Wringing Extra Life From Inserts - R and J Tool Inc., machine part reconditioning

Throwing away worn carbide inserts? Then you may be interested in a service that not only resharpens those inserts for added use, but also guarantees that the reclaimed inserts will perform at least as well as brand new ones.

"Most companies do throw away their worn inserts," explains Bob Laflamme, president of R & J Tool Inc. (Laconia, New Hampshire). "That's a waste, because the insert's usefulness has not been exhausted. We can resharpen it as many as three or four times before it is no longer usable."

Insert resharpening is hardly a new idea, but the process has had some definite drawbacks. "The traditional insert-resharpening process has been a downsizing process that retains the original shape of the insert but grinds it to the next smaller standard size," Mr. Laflamme continues. "The user must then go out of the way to accommodate the smaller size, resorting to such things as shimming the insert, going to a different tool body, and so on."

R & J Tool has developed an insert-resharpening process that overcomes most of the shortcomings of the traditional process. The firm's process sharpens the worn insert without changing its inscribed circle (IC) size or clamping height. As a result, the resharpened insert can be installed in the tool as if it were a brand new insert; no adjustments are required because the overall size of the insert is unchanged.

Worn inserts are ground using one or more of four grinding patterns that can be used for virtually any carbide insert. Grinding of the worn insert is confined to the cutting edges. "For example, on a square milling insert, we generally just grind the top of the insert on its outer edge; we don't grind the full thickness of the insert, so the IC size of the insert remains unchanged," explains R & J Tool sales manager Michael King. "And when grinding the top of the insert, we avoid the area where the insert is clamped, so that the reground insert fits the holder just like a new insert."

Better Than New

However, grinding is only a part of R & J Tool's insert-reconditioning process. The process begins with analyzing the user's particular application to modify cutting edge geometry of the insert for optimum cutting performance, grinding and honing the insert, and then applying a coating (which can be one of several proprietary coatings).

"The worn inserts are the starting point for our analysis, but we also ask for enough information to enable us to engineer a cutting edge for the customer's particular application," Mr. King elaborates. "We guarantee that our reconditioned inserts will provide 100 percent of the performance of new inserts, however they typically deliver 125 to 150 percent, and in some cases as much as 300 percent of new insert performance.

"Our analysis also includes the cost to recondition the insert so that the customer can calculate the savings compared to new-insert costs," Mr. King continues. "New carbide inserts range in price from $2 to $32. We can recondition inserts for about half of the cost of new, so as the price of the insert increases, sharpening becomes an increasingly attractive alternative."

R & J Tool's insert-recycling program is geared primarily to users of inserts in large quantities. "Our customers typically spend many thousands of dollars annually for new inserts, and we can offer them significant cost savings," Mr. Laflamme adds. "Our process also addresses environmental concerns. We can reclaim inserts for only 5 to 10 percent of the energy required to produce them originally. And our automotive and aircraft/aerospace customers are pleased that we can offer them a recycling process that reduces their waste stream, addressing ISO 14,000 concerns, at the same time that it reduces production costs."

Smaller firms can also take advantage of the insert-recycling program, however. Mr. King cites as an example a small shop that uses basically one insert type for machining aluminum. The shop placed an order with R & J Tool to recondition 250 inserts, which represented a year's supply. The shop paid $6 per insert for the reconditioning as opposed to $12 apiece for new inserts. The savings more than justified stocking a year's supply of reconditioned inserts.

Making a flexible machine tool more flexible: cutting tools that can perform more than one machining operation can help realize more of a multitasking

Anyone with the resources and the inclination can buy a machine tool. But not everyone can wring out the same amount of production from the same machine. Multitasking machines loaded with multiple turrets and/or spindles offer a great deal of production potential, as they can often completely machine a part on its own. Granted, these machines are more costly than their straightforward lathe and milling machine brethren. However, it's clear that shops battling just-in-time delivery schedules and shrinking batch sizes recognize the moneymaking potential of such machines, as their sales increase every year. It's the classic case of biting the bullet and choosing equipment that initially is more expensive, but offers greater payback down the road.

