Precise grinding of cutting tools with nanometer accuracy
Photo: ANCA
Lathes / CNC Tools / CNC Machine Tools / CNC Solutions / Milling Machines / CAM, Metalworking

Precise grinding of cutting tools with nanometer accuracy

13/10/2022
Source of information: ANCA Machines
Category: Lathes / CNC Tools / CNC Machine Tools / CNC Solutions / Milling Machines / CAM, Metalworking

The new MX7 ULTRA can manufacture large volumes of endmills and other cutting tools of the highest accuracy and quality. The minute size of a micron is beyond the human eye, but in becoming even more precise and moving from micrometres to nanometres, ANCA will offer the highest accuracy and quality in a cutting tool in the market. New software, hardware and design features are combined to make significant advances in surface finish, accuracy, and controlled runout, to deliver batch consistency from the first ground tool to the thousandth.

The MX7 ULTRA includes:

  • nanometre control system,
  • new servo control algorithm for smooth motion,
  • system and mechanical upgrades enhance stiffness and rigidity,
  • in-process measuring, balancing and runout compensation for consistent accuracy,
  • Motor Temperature Control (MTC) – compensation for thermal expansion on the grinding spindle, and specialist training support in how to grind industry leading cutting tools.

Cutting tools like ballnose, corner radius, barrel shape ballnose and double corner radius endmills are used widely across industries including diemold, aerospace, and power generation. The surface finish quality, accuracy and runout are critical for the performance and cutting life in all applications – so our customers want a guarantee that their first tool will be exactly the same as the hundredth, or thousandth. The MX7 ULTRA can produce high quality cutting tools to suit all customer needs to satisfy all industry types – says Pat Boland, ANCA co-founder.

Characteristics of the new machine for the production of cutting tools

 
Greater control for the velocity and acceleration or deceleration along with machine jerk limits: To increase the stiffness of the C-axis, the MX7 ULTRA combines developments to the nanometre or micro degree resolution in the linear and rotary axis, tuning parameters, several system enhancements, and major mechanical changes.

ULTRA-fast response to internal or external disturbances: ANCA’s newly designed servo control algorithm allows silky smooth motion of an axis with the use of a unique algorithm and nanometre measurement in the control system. This will create finer cutting edges and eliminating micro-chips making it more efficient while used in actual machining of materials.

Better cycle time and higher productivity of high-quality cutting tools: The unique algorithm is key to the performance of the machine and ensures outstanding tracking performance. It also allows ULTRA-performance of the servo system without using a complex, complicated, or expensive mechanical system.

Reduces setup times and scrap: Cutting-edge software has been developed by ANCA to ensure batch consistency in large volumes. LaserUltra is part of the MX7 ULTRA package to maintain consistency and accuracy of the grinding process which includes in-process measurement and compensation to accommodate wheel wear and other external variations during large batch grinding. Its analog capability can maintain less than +/- 0.002mm line form accuracy of any profile which includes ballnose and corner radius tools.

Increased wheel life and better-quality tools: Tool and wheel performance can be further optimised by the iBalance software, which guides a user to the optimal grinding position and RPM for vibration monitoring and balancing the wheelpack inside the machine. Correctly balanced wheelpacks result in superior surface finish and reduced wheel wear due to the elimination of wheel vibration.

Consistency in finished tool quality: A major inclusion in the MX7 ULTRA package is the total tool runout measurement and compensation operation in iGrind. When an endmill is in rotation it is important that each tooth hits at the exact same spot along the workpiece for longer tool life and efficient cutting. Every tool in the batch can be measured and compensated for runout to make sure the entire batch is within a tolerance of 0.002mm. It is another piece of assurance that the first endmill will be as good as the last.

Consistent spindle thermal stability: Motor Temperature Control (MTC) is a patent pending innovation built into the motor spindle drive firmware. Smart control algorithm actively manages and maintains the temperature of motorised spindles in the MX7 ULTRA. Dramatically reduced machine warmup time means production can start sooner, once the machine has reached thermal stability. This improves productivity and machine use. Consistent thermal stability of the spindle over time regardless of changes in load or speed, or coolant temperature, greatly improves the dimensional stability of grinding results.

Post grinding processes: The smoother, finer cutting edge and surface finish as a result of the combination of all the above including the nanometre control will assist in all post grinding applications like edge preparation and coating. A finer edge that has been properly prepared has greater stability, which reduces the likelihood of it chipping, while also decreasing surface roughness which can cause increased friction between the tool and the workpiece.

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