RAPID TRAVERSE Machining Technology in Brief High-Speed Spindles Powered by Coolant Pressure BY DEREK KORN uxiliary high-speed spindles offer a number of advantages. They enable a conventional machine tool to achieve the higher rpms that are typically required to effectively use smalldiameter tools for semi-finishing and finishing operations. This increases a machine’s flexibility while saving energy and reducing wear and tear on its main spindle. It’s also possible to achieve faster cycle times and improve tool life by taking high-speed machining passes. Common versions of high-speed spindles include electric, air turbine and mechanical “speeder” designs. That said, Colibri Spindles, an Israel-based spindle designer and manufacturer, A The Spinjet/Typhoon auxiliary high-speed spindles use a machine’s through-spindle coolant delivery system to achieve speeds ranging from 20,000 to 50,000 rpm. This enables conventional machine tools to perform a range of operations using small-diameter tooling, including thread milling as shown here. 26 MMS January 2015 mmsonline.com RAPID TRAVERSE Machining Technology in Brief The compact high-speed spindles can be stored in a machine’s ATC magazine when they are not being used and installed in the main spindle like any standard tool. has developed a new version that uses a machine’s through-spindle coolant delivery system to rotate the auxiliary spindle. Its coolant-pressure-driven high-speed spindles, distributed worldwide by the IMC Group, are well-suited for operations such as milling, drilling, engraving, chamfering, thread milling and grinding using small-diameter tools. IMC Group companies Iscar and Ingersoll market the spindles in North America under the names “Spinjet” and “Typhoon,” respectively. According to Colibri, using coolant pressure to power the spindle overcomes a number of inflexibilities common to other types of highspeed spindles while offering lower operational costs. The Spinjet/Typhoon spindle models are available in 20-, 30- and 40-bar (290-, 435- and 580-psi) versions. The 20-bar spindles achieve 20,000 rpm, 30-bar spindle models can reach 30,000 or 40,000 rpm, and 40-bar models can reach 40,000 or 50,000 rpm. The company says tailoring machining parameters to these higher spindle speeds can enable shops to reduce Ingersoll, call 815-387-6600 or visit ingersoll-imc.com. Iscar, call 877-294-7227 or visit iscarmetals.com. 28 MMS January 2015 mmsonline.com machining time by as much as 70 percent. The compact high-speed spindles can be stored in a machine’s ATC magazine when they are not being used and install in the main spindle like any standard tool. They are available for use with a number of spindle interfaces, including ER 32 shanks, cylindrical shanks, HSK A63, CAT 40, BT30 and 40, and Capto C5 and C6 (ISO 266231). The spindles attach to toolholder bodies via an ER 32 collet chuck, and cutting tools install into the spindles via an ER 11 collet chuck that accommodates a maximum tool shank diameter of 0.236 inch. Recommended tool diameters range from 0.0787 to 0.1378 inch for 20,000 rpm, 0.0394 to 0.0984 inch for 30,000 rpm, and 0.0078 to 0.0591 inch for 40,000 rpm. To determine an approximate new feed rate for an existing operation being switched to high speed, Colibri suggests calculating the ratio of the auxiliary spindle speed to the original spindle speed, and multiplying that by the original feed rate. For example, if the existing operation used a spindle speed of 8,000 rpm and a feed rate of 6.3 ipm, the calculation for the new feed rate using a 30,000-rpm spindle would be: (30,000/8,000) × 6.3 ipm = 23.6 ipm Real-time spindle speed monitoring is possible using a compact display that connects wirelessly to the spindle via Bluetooth. The display can read speeds of as many as 127 spindles being RAPID TRAVERSE Machining Technology in Brief used on a specific machine tool. The spindles are available on new DMG MORI equipment, and their design has been integrated into SolidCAM’s iMachining software. SolidCAM built models for spindle use, which will make it easier to determine the proper cutting parameters, reduce the time needed to write part programs and shrink the learning curve. Second Chances for Surplus Tools BY PETER ZELINSKI f you held your shop upside down and shook it, how many cutting tools would fall out? That is, apart from the tools that are in the machines’ toolholders and ready to be used making parts, how much excess or unneeded tooling is sitting untouched in the tool crib or in the drawers of tool chests? Shops routinely are left with cutting tools for which they no longer have a direct need because of jobs that went away, or jobs that didn’t require all of the tooling purchased. In fact, because excess tooling has a way of filling small spaces, shops routinely carry much more of this unneeded inventory than they are aware of having. And in a way, it makes sense to carr y this inventory. While there are options for selling preowned tools through a secondary market (eBay is an example), arguably there has not been an option that is easy enough to use for a shop to sell many varieties of tools in small quantities. There also has been no easy way for potential buyers to be aware of surplus tooling available this way so they can quickly find what they need. As a result, the shop’s best practical choice for I surplus tooling is to hang onto it, on the chance that some use for it will present itself in the future. This is the problem that Industrial Surplus S o l u ti o n s a i m s to a d d re s s. T h i s ye a r, th e company launched a website, toolingmarketplace. com, which was designed by cutting tool professionals to serve as a secondary marketplace connecting the owners and buyers of discounted surplus tooling. The idea seemed like an attractive solution for machine shops with excess tooling sitting around, says Brian Nowicki, Industrial Surplus Solutions’ CEO. But cutting tool suppliers have embraced it, too, he says. Brand-name cutting tool OEMs proved to be the first sellers to use the system, and seem likely to account for most of the site’s available tool inventory going forward. After all, these companies have even more surplus tooling on hand than machine shops do. Mr. Nowicki says simplicity is the key to the system. Buyers and sellers will only use the site if posting tooling for sale and finding tooling to fit a particular need are both intuitively easy to do. And achieving simplicity, he says, is difficult. The website organizes cutting tools by various key details to make the right tool easy for a potential buyer to find. 30 MMS January 2015 mmsonline.com
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