But the multitasking machine can't do it alone. The choices made in combining various machining elements and strategies into an efficient process ultimately separate the great shops from the average Joes. CAM programming continues to be a challenge for multitasking machines, which isn't surprising considering it involves simultaneous machining operations and orchestrated movement of a number of machine components.

Tooling can also play a make-or-break role. It's logical to think that a multitasking machine designed with flexibility in mind would use tooling that was also flexible. Such tooling would provide the capability to perform a variety of different machining operations with just one tool. A universal spindle interface that can accommodate both turning and milling operations can also augment process versatility. There are a few reasons for this.

First, space can be saved--turret space, to be more specific. The multiple turrets and spindles located within a multitasking machine not only limit space within the machining zone, but also place limits on tool magazine capacity. A single tool that offers five different cutting operations, for example, could free up four tool pockets. Those extra pockets could then be used to hold different tools for parts that require many machining operations or sister tooling to allow extended, unattended operation.

Second, cycle times can be quicker through the elimination of non-value-adding tool change time. A multitasking tool might just require spindle indexing to bring a different turning insert into position, for example.

Third, a universal, modular spindle interface that is effective for milling, turning and drilling operations allows for one common tooling platform for the shop's entire operation. This concept of standardization falls in line with the strategies of lean manufacturing.

During a recent visit to its international headquarters in Sandviken, Sweden, Sandvik Coromant (Fair Lawn, New Jersey) demonstrated the value that a multitasking tool platform, such as its Coroplex line, can provide for multitasking machines. The visit included a tour through the production facility for its mining and construction division, which heeds the advice of its sister tooling company by using robot-tended cells that combine multitasking machines with multitasking tools to produce various mining drill bit components (see "Multitasking Application").

Tooling Versatility

There are a few different approaches in terms of multitasking tool design. One is the combination of turning and milling inserts on a single tool body. That one tool could perform shoulder milling, turn-milling or circular interpolation, for example, as well as face and longitudinal turning, profiling or internal turning. To combine turning and milling capability on one tool requires a design in which the turning inserts don't contact the workpiece while the tool is milling. To avoid this, the milling inserts are located just ahead of the turning inserts axially and radially so that the turning inserts are not in cut when the tool is milling.

Another technique combines two turning inserts located on opposite sides of a tool body. The tool can perform a rough turning operation, then be indexed 180 degrees in the spindle to allow finish turning.

Yet another concept uses a modular mini turret unit that can combine four different cutting modules to allow four turning operations on one tool. This would enable a single tool to rough turn, finish turn, cut a groove and turn a thread, for example. The combination of cutting modules is user-selectable, and it would depend on the type of part and the required machining operations.

Maintaining tool center line accuracy is especially important for multitasking machines to make sure that the tool is precisely positioned to perform a turning operation. This is where it is helpful to have a modular, universal spindle/tool interface. Such an interface is effective for multitasking machines, as their spindle(s) could be called on to mill or lock into position for a turning operation.

Software Links Presetters To Machine Controls

Designed to maximize efficiency, the new Gamma Tool software passes presetter information to machine tool controls. This Windows-based software eliminates the manual input of data and does away with data entry errors, the company says. Integration into Lyndex/Elbo Controlli presetters is said to be easy.

Using a serial connection (cable included with Gamma software) between a PC and a presetter, an operator can acquire tool measurements and then organize them into tooling tables. Tables can then be translated into the desired CNC language (G-codes). After creating and measuring the tooling table, offset data can be directly sent to the CNC. Data storage is limitless.

An easy and powerful programming module (GUPP) allows for editing and the creation of post processor templates by the operator/programmer. GUPP makes customization of any postprocessor possible for adaptation into a CNC. More than 50 post-processor templates, all pre-tested, are included.

Status Quo Rules - predictions for the coming year in the machine tool industry and metalworking business

In January it's customary to look into our respective crystal balls and try to divine what fortune or misfortune is likely to befall us. One interesting aspect of this exercise is that in spite of our confidence that some of our guesses will be right or close to right--and indeed some will--experience tells us the completely unanticipated blind-sides are lurking as well. The following are some of the things that I think will happen as we cruise through 2001, officially the first year of the new millennium.

