Article by: Haimer Asia Pacific Ltd.
The spindle speed of modern machine tools has increased on a continuous basis in the last few years in order to achieve higher cutting volumes and machine in a profitable manner. The increases have also raised the demands for the tools and holders used, because the higher spindle speeds make the effects of imbalance increasingly more noticeable. The consequences are vibrations, bad surface finish and shorter tool life.
Only the high-precision balancing of tools and tool holders can make the complete capacity of the machines tool with regards to speed, cutting volume and produced surface finish accessible. Because balancing provides for fewer vibrations. It reduces wear of the spindle and tool, reduces the downtimes and increases process security.
With the Tool Dynamic balancing machine series, HAIMER offers a comprehensive solution for the balancing of tool holders, grinding wheels and big rotors with diameters up to 800 mm. Starting from the table and complementary machine TD 1002 to the automatic balancing machine TD 2010 Automatic, HAIMER has for every need the suitable balancing machine.
TOP 10 REASONS TO USE HAIMER TOOL DYNAMIC
HAIMER Tool Dynamic can give you the edge that will allow you to sustain a long-term competitive advantage for your company.
1. Longer Tool Life: On average, balanced tools (solid round tools and inserts) last 20% longer when the entire tooling assembly is balanced. Depending on the amount of unbalance, the tool life increase can be much greater.
2. Faster Speeds: Poor sound from vibration is often the reason faster speeds are not realized. Balanced assembly’s permit 10~15% faster spindle speeds without degradation of sound or tool life.
3. Repeatable Tool Performance: The elimination of vibration dramatically reduces problems like chatter and tool chipping, thereby stabilizing tool performance and making lights out machining possible.
4. Longer Spindle Life: Unbalance in a tool assembly creates excessive centrifugal forces that can damage spindle bearings. Such damage reduces spindle life and can lead to costly unplanned downtime.
5. Better Surface Finishes: Unbalance creates excessive vibration that can be translated to the finished part in the form of chatter and poorer finishes. To achieve the best finish, balance the full assembly.
6. Improved Accuracy: At higher speeds, unbalance can actually induce runout during rotation where none was measured statically. Without balance, the solution is slower speeds and less productivity.
7. Fewer Tool Changes: When tool life increases 20% to 100%, tool changeover time is reduced.
8. Accurate Process: A solid concrete base construction, centrifugal force sensors for measuring, patented spindle that clamps the tools identical to the machine tool, and a simple/reliable machine calibration process.
9. Ease of Use: Simple software and clear compensation options (removing or displacing weight) make the balancing process fast and simple for all users.
10. Industry 4.0 Success: Industry 4.0 is all about using gathered data to automate changes on the fly that optimize the machining process. Without balance, the optimal machining logic will ultimately require a reduction of speeds until the problem is resolved, thereby reducing productivity.