article Type: Aerospace technology From: Aircraft Engineering and Aerospace Technology: An International Journal, Volume 81, Issue 5

By networking a Walter Helicheck Basic automatic tool measuring machine with 11 CNC tool grinders, tooling manufacturer Quickgrind claims to have effectively created the final link in an automated tool design, manufacturing and inspection chain that eliminates the potential for human error at every stage of the process.

Quickgrind's investment in the Walter machine is, says Director Ross Howell: “A natural progression for our integrated tooling manufacturing process that enables the production of ‘any tool to any design’.”

“It will not only enable us to maintain consistent high-quality production, but will also allow us to provide customers with measurement certification to demonstrate that each tool is 100 per cent accurate.”

“In addition the facility will, by definition, open up new markets where confirmation of form is a prerequisite of supply.”

With around 80 per cent of output already being exported world-wide to users in all industry sectors in countries such as Canada, China, Mexico, South Africa and Russia – as well as throughout Europe – Quickgrind's “guaranteed total tooling solutions” capability will, adds Ross Howell, undoubtedly enhance the company's continuing advance in global tooling sales success.

Being used to automatically set-up grinding wheels at the start of the manufacturing process, as well as inspecting ground tool profiles and cutter geometries via integrated links with the company's 11 CNC tool grinders, the Walter Helicheck completes an automated end-to-end manufacturing process that begins with sophisticated 3D design and ends with, if required, printed certificates of conformity for every tool produced (Figures 6 and 7).

Figure 6 Quickgrind specialises in the development and production of carbide tooling – including a range of “special standards” based on 120 different taper designs

Figure 7 The Walter Helicheck basic tool measuring machine is networked with 11 CNC tool grinders and has effectively created the final link in Quickgrind's automated tool manufacturing chain

Supplied by Körber Schleifring UK of Honiley near Kenilworth, the Walter Helicheck Basic offers 3 C Direct View camera technology with cameras for back, front and top light illumination of tools measuring up to 320×400 mm (diameter×long). The back light provides magnification of 50×, front and top of 100×; and combined with the solid granite base plate for temperature resistance and high stability, the result is a repeatability of 1.5 μm and an absolute accuracy of ±2.2 μm at a measuring length of 10 mm (VDI/VDE 2617: E1=2.2 μm+L/300).

According to R&D Manager, Martyn Cross, there were three main reasons why the Helicheck was considered vital to Quickgrind's twenty-first century manufacturing ethos:

1. 1.

   Its use at the start of the process for automatic wheel set-up away from the grinding machine not only eliminates the potential for human error but also means the tool grinders constantly operate on statutory manufacturing protocols for each tool being produced.

2. 2.

   Helicheck tool measurement provides total confidence that production is right – every time.

3. 3.

   The machine enables Quickgrind to “analyse tooling geometries” and identify potential performance limitations as well as use the measurement reports to validate geometry enhancements to suit customers' particular manufacturing requirements. This further enhances cutting tool performance, tool life and, ultimately, customer profitability.

“The measuring protocol that the Helicheck adheres to is the direct result of an integrated manufacturing system that begins with on-screen 3-D tool design,” says Martyn Cross.

“The resulting 3-D tool models are then used to create the appropriate manufacturing drawings and measuring routines, ensuring the creation of specific master criteria dedicated to each design.”

All data are held on the company's server system, which is accessed by the shopfloor – starting with the grinding wheel set-up routines.

With 24 employees, Quickgrind specialises in the development and production of a wide range of carbide tooling which includes an extensive range of “special standards” based around 120 or so different taper designs, which can feature varying geometries and a wide range of lengths, as well as one-off “specials” and, for example, the Bulldog range of solid carbide milling cutters.

The investment in the Walter Helicheck is the latest evidence of how the company is, says Ross Howell, “forever moving forward” – a philosophy that is underpinned by a high-tooling technology skills base at the Tewkesbury site and a shopfloor populated by high-specification CNC tool grinders.

Another invaluable asset that enables the company to work closely with clients and provide fast-response tooling solutions is Quickgrind's Quick Lab service.

Based around close discussion with customers (via e-mail, skype and face-to-face), Quick Lab is designed to effectively and efficiently develop tooling solutions based on improved tool life, quality and performance (aka reduced cycle times).

“The Walter Helicheck is the final piece of the puzzle,” concludes Ross Howell, “which means we now have a formidable armoury in the battle to constantly win orders on a global basis.”

Details available from: Körber Schleifring, UK, Tel.: +44 (0)1926 485047; E-mail: neil.whittingham@walter-machines.de; web site: www.walter-machines.com