Call me a wide-eyed dreamer, but I do think we will inaugurate a new president of the United States on January 20. Obviously, half of us will be happy with the new guy, and half of us won't be. But, I see we the people coming together, as is our custom, to support our new leader--at least until he screws up, which I also predict will happen.

I think that some consolidation of the machine tool industry will continue, as too many builders chase too few customers. Moreover the increasing demands of globalization require companies to join together to create a competitive level of critical mass (read size) to play the global chess game.

On the other side of the coin, I think some builders are going to look hard at some of their product offerings and lop off non-viable machines in an effort to define and focus more resources on their core competencies.

As far as processing technology, I see a continuation of the trend of more operations performed on a single machine tool platform. Better programming tools and increased performance of the metalcutting modules will represent continued refinement of this multiple process class of machine tool.

I see the market drivers for these developments coming from shops looking to increase the performance of each spindle in the shop. The shortage of qualified workers will continue to plague the nation's shop floors in 2001, making the need for process automation, reduced setup times and reduced workpiece handling even more acute.

Everyone is interested in what business levels will be in the upcoming year. Most guesses seem to indicate a flat to moderately up year for metalworking overall. One way to keep tabs on metalworking's health is to monitor the plant capacity utilization index. It reflects a percentage of the theoretical metalworking capacity of the nation. If the number is 80 percent or above, it indicates growth. It's a helpful index. Now, let's sit back and see what happens.

Okuma named official machine tool of NHRA

Okuma America, a world-class leader in machine-tool technology and manufacturing, has been named the official machine tool of NHRA.

The official marketing partnership is the first for Okuma in NHRA POWERade Drag Racing and increases Okuma's presence in NHRA. The company also is the primary sponsor of Bill Miller's Top Fuel team and an active sponsor of a NASCAR race team.

"We believe the lessons learned from the application of advanced machining technology to the production of highendurance, high-reliability racing engines give Okuma machine tools a competitive edge in the market," said Okuma President Larry Schwartz. "That's why we're very excited about our partnership with NHRA."

As part of the exclusive multiyear agreement, NHRA is providing Okuma with multiple exposure opportunities through a variety of marketing platforms, including NHRA-produced publications and track signage at each NHRA POWERade Drag Racing Series event. In addition, Okuma will have the opportunity to use the NHRA mark in its advertising and promotional campaigns.

"We are pleased to welcome Okuma America as a valued official sponsor of NHRA," said NHRA Vice President-Sales & Business Development John Covarrubias. "We are looking forward to providing Okuma with optimum marketing value by helping them identify more potential customers through their association with NHRA."

Monitoring Service Platform suits machine tool industry

Internet-based ePS Network Services supports maintenance processes while simultaneously forming platform for cross-company service and support between OEMs and machine operators. Service provides detailed information for localization of machine faults and can send service personnel notifications by email or text message if fault occurs. Direct connection to Internet with web browser allows data to be analyzed via servers as well as remote machine control.

CHICAGO, August 11, 2005 - ePS Network Services from Siemens is offering the machine tool market powerful IT infrastructures and service packages that build on each other to provide simpler, safer and more efficient methods for performing service and maintenance.

ePS Network Services is an Internet-based service from Siemens that supports maintenance processes while simultaneously forming a platform for cross-company service and support between OEMs and machine operators.

Any machine tool equipped with Siemens SINUMERIK 810D, 840D or 840Di CNCs, along with the Siemens PCU 50 industrial PC, Internet access and a standard web browser, can operate within this system.

By using ePS Network Services, customers will have detailed information much faster for the localization of machine faults, thus allowing for a faster analysis without needing direct access to the machine or influencing the production process. Service personnel can be notified by e-mail or text message, should a fault occur. A direct connection to the Internet with a web browser will allow data to be analyzed via the servers and even allow remote machine control.

Unplanned downtimes and maintenance costs are reduced when ePS is used for preventative maintenance. Standardized testing procedures can help machine operators and maintenance technicians to quickly determine a machine's condition. Continuous evaluation of the machine tool also makes it possible to identify trends and plan measures in advance.

Data security is guaranteed by restricting data to the servers that ePS provides and, in turn, are protected by firewall and virus scanners. Communication is only established from the machine and/or the PC server to the ePS servers and is protected from unauthorized access by 128-bit SSL encoding.