ANCA has upgraded the FX5 Linear 2-wheel pack machine with a new grinding spindle rated at 12kW peak power as well as releasing a further high-powered spindle option of 19kW.
CNC tool grinders strive to achieve the shortest possible cycle times - to keep the cost per tool produced at a minimum. Machine performance and grinding cycle time are linked to the power capabilities of the grinding spindle.
To maximize material removal rate, a commonly accepted industry practice is limiting the spindle load to between 30% and 40% for fluting operations. If the spindle load is likely to exceed 40%, tool manufacturers tend to allow for a second fluting pass as this contributes to longer wheel life and less wheel load. Auto white-sticking becomes an important option as batch sizes increase.
ANCA has conducted a spindle load analysis of fluting operations, identifying how many passes are recommended in relation to spindle load. The analysis compares two flute endmills ground with either 6mm, 8mm, 10mm, or 12mm diameters. The new FX5 which has now been upgraded from 9.5kW to a 12kW spindle can comfortably grind tools up to 10mm diameter in a single pass. A 12mm tool required a second grinding pass to keep the spindle load at 40%, rather than increasing to 60%.
This is where the new high-powered 19kW spindle option makes all the difference. The 12mm endmill was ground at a 40% spindle load in one pass, with an overall time saving of one minute and four seconds – opposed to two passes at 12kW.
The FX5, with the new 12kW spindle delivers increased productivity up to a diameter of 10mm. At 19kW, the new high-powered spindle option can enhance productivity further for tools up to 12mm and above. The high-powered spindle option on FX5 matches the grinding spindle fitted to the FX7 machine with 6-wheel packs, suited for a more industrial environment.
The new FX5 upgrade option features a striking high-powered decal indicating it has been fitted with the more powerful 19kW spindle.
For complex cutting tools, there can be of course further factors which influence actual grind cycles besides the tool geometry. These include the quality of the grinding wheel used and the supply of an adequate amount of cooling liquid at stable temperature, to avoid thermal damage of the workpiece. As batch sizes increase auto white-sticking helps to achieve maximum output by frequently refreshing the wheel.
Customers will benefit from the increased spindle power provided by the new 12kW standard spindle on FX5 and now have the option to purchase their new ANCA FX5 with a high-powered spindle, adding more flexibility in the tool room. Most importantly the high-powered spindle reduces the production cost and increases net output across a wider range of tools.
The use of “One Pass Productivity” for tools with 12mm diameter translates into an increased output of 15.8% – with 70 tools produced in an 8-hour shift compared to 60 tools with the new standard 12kW spindle.