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Fast Change Tooling System Increases Spindle Uptime

6/14/2022

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Appears in Print at Production Machining as: 'A Swift Tool Change for Swiss-Type Machines'
​
​This coolant-through tooling system replacement for the gang plate on a Swiss-type machine can save hours of spindle downtime per day as well as increase tool life and enhance chip control.

by LORI BECKMAN Senior Editor Production Machining
​
While servicing the tools on a traditional platen on a sliding headstock lathe, it can take 10 minutes or more to index one insert. While indexing the tools, coolant spigots can get knocked loose by an operator and can cost a machine shop tool life and time. Once the inserts are indexed, it can take several starts and stops of the spindle for the operator to see if the coolant stream is being directed to where it needs to be.
​
To optimize this tool change process, Arno-Werkzeuge USA LLC has developed a coolant-through fast change tooling system that eliminates the high-pressure coolant lines in a Swiss-type’s compact workzone.

​The company says it also significantly decreases tool change downtime as well as setup time from hours to minutes while offering accurate repeatability.

​These advantages not only increase finished part output but also save thousands of dollars per spindle per year, according to the company.
Arno’s Fast Change (AFC) tooling system consists of a gang plate that holds split-shank, coolant-through turning tools, parting tools and grooving tools. Photo Credits: Arno USA
Arno’s Fast Change (AFC) tooling system consists of a gang plate that holds split-shank, coolant-through turning tools, parting tools and grooving tools. Photo Credits: Arno USA
Arno’s Fast Change (AFC) tooling system consists of a gang plate that holds split-shank, coolant-through turning tools, parting tools and grooving tools. Designed like a manifold, the coolant is rerouted through the gang plate to the tools. The UN-style slot in the fixed stop picks up the coolant and runs it through the pipette to the front end where the coolant goes directly to the cutting edge. The AFC system can supply coolant to one port that supports all the tooling positions, or it can supply two ports and divide the tooling positions with the needle valve.

The tooling system only needs to be plumbed once and, according to the company, after that, a high-pressure coolant line should not need to be touched again. With proper setup, the high-pressure lines are moved behind the machine guards, creating a clean machining environment. This enables operators to complete safer routine maintenance. Also, the AFC’s low-profile clamps do not collect as many chips compared with a typical clamping system.

When replacing a split-shank tool, the operator simply loosens two clamps to remove the cutting head and then replaces it with a new one, the company says.

Simple, Quick Functionality

A Time and Money Saver

Using the AFC system, Arno reports that it takes 17 seconds to change a tool, a vast improvement to the typical 7 to 10 minutes it can take using a traditional gang plate. The conventional method might take five minutes to change a tool, a minute to touch the tool off and another minute to adjust the spigot, for instance.
ARNO Fast Change Tooling System
Arno’s Fast Change (AFC) tooling system consists of a gang plate that holds split-shank, coolant-through turning tools, parting tools and grooving tools. Photo Credits: Arno USA
“Then, when you scale that up to a three-shift operation, you will change tools in all five stations twice per shift,” explains Keith Stroup, business development manager at Arno.

“So, 10 tool changes per shift on all five stations twice per shift equals 30 times that spindle will be idle at seven minutes each.”

He figures that is three and half hours, or nearly half a shift of idle time, just to service the tools in that traditional manifold and spigot platen.

​“Three and a half hours every 24-hour cycle equates to $70,000 per year of spindle downtime to service the tooling in that gang plate,” he adds.
In comparison, when an operator is working with the AFC system, retouch is not necessary because the tool will repeat within plus or minus a thousandth of the previous tool positions. There is also no need to factor in time for readjusting coolant lines because the new system is a true, coolant-through system.

It is also not necessary to factor in the clearing away of chips because those surfaces have mostly been eliminated with the smooth AFC design, according to Stroup. Therefore, the 17-second tool change time is the only time to factor in.

​But, for a real-world example, he increases the time to one minute to consider a distracted operator that might use extra seconds
Arno Cost Calculator
These charts show estimates of cost savings using Arno Fast Change tooling system versus the standard monoblock tool system. Arno says users can gain $60,000 per year by using its Fast Change system.

