In the manufacturing industry today, machinery is being developed and designed to be more consistent with manufacturing processes based on the need to meet cycle time, complex part and good surface finish requirements.
Therefore, manufacturers are enhancing the capabilities of their machinery, such as by increasing spindle speed effectiveness to exceed over 10,000-40,000 rpms to meet production targets and increase profit. As such, it is necessary to use tool holder equipment that are of the same quality and effectiveness.
MEGA Tech proud to recommend the right tool clamping technology for every kind of machining operation during machining, specific demands for tool holding are laid down by each industry and application. The range varies from high-speed cutting to heavy roughing.
With the HAIMER tool holders, HAIMER offers the right solution and tool clamping technology for all specific requirements.
When discussing effective tool holders, it is necessary to consider 3 components as follows:
- Rigidity and clamping force.
- Accuracy and precision.
- Balance and safety.
Currently, parts manufacturers in different industries are primarily emphasizing the strength and precision of tool holders. In practice, most industrial factories only check static run-out values and continue their use. In reality, however, specifying the balance value of tool holders is also vital. When excessive speed is used, imbalance (unbalance) will occur and cause the following impacts:
1. The machine spindle will vibrate and corrode prematurely.
2. The lifespan of cutting tools will become shorter, or breakage or damage might occur.
3. The output workpieces will be of poor quality, causing production time to increase and for more work time to be wasted.
Causes of Imbalance in Tool Holders
1. Asymmetry of cutting tools such as in the case of special tools.
2. Faults in the shape design of tool holders or use of inappropriate materials.
3. Additional equipment attachments are placed at the tool holder such as when adding attachments to increase length, 1pull stud, screws, etc.
Working Principle for Balancing Tool Holders
- Calculation for balancing of tool holders’ permissible residual unbalance value is done to use the value to perform balancing by increasing or reducing weight at the tool holder, followed by testing at the balancing machine.
- Balancing Criteria for Each Production Process with ISO1940
G 4000 – Crank shaft/drive of diesel engine with an uneven number of cylinders.
G 100 – Engine system (benzene or diesel) for cars, trucks and locomotives
G 40 – Vehicle wheels, wheel sets and drive shafts.
G 16 – Specific engine components for cars, trucks and locomotives.
G 6.3 – General tools, machinery and machine parts.
G 2.5 – Spinning of cutting tools for CNC machines.
G 1 – Grinders.
G .4 – Disks and fine grinding work.
Most parts manufacturing and mold work today prefer to use Grade G2.5 along with machines for balancing tool holders to offer better standardization and greater convenience as shown in Figure 2.
3. After obtaining the permissible unbalance value of 1.67 gmm, there are 4 main methods for balancing tool holders as follows:
1. Weight reduction by drilling.
2. Weight reduction by milling.
3. Weight increase by fastening screws.
4. Weight increase by adding rings.
All of these methods require changes to every parameter in the software of the balancing machine such as drill size, drill depth and drill bit angle in order to correctly calculate mass and test balance.
4. Type of work required for effective implementation of balancing:
1. Work with long handles, low speeds and large sizes.
2. Work with long handles and high speeds for finishing details.
3. For small cutting tools.
4. For special cutting tools (special tools and from tools).
5. Balancing has several benefits as follows:
1. It extends the lifespan of machine spindles.
2. It makes it possible to increase speed and feed rate.
3. It reduces cycle time.
4. It increases the lifespan and effectiveness of cutting tools.
5. It improves surface quality.
6. Operate the machine with full efficiency
From the information stated above, balancing clearly is highly essential to modern manufacturing that requires control over the time, shape and quality of workpiece surfaces, and it is necessary to learn their proper principles and application in order to achieve maximum work effectiveness.
Article by: Haimer & MEGA Tech