hp tooling 2020 #1

materials & tools
The key advantages of RFID technology are that it prevents
incorrect component installation, it automatically
reads and transfers component data, it prevents incorrect
entries, which results in shortening of the overall input
time, as well as preventing downtimes due to incorrect
component installation.
Tool data management and digital workbench
KAPP NILES has developed its own platform called KN assist
which contains a tool data management system among
other features. Exchangeable, intelligent components with
all geometric and process-related data can be managed and
clearly displayed outside of the machine within the tool
data management system. All tool data is therefore stored
centrally in a single location and is retrieved from there.
KN assist also provides supportive functions for the setup
process. This means that essential assembly and disassembly
operations for multi-part-tooling can be carried out
by the operator in advance. This results in shorter preparation
times for the subsequent grinding project. Furthermore,
information is provided to the intelligent components
which, together with the RFID technology, optimises
the set-up process.
CBN grinding worms
KN assist, together with the KN extender (computer assembly
for workshops, which equips workbenches with
digital functionalities), manages the customer’s operation,
labelling and management of all components outside of
the machine. Besides the identification of components by
RFID, optical component recognition is also possible. The
system is designed to also manage components without
RFID or a QR code/DMC identification.
GrindTec 2020, hall 3, booth 3001
information: www.kapp-niles.com
With additive manufacturing to more productivity
If the weight of PCD tools is reduced, as a rule
significantly higher cutting data can be used.
Along with design freedom, the possibility of
weight optimisation is one of the crucial advantages
offered by 3D printing. Due to the specially
developed structures inside the tool, which cannot
be manufactured conventionally, the weight
can be reduced significantly.
New bell tool with low weight,
long tool life and best cutting data
An example of how MAPAL uses this advantage of 3D
printing in practice is the new bell tools with brazed PCD
inserts. Bell tools are used for the external machining of
hose connections, among other applications. These connections,
for example on turbochargers, must satisfy com -
plex contour requirements. Manufacturing must be cor re -
spondingly precise. Existing processes are also subject to
continuous improvement so that manufacturing is costeffective
and reliable in series production.
MAPAL has therefore optimised the existing, conventionally
manufactured bell tool. Using the selective laser
melting process, the inside of the tool has been modified
- instead of solid material there is now a specially designed
honeycomb structure. As a consequence, the tool is
30 % lighter and the tool life is increased by approx. 40 %
due to the damping effect. It is therefore possible to machine
faster; the machining quality remains at the same
high level.
MAPAL is presenting a new
bell tool with low weight,
long tool life and
best cutting data
The honeycomb structure
inside the tool can be
realised thanks to
additive manufacturing
In total the machining time has been reduced by 50 %.
Furthermore, the cooling channel design has also been optimised.
The new bell tool is of hybrid design. Using selective
laser melting, the new tool geometry is printed on a
highly precise tool body with a HSK-63 connection. The
additively manufactured part is subsequently machined
conventionally. Then the PCD inserts are brazed in place
and cut to shape using a laser.
information: www.mapal.com
no. 1, 2020, March
23