TIME SAVING

Using modular quick-change tooling instead of conventional tools can mean huge savings in time and costs. A modular tool system should provide quick tool  changing accuracy, stability, strength, and flexibility for future development and tool management. This will lead to a substantial increase in productive metal cutting, improved tool handling and administration, while reducing inventory.

Modular tools can be incorporated into most old or new machines tools resulting in considerable savings. Even existing turret lathes can have modular tools easily built-in to provide quick tool changing. Changing or replacing a conventional lathe tool normally takes three to five minutes to change, while modular tool takes approximately one minute. Faster, better insert indexing is also carried out in the toolroom or away from the lathe or mill, often in less than half the time and with better inspection in a safer location. Measuring cuts, that can take up to five minutes, are virtually eliminated due to the repeatability.

A new working environment is created with modular tools, giving several advantages in performance, quality, working and economics. Tool Management can be established, Fig. 3-3-2, on any level whether it concerns one conventional machine or a large machine shop full of CNC machinery.

Fig. 3-3-2 Tool management can provide advantages in performance. (Modern

Machine Shop)

Computerized planning and sound administration should produce the following:

1)       Programming and network systems will help to drive the organization.

2)       Tool identification keeps track of tools and data.

3)       A storage system will assist handling and mechanical tool handling.

4)       Leads down the path to automated manufacturing.

5)       Tool monitoring keeps an eye on the machining process and driven toolholders.

6)       Allows for additional operations to be performed.

7)       In-process measuring is a reality with probes.

8)       A minimized inventory of modular tools can be completely controlled.

Modular tools provide considerable practical and economical advantages for almost any application. The benefits continue to increase the more often tools are changed. The change to modular tools involves a modest investment, which is repaid in a few months by the economic gains.

ADOPTING MODULAR TOOLS

Before making the change to modular tooling, it is wise to investigate whether the change will produce productivity improvements that will justify their initial expense. The personnel must also support the change because they are the ones who will have to implement the change to modular tooling. According to reports, modular tooling when used on proper applications could make tool-change time up to eight times faster than with conventional tooling.

Suggested Checklist

• Make sure that true universality is provided for today, tomorrow, and the future to provide flexibility in handling and inventory.

• Invest in a system that can be used for many types of machining operations.

• Ensure that the system is suitable for all foreseeable machine tool types.

• Choose a system that provides the best stability and repeatability.

• Check for the best function in regards to stationary and rotating tools.

• Establish values for the built-in safety margins, especially for heavy-duty applications.

• Test for effect on workpiece quality.

• Determine how the tooling may reduce or eliminate inspection costs.

• Have quick changing facility of tools as a high priority for machining operations. Modular systems vary in speed and complexity, which will affect the practical use of the system and the ability to reap benefits of higher productivity.

• Select a system from a supplier who can provide technical support and a wide range of products, now and in the future. Choose a system that provides coolant through the tools as the standard method. This is often a crucial requirement in those operations requiring chip removal and cutting fluid to be directed to the right spot on the tooling.

SELECTING A MODULAR TOOLING SYSTEM

A modular cutting tool system will yield outstanding results, provided it receives the planning required to make it work, Fig. 3-3-3.

Fig. 3-3-3 CNC turning center with live-spindle capability. (Sandvik Coromant)

JIT, FMS, modular tooling, and quick-change tools are terms often seen and heard about. However, the one word that best describes the very essence of manufacturing today is change.

All quick-change tools are modular, however, not all

modular tools are quick-change.

Changes are taking place in the workforce, labor relations, the global economy, and in worldwide competition.

There is an ever-increasing goal for lower costs, higher output, better quality, reduced cycle times, and increased flexibility. One method of preparing for and meeting these changes is the application of modular tooling, specifically quick-change tooling .

The following information is designed to help in the decision-making process for the application of a quick-change cutting tool system.

With the ever-increasing number of CNC machines, these machines are becoming more and more of a factor in the manufacturing process. CNC lathes outnumber CNC machining centers by almost two to one. In the mid-1980s, the introduction of the mill-turn center or CNC lathe with live spindle capability allowed turning and milling operations in one work setup. These machines are available with higher horsepower, allowing increased metal removal with rotating cutting tools (live tooling).