Vertical power-skiving machines from Gleason intended for the production of soft and hardened gears up to 600 mm in diameter can now be equipped with an on-board cutter re-sharpening unit to reduce cutter changes and help ensure consistent quality.

As a result of automating cutter re-sharpening operations, Gleason power-skiving machines require minimum operator involvement, reducing the time typically required for frequent tool changes and subsequent first-part inspection cycles. Additionally, the usual cost for external tool refurbishment can be avoided.
Compared with the typical cutter re-sharpening process, the on-board unit is fast and simple. The machine’s axes position the cutter to the grinding wheel, before the re-sharpening unit executes the necessary grinding strokes, with the cutter performing the infeed and indexing from tooth to tooth. All of this is undertaken automatically and based on the cutter geometry that exists after a certain number of gears have been cut. After the initial corrections are made based on the first gear cut, a consistent gear quality is more easily maintained throughout the complete life of the tool. The frequency of re-sharpening cycles can be selected depending on the gear quality required.
Tool cost-per-piece is also lower compared with external reconditioning, with no tool changes, first-part-inspections and machine adjustments during a cutter’s lifetime, as well as no handling and logistics costs for reconditioning cycles. With a lot less cutters in circulation, tool investment is reduced significantly.
For further information www.gleason.com

A specialist in the manufacturing of cutting tools, Lincoln, California-based AB Tools, has taken delivery of an Anca MX7 Linear grinding machine with automation to help it produce the company’s Shear Hog range of carbide inserts. Existing machines and processes were proving insufficient to keep up with demand.

The engineering team at Anca worked closely with AB Tools to find a solution, as it can custom-design mechanical, electrical, software and process solutions to enhance the standard product range and meet specific customer requirements. The engineering team was requested to deliver a solution that was able to automatically load and grind the Shear Hog inserts, perform grinding operations in one set-up and meet cycle time requirements.
Developments included a modification to the loading system, with custom pallets to suit the inserts. The custom pallets can hold up to 442 inserts, although this capacity can be increased by ordering the four-pallet upgrade option available on the MX7 Robomate universal loader. A modification to the robot gripper head allows the robot to pick up and handle the insert/nail combination. In addition, robot loading software was developed to support the insert pick-up operation, and load and unload the nail via an interchange station. Inserts can now be ground in a cycle time of less than six minutes.
“Anca impressed me from day one,” states Alfred Lyon, AB Tools’ shop supervisor. “Creating a whole new type of machine for AB Tools is not merely impressive, it’s extraordinary. We could have purchased another machine similar to the one we were using, but we asked Anca for help because we wanted to expand our capabilities and simplify the process. This new machine has exceeded both desires.”
For further information www.anca.com

Following 12 months of trouble-free operation at the Crewe manufacturing facility of CoorsTek, a manufacturer of engineered ceramics, an Okamoto 818 CNC surface and profile grinder has been integrated as a core part of the company’s specialist grinding operations.

The machine was one of the first to be supplied by Jones & Shipman Hardinge, Okamoto’s sole UK distributor. Tristan Weller, production manager at CoorsTek, says: “In the surface grinding cell, we are precision grinding ceramics to typical tolerances of ±10 µm on form radii, and down to 5 µm on flat surfaces. It is a complex process with slow feeds and speeds, and can take its toll on machines and wheels alike. Inherently, it is a time-consuming task, so sustained machine integrity and stability are important.”
Offering a compact footprint, the Okamoto 818 CNC features a 450 x 200 mm table area with the machine based on a small moving saddle design. The ISO type programming menu is delivered through a Fanuc CNC unit with other key features being automatic lubrication to guides and slideways to optimise reliability and prolong maintenance-free operation.
All of the core machine castings exhibit high static and dynamic stiffness, and are fully damped. Scraped V-slideways with low-friction Turcite coatings are standard.
Harry Hodgson, Crewe plant manager, and Tristan Weller, production manager, say: “The Jones & Shipman overall commitment to quality and aftersales technical support convinced us to invest in the machine.”
For further information www.hardinge.com/jones-shipman