Press Release - September 2010

Blanket grinding is a new process approach to tool manufacture where the complete tool manufacture from blank stock to finished tool is achieved within a single manufacturing cell. This eliminates the need for separate sequential machines and processes traditionally required for the complete tool manufacturing process. This single setup approach to the entire tool manufacture process brings with it competitive advantages in production flexibility, accuracy and bottom line profit.

1 Separate machines used for each operation. Blank parting, shank chamfer, cone point, step OD, tool grind. 2 TXcell wheel packs are fully configured prior to change over and includes p-axis with arobotec steady, precision multi jaw chuck on TXcell for blanket grinding

Blanket Grinding

New heights of automation in tool manufacture

Conventional drill manufacture process1

Step 1. Stock cut to length

Step 2. Blank grind (shank chamfer)

Step 3. Blank grind (cone point)

Step 4. Blank grind (step OD sections)

Step 5. Tool grind (flute, OD, Point)

Blanket Grinding process2

5 steps using only 1 machineBar stock to finished tools in a single setup!

5 steps 5 different machines5 x machine set up and part