A well-known problem in Machining is Tool Breakage. However, a lesser known but one that causes more rework, rejection, scrap and affecting bottom-line is wrong tool used.
Does only using CNC Machining guarantee Precision of components machined? While, CNC machines come with a certain level of precision, accuracy and automation in manufacturing, achieving an optimal level of precision requires another very important but largely ignored aspect to be done well and that is TCM or Tool condition monitoring.
A well-known problem that is common for all Machining is Tool Breakage. However, a lesser known but one that causes more rework, rejection, scrap and affecting bottom-line is wrong tool used while machining. If we shift our focus to IMPORTANCE OF ACCURATE TOOL OFFSETS IN DIE & MOULD, we will see the exponential impact of solving these two problems.
What happens when wrong tool loaded goes undetected?
It is so common to have instances of wrong tool loaded! For example, instead of a 6 mm End Mill, an 8 mm one is used in the CNC Machine. The difference is barely recognizable to the naked eye especially in the last hours of shift, when fatigue has set in.This error can lead to Tool damage, Job rejection and rework!
How do you effectively do wrong tool detection?
What if you had an Automatic Tool setter that has the ability to detect wrong tool loaded and stop the program?
The operation stops till the operator takes corrective action & replaces wrong tool with the right tool and then resumes the operation.
What happens when Tool Breakage goes undetected?
Cases of Improper cutting tool, or where the tool tip is damaged and not sharp, will cause the poor surface finish on the part, and even leave cutter mark on the material, which speeds up the tool wear at the same time. In the metal cutting process, the tool condition has to be administered either by operators or by online condition monitoring systems to prevent damage to both machine tools and workpiece.
How do you detect Tool breakage/damage effectively?
Using a good 3D Tool Setter/height master either manual or automatic with a direct CNC interface can help early detection of Tool wear/tool breakage.
A good Tool condition monitoring system helps you know when to:
- Replace the tool with a new one if it’s blunt.
- Choose the right tool and setting according to the characteristics of the material
- Adjust the settings to proper specification for a particular cutting tool
Results
Die & Moulds industry is one where the unit cost of each mould is high and cases of rework, rejection or scrap can adversely impact cost as well as profitability and reputation of the customer.
By replacing manual, human centric methods, where the scope of error is so high, with an automatic solution, a company can look at reducing rework, rejection, scrap on account of wrong tool by >50%. Studies have shown that this can result in 60-90% reduction in scrap i.e. today if scrap in your production is around 1.26%. Assuming a high precision machining scenario, using a quality Tool setter like that of MANLEO can help you reduce this to 0.42% and this adds to huge cost savings when you are looking at total components manufactured per year.
Manleo Auto Tool Setter
Manleo Auto Tool Setter is designed for the following applications:
- Automatic Tool Lenght and Radius
- Automatic update to the tool banks
- Automatic detection of wrong tool
- Tool Breakage detection
- detect and control the key tool dimensions