Although there are still 30 idle times per day, there are now only 30 minutes of downtime per day instead of 210 minutes using the traditional gang plate. “That only costs $10,000 per year, which means you’ve just made $60,000 a year on that one spindle by adopting the AFC system,” Stroup says.
​

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Jeff Terrace joins the Browne & Co Team!

6/11/2020

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In January of this year we welcomed a new member to our Browne & Co. sales team and with manufacturing companies opening up again, it's about time we introduce you to Jeff Terrace!

Jeff graduated from Ohio University with a Bachelor of Science in Mechanical Engineering in 2008.  He started his professional career at Lincoln Electric in Euclid, OH as a process & project engineer in the machining and mechanical parts group.  He was tasked with new product development for all the machined parts in the plant as well as new equipment implementation and process improvement.

After Lincoln Electric, Jeff joined the application engineering team at Ingersoll Cutting Tools in both the general marketplace and Automotive division.  The majority of his time at Ingersoll was spent working with local manufacturing companies as well as the Big Three automakers on custom tooling applications  for high and low volume production, custom carbide, CBN and PCD tooling.
Jeff Terrace Browne & Co Manufacturers Agent Rep
Jeff Terrace joined our Browne & Co team in January 2020
Jeff Terrace
cell: 216-556-3344
Jeff@Brownesales.com

Just before joining Browne & Co in January 2019, Jeff worked at Hoffmann Group, a German cutting tool, hand tool, workstation and storage solutions manufacturer.

Jeff has been working as an InovaTool representative since February of 2019 and recently joined Browne & Company at the beginning of 2020 as our Cutting Tool Specialist. Please send Jeff and email or give him a call to introduce yourself or pick his brain about an application question.
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Are You Boring Or Profiling  Nickel/Chrome Based Materials?

5/19/2020

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Picture
The Dummel Ultramini Xtraline Typ X050 is the Ferrari of mini grooving and boring tools. The modified geometry is specifically designed for high Nickel/Chrome based Superalloys.

They come with an internal coolant bore, chipbreaker, special carbide grade and an optimised cutting edge and shank geometry.

We have seen 200% increase in tool life vs our competition in machining the most difficult to machine materials.

Please call Browne & Company or email us for your nearest, authorized Dummel distributors:
440-463-3970
​dmb@brownesales.com
Ultramini Xtraline Catalog Pages
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The Dümmel Minimill-System for ID Grooving and Threading

11/12/2019

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The Dümmel Minimill-System with three or six cutting edges is the next big thing for ultra groove milling and threading machining from 0mm to a 32mm bore diameter.

The indexable carbide heads are screwed on with three ribs coupling. This guarantees the best possible rotation and repeatable accuracy. A large selection of standard inserts as well as toolholders from steel and carbide are available from stock.

With six cutting tools available, there's sure to be one that you can use to generate higher feed rates, longer tool life with higher stock removal rates.

The six cutting edged Minimill-system is also available with an anti-vibration carbide toolholder or a steel tool holder.
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HB Rouse Carbide Cutting Tool Brand Reintroduced by Arno Werkzeuge USA

6/27/2018

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Arno Werkzeuge USA has reintroduced the H.B. Rouse brand of American-made carbide cutting tools and inserts.
Picture
Arno Werkzeuge USA has reintroduced the H.B. Rouse brand of carbide cutting tools and inserts.

Formerly sold and marketed under the Arno-Rouse name, the company has reintroduced Rouse as a standalone product offering a broad range of carbide boring bars, tools and inserts for manual turning operations.

The carbide insert turning tools have triple-sided inserts for quick change turning operations.

Triple-tip boring bars offer an improved triangular insert located within a precision-machined pocket to eliminate shifting under heavy cuts; the insert requires the simple removal of one screw for indexing.

Boring bars feature carbide inserts that provide three cutting edges instead of only one (as is common with brazed-tip tooling).

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