Having the best workholding system is just as key as having the best tools! Jim Carr and Jason Zenger know the importance of keeping up with the game as manufacturing leaders. Growing up working the shop floor, guest speaker, Alvin Goellner, is the Business Development Leader of North America at Amrok Workholding. In this episode of MakingChips, he shares the latest trends in workholding systems and why you need to implement them for optimal efficiency and quality performance in your manufacturing business.
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The workholding process is all about how rigid you can make your setup - creating a solid foundation that will hold your material for optimal performance. Without a steady and rigid workholding system, your process will be riddled with chatter, less tolerance, and damaging vibration. While it is less of an investment to just keep upgrading your cutting and milling tools, it is still key to keep your workholding system up-to-date. The way your tool and materials are being held is vital to the outcome of the end-product. The workholding system must be rigid, robust, and competent at holding your material and efficient at resizing and holding different projects. Alvin explains that you can own the best cutting tools in the world, but without a competent workholding system, your product will not be the best on the market.
Alvin explains that over the years, he visited different manufacturing shops and studied the varying methods and machining solutions to the workholding process. He then went back to his own company - Amrok - and built the workholding systems that solved the problems he had found in his travels. The result was the 2-inch grid system, which has become an industry standard. While there used to be odd-sized grid systems with varying sized plates, Alvin found that most products can fit into the 2-inch grid plate. An incredibly efficient system, the hardened bushing, lock-tightened, slip fitted grid retains center distance tolerance because of its minimal clearance. 2-inch sub-plates are the common sub-plate, which allows for efficient adjustment of the numbers for varying projects. To learn more about the efficient and customizable applications of the 2-inch grid system, listen to the entire episode!
When projects become large a TRIAG modular vise system is the most efficient. With modular clamps that can fit almost any shape, the system boasts serrated base rails that mount on a standard, 2-inch grid and locate with dowel screws. This system enables the spindle to keep moving, thereby creating a more efficient process. The modular components can be loosened in seconds, and you don’t have to spend time indicating because of the dowel screw location. Listen to the full episode for more information on how the TRIAG modular vise system works and why it improves overall performance.
With so many options available on the current market, Alvin supplies three workholding systems that will instantly improve efficiency in the shop. First, optimize your foundation. Implementing a 2-inch grid system enables you to work with a lot of different system types, tools, and materials. Second, hydraulic, dedicated fixtures that automatically fit the part with a flip of the switch will save you time and energy. Third, introducing a low mix, high volume TRIAG system to your shop floor will prove invaluable. Center-less vises that mount on a rail are lighter and more efficient. Alvin explains that if you need to move from one sized part to another, the application is easy and fast, allowing you to produce more chips and earn more money.
The team at MakingChips knows how important it is for the Metalworking Nation to optimize efficiency and productivity. Having the right tools for the job is at the foundation of a leading manufacturing business. Guest speaker, Tom Senger, gives the run-down on the latest and greatest tools to utilize on the shop floor. Tom is the manager of the Vending, Integration, and Productivity (VIP) program at Zenger’s. Helping customers integrate new operations, realize new levels of productivity, and bring in greater revenue is his specialty. Manufacturing runs in his blood, and he understands what tools to use to get the job done.
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The tools you use can make or break the impact of your manufacturing business. Hosts Jim Carr and Jason Zenger know you need to be making chips. Being on the cutting edge of cutting tools is imperative to saving money. Tom gives several suggestions for what tools to use for what job and explains that several improvements are being made throughout the manufacturing tool spectrum. Consistency is one of them.
Small diameter, multifunctioning drilling tools have seen huge improvements in all-around consistency. It’s no longer the case that you need specialized tools for each part of the job. Not only do multi-functional drilling tools save you a ton of space in your collection storage, but they also get the job done with consistent quality and efficiency. Invest in one tool that can serve multiple functions.
Coolant through is being implemented across the tool board. This quality helps reduce wear and tear on your drill bits, improves lubricity, and saves you time and money on maintenance, especially with solid carbide spindles and bits. It also improves consistency. Tom shares about some of the utilization of coolant through on the shop floor.
Flat-bottom drills are excellent because they don’t have to be followed up by an end mill. They have replaceable tips and a myriad of products that you can place on the high-speed, coolant through, steel body. The flexibility of this tool enables you to save on carbide costs, and it is incredibly precise with diameters down to a millimeter and a half.
Coolant through is also improving the performance of turning and cutting tools, cut-off and groove tools, and milling tools. Fast and high-speed milling tools are seeing smaller diameters, indexable end mills, and dynamic milling processes with the help of CAD CAM software. Different high feed cutters are being utilized to create more corners, even up to 6, 12, and 16 corners with repeatable functions. Turning and cutting tools are being improved with higher feeds and a greater depth of cut. The coolant through allows for less load on the spindle. It’s much the same story with cut-off and groove tools. Tom explains that the coolant through allows for a cooler cutting zone, cutting the cutting time by almost half.
Be sure to listen to the full episode for all the details on how and why these improved tools need to become your next investment!
As Tom points out, coating is king. Products and tools are no longer simply coated in a layer of tin. Now, there are several layers of different materials being applied for improved performance. Post-treatment coating is especially valuable, coming over the top insert and applying a clear, shining, polished surface. The polish protects and preserves carbide function and strength, improving the shelf-life of the tool up to 25%.
Tolerancing is also an obvious ingredient of a great tool. Improved molding technology paired with coolant through enables tools such as the solid carbide spindle coolant drill to function with consistent quality up to a thousand repeatability.
Carbide is expensive, and the more you can save on the life of your carbide tools and bits, the better. Solid carbide end mills have been a staple, but Tom explains that many are moving away from solid carbide and choosing steel shanks instead. Different types of end mill heads can be applied to the shank, and many of them have been made smaller for improved performance. Investing in coolant through applications and the right coating can have a huge, positive impact on the shelf-life of your carbide collection, allowing you to work harder, longer, and better without the constant maintenance costs.
For more insight into the latest cutting tool trends, be sure to listen to the entire episode!