Efficiency and precision are paramount in today's manufacturing landscape. One area that remains a big opportunity for shops to increase their bottom line profitability is to implement offline tool presetting. Only about 30% of machine shops have adopted this technology and it really should be about as common as a vise or a boring head in every shop because it can make you money! Why Preset Tools Outside the Machine Tool? The practice of presetting tools outside the machine tool offers numerous advantages over traditional in-machine setup methods. Let's start with the dollars and cents. When tools are preset outside the machine, the machine tool can continue operating, and not interrupting production. This ensures that your CNC milling machine is utilized for what it's designed for—making parts—not sitting idle during tool setups. This approach not only maximizes machine uptime but also significantly enhances productivity by eliminating non-productive setup time. Offline presetters are equipped to measure tools with high precision, typically achieving accuracies of at least ±2µm, which ensures that tools start producing parts within dimensional tolerances immediately, without the need for test cuts that do nothing more than produce scrap and chips. This level of precision is crucial for maintaining consistent production quality and minimizing tool wear and potential damage to the machine or workpiece. Advanced Features of Offline Presetters High-end offline presetters, like those from HAIMER, come with features that amplify their utility in a modern shop floor. For example, they often include integrated computers with user-friendly software that guides the operator through complex measurement programs. This capability not only simplifies the task for operators of any skill level but also allows for the storage and recall of tool data, ensuring repeatability and reducing the risk of errors during production runs. The Haimer VIO series exemplifies versatility and high-tech sophistication, making it suitable for complex and varied manufacturing requirements. It offers a seamless interface that simplifies operations while ensuring the highest standards of accuracy ad can even integrate shrink fit capabilities. On the other hand, the Haimer UNO series, starting with its benchtop variant presents a more economical solution without compromising quality, ideal for straightforward applications. Most importantly, these presetters can perform comprehensive inspections of the tool's geometry, which is crucial for catching any potential issues before they result in machine downtime or defective products. This preemptive capability can translate into substantial cost savings and more efficient material use. Economic Impact
The economic benefits of investing in an offline tool presetter are significant. While the initial investment may seem substantial, the return on investment can be rapid. Shops have reported that presetters pay for themselves within days to months by drastically reducing machine downtime and scrap while increasing throughput. Given these substantial benefits, the question isn't whether to invest in an offline tool presetter, but rather how quickly your shop can be integrate a presetter into existing operations. The strategic deployment of this technology not only streamlines production but also enhances the overall agility and competitiveness of manufacturing operations. For more details on how tool presetting can enhance your manufacturing efficiency, exploring further resources on this subject would be beneficial get in touch with the team at Browne Sales
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The team at Browne & Co are excited to invite you to join us at IMTS 2024, which will be held from September 9-14 at McCormick Place in Chicago. This premier event is a vital opportunity to explore the latest advancements in manufacturing technology, network with industry leaders, and discover innovative solutions that can enhance your operations. There will be participation of several of our key principals at the upcoming show.
Dümmel (Booth: 431481) As part of Everede's booth, Dümmel will be showcasing their exceptional micro-cutting tools, which are ideal for small-part machining and fine-detail work. Dümmel's product range is designed to meet the highest standards of precision and reliability, ensuring optimal performance in intricate machining tasks. Everede Tool Company (Booth: 431481) Everede Tool Company will be showcasing their advanced cutting tools, including indexable tools, boring bars, and other precision cutting instruments. Everede is known for producing high-quality tools that provide superior performance and durability. Their products are designed to meet the rigorous demands of modern machining, offering solutions that increase efficiency and precision in manufacturing processes. Haimer USA (Booth: 431510) Haimer will be showcasing their industry-leading tool-holding systems, including shrink-fit technology and high-performance balancing machines. These products are known for their ability to improve machining accuracy, reduce vibration, and extend tool life, ultimately boosting overall efficiency in manufacturing environments. Additionally, Haimer's Power Clamp and Tool Dynamic series provide unmatched reliability in tool clamping and balancing, ensuring top-tier production quality. Nine9 (Booth: 431481) Also as part of Everede's booth, Nine9 will be exhibiting their innovative cutting tools that are designed to streamline complex machining processes. Highlighted products include the NC Helix Drill, which ramps at 20° angles, enabling the production of multiple features with a single tool, and the i-Center indexable center drill, which offers extreme repeatability and precision. Precision Brand Products (Booth: 431781) Precision Brand will display an extensive array of shim products, toolroom supplies, and maintenance tools at their IMTS booth. Their offerings include slotted shim kits, feeler gauge assortments, and stainless-steel shim stock, all of which are critical components in achieving exact measurements and ensuring the longevity of machinery. IMTS 2024 is the ideal venue to explore these innovative products and speak directly with the experts who design and produce them. We strongly encourage you to add these booths to your IMTS show planner and take advantage of the opportunity to engage with the cutting-edge technologies that can propel your business forward. For more information and to plan your visit, please visit IMTS 2024 Let us know if you will be going and we can join you at one of our principals booths!! Innovative Facility Showcases the Latest in Metalworking Precision and Efficiency Chardon, OH. - Browne & Company, a leader in the metalworking industry, is proud to announce the grand opening of its new Metalworking Technology Center in Northeast Ohio. This state-of-the-art facility is set to revolutionize the metalworking sector with its cutting-edge technology and tooling, provided by the renowned Haimer presetting and shrink fit tooling. You can also find the latest high performance cutting tools displayed from Fullerton Tool, Regal Cutting Tools, Rocky Mountain Twist Drill, The Everede Family of tooling, Dapra, and others. The Technology Center is designed to meet the growing demands for higher precision, efficiency, and performance in metalworking. It is equipped with the latest advancements in Haimer technology and tooling, ensuring consistent set-up, unsurpassed machining accuracy, better tool life, and improved part finishes. The center represents a significant investment in innovation and demonstrates Browne & Company's commitment to advancing the metalworking industry. "We are excited to unveil our new Technology Center, which symbolizes our dedication to providing the best in metalworking solutions," said Dave Browne, President of Browne & Company. "This facility not only showcases the latest in technology and tooling but also serves as a hub for innovation, collaboration, and education." The Technology Center boasts an impressive display of the latest high-performance cutting tools from leading manufacturers, including Fullerton Tool, Regal Cutting Tools, Rocky Mountain Twist Drill, The Everede Family of tooling, Dapra, and many others. These partnerships underscore Browne & Company's commitment to quality and excellence in providing comprehensive solutions to its clients. Industry professionals, clients, and partners are invited to explore the capabilities of the new Technology Center and witness firsthand the advancements in metalworking technology. Browne & Company is offering personalized demonstrations to showcase the benefits and efficiencies that their state-of-the-art technology and tooling can bring to any operation. "To see the future of metalworking, we invite you to visit our Technology Center. Our team is ready to demonstrate how our latest technologies and tooling can enhance your operations," added Browne. Schedule a Demonstration Don't miss the opportunity to experience the latest in metalworking technology and innovation. Click the button below to schedule a demonstration with our team and discover how Browne & Company can elevate your metalworking projects. About Browne & Company
Browne & Company has been at the forefront of the metalworking industry, offering innovative solutions and high-quality tooling to clients across various sectors. With a focus on precision, efficiency, and reliability, Browne & Company continues to lead the way in metalworking technology and services. If you would like to learn more about any of Haimer's World Class products, please reach out to a member of our team in the Ohio, Western PA, or Kentucky areas with a click of the button below.
HAIMER, an innovative global player in tool management for machine tools, is convinced that production engineering will be determined by automation and digitization in the future. This development is an established part of the company's own production and has accordingly also found its way into the product range from i4.0-capable machines to the HAIMER Automation Cube robot cell, which can be scaled according tocustomer’s request and is suitable for automated shrinking, presetting and balancing. Efficient machining demands powerful machines and tools “as well as high-precision tool holding technology which ensures that the precision of the spindle is transferred to the cutting edge,” says Andreas Haimer. This is the sort of statement you would expect from the Managing Director of Haimer GmbH and President of the HAIMER Group, the worldwide leading manufacturer in the field of tool holding. But it is not simply a marketing slogan – there are many years of experience behind it. HAIMER started off 45 years ago as a machine shop for the aerospace industry and soon started to develop high-precision toolholders for their own use. HAIMER also has many years of experience in automation. The Bavarian family company made the decision to equip their first machine tools with robots for loading and unloading over 20 years ago. Since then, automation at HAIMER has advanced swiftly, as evidenced by their manufacturing facilities at their headquarters in Igenhausen or in Motzenhofen, just 3 miles away. The Motzenhofen production plant in particular, which has been operating since 2018, has been equipped from the beginning with numerous automated machining centers in recent years. Automation is a Necessity Andreas Haimer stresses: “If, like us, you depend on a very high level of in-house production completely ‘made in Germany’, there is no way you can avoid extensive digitization and automation. Otherwise we would not be able to keep up economically with our global competition.” Soft machining of the tool holders is carried out in Motzenhofen alongside all precision components for shrink fit and balancing machines including accessories. Up to 4,000 rotating tool holders can be turned and milled there per day before heat treatment, followed by µm-precise grinding at the headquarters in Igenhausen. Fine balancing is also carried out in Igenhausen – using systems that have been developed in-house and are fully automated. Not Every Automation is Complex Back to Motzenhofen: Amongst others, HAIMER operates a fully automated manufacturing cell with several five-axis DMG MORI MILLTAP 700 machines. These highly dynamic vertical machining centers, which were installed at the beginning of 2019, are perfect for boring and milling components such as the BT30 or the SK30 steep taper tool holders. Manfred Mayr, who completed his apprenticeship at HAIMER over 40 years ago and is now responsible for around 100 machine tools as the plant and production manager, explains: “Here we use a simple plug & play complete solution, which includes a fully automated loading and unloading system using a KUKA robot. Blanks and the machined parts are placed in three drawers, each of which has around 78 positions. This ensures that unmanned production is possible for a minimum of eight hours up to 20 hours.” The automation of four identical DMG MORI NHX4000 machining centers, which are equipped with a pallet pool FMS system, is considerably more demanding, as Manfred Mayr describes: “There are twelve pallets, each with 400 places, ready to process various components. This provides us with ideal flexibility, also when it comes to smaller batch sizes and short-notice changes in the production flow.” The machines generally work highly productively and trouble-free in a 3-shift operation, supervised by just one employee. In order to operate the machines as autonomously as possible with a large variety of products, HAIMER had the machines equipped with a tool magazine with 183 tool pots. Manfred Mayr considers the fact that all tools for these machines are equipped with an RFID chip on the tool holder to be a key factor of success. They are read in at a dedicated station when they are changed into the magazine. This means the control receives the correct tool data digitally from the HAIMER Microset VIO linear presetter. This completely eliminates any input errors or mix-ups. Digital Data Flow Between the Tool Room and the Machining Center A key basic requirement for economic operation of the NHX and all other machine tools – according to the plant manager – is a perfectly operating and well organized tool room: This technology represents a central component of our expertise. Of course we use our own products here – from shrink fit, balancing and presetting machines to tool holders and cutting tools. This enables end-to-end digitization all the way to the machine, which is an essential component for automated, economic manufacturing operations.” This means that all tools for milling and turning machines are centrally prepared and managed in the tool room. They are mounted, shrunk, measured, and balanced – and all data is digitally recorded. This either takes place on the aforementioned RFID chips, by means of digital interfaces, such as post processors, or via a QR code. Only then they are packed onto special tool wagons as required, where the machine operator can pick them up for their machine. This eliminates extra walking throughout the shop. “Only with optimal tool presetting room, the machines run and not the employee,” is Plant Manager Mayr’s credo. The Tool MUST Fit into the Digital Production Environment ![]() HAIMER evolved to become a complete system provider for tool management centered around the machine tool. HAIMER Microset tool presetting technology complements the existing HAIMER portfolio, which consists of an extensive tool holding program, shrinking and balancing technology, tool management logistics as well as 3D measuring devices and solid carbide cutting tools. The digitization of the production processes represents a key factor for success not only for HAIMER but for every company. “As the tool with its specific data is a central component of the process chain for machining, it needs to fit into the digital production environment,” explains Andreas Haimer. This includes the consistent implementation of all digital options – from the tool itself, the tool holder including the clamping process, the balancing to the tool presetting, and the use on the machine. Especially when making new investments, the user should ensure that every element in the tool environment is Industry 4.0 capable and can be incorporated into the digital workflow, advises Andreas Haimer: “Our products are fully prepared for digital production. We have even developed our own tool management software, the HAIMER Data Analyzer and Controller (DAC), which establishes and manages the exchange between the actual and target values along with other tool data between the individual stations in the tool room and the company network. Our equipment in the Industry 4.0 series are prepared for automation with modern digital features and interfaces. Moreover, they have been designed to be robust with a long service life, which is a guarantee of the highest process reliability – a decisive factor for successful automation.” HAIMER supports a wide range of automation models with its products. The range starts with individual machines which combine several work steps, such as the presetter HAIMER Microset VIO linear toolshrink. It is capable of shrinking tools with a length adjustment on the μm scale and at the same time measuring the tool. Amongst other things, it is ideal for sister tools, which always need to be shrunk to the same dimensions. Their use in series production or in multi-spindle machines promises to increase process reliability and minimize setup times. One Robot Cell for |
HAIMER shrink fit tool holders make processes throughout production significantly easier in regards to tool runout, reach and clamping force. “The main reason we use heat shrink is it significantly reduces runout and increased rigidity,” another 5-Axis Programmer at Omega Tool, Inc. explains. “With coolant through drilling applications, this means near complete confidence that runout is eliminated when using a HAIMER heat shrink.n Milling is even better, since runout is under .0001”, tools cut naturally, allowing for more aggressive HEM, higher SFM, consistent tool wear, with superior surface finish.” Uniform pressure on the cutting edges in the HAIMER shrink fit tool holders leads to, among other things, better dimensional accuracy, surface finish, smoothness and tool life and Omega Tool, Inc. experienced that firsthand. “With the HAIMER tool holders, I can in certain situations not polish the mold if it lends itself,” Randy describes. “I can actually mold right off of the finish with the HAIMER tooling.” |
HAIMER tool holder’s slim profiles are another great feature that Omega Tool, Inc., Inc. benefits from on a regular basis. “Certain features in plastic molding application, especially gates, would be extremely impractical to cut without the use of the slim HAIMER holders,” an operator at Omega Tool, Inc. explains.
“They allow the holder to get much closer to the feature, and as a consequence, result in significantly less tool stick out.”
HAIMER uses special raw materials, according to its own standard for the tool holders, and this is 100% checked by detailed spectral analysis. The material offers high strength, high toughness and is perfect for the requirements of shrinking technology - so that you can shrink in and out with repeatable accuracy as often as you like.
“I tried to make the HAIMER tool holders fail,” Randy states. “I overcooked them, triple cooked them just to see if I could make them fail and I couldn’t.”
Perfection and Quality Always Win
Now when someone at Omega Tool, Inc. needs additional tooling, he simply sends Randy the HAIMER part number.
“There is no comparison to what we were using to the HAIMER product,” describes Randy. “Whenever someone asks about our tooling, at a trade show or at work, I always lead with HAIMER.”
Haimer is giving away 10 Rotary Toolholders with the Purchase of a PC SE Shrink Fit Machine!
12/6/2021
For fastest tool change and highest process reliability
- Precision with 100% repeatability
- Fast tool changes - less than 5 seconds
- Easy to use - tool changes at the touch of a button
- Versatility - compatible with any shrink fit holder
- Includes a $250 cutting tool certificate and 10 Basic Line Tool Holders
- 1/8" - 1-1/4" Tool Holder capacity
Both short and long probe tips are available with no tool change necessary because there is no re-calibration of the sensor needed and it has an enhanced overrun distance! It's ideal for Milling and EDM machines (isolated probe) as well as for work piece-reset and length measuring in any direction approach (X-, Y-, Z-axis). And it can withstand exposure to coolant because it's IP 67 water and dust proof!
The Benefits of the Haimer Sensor
No math needed
3-Axis edge finder
Quickly verify part dimensions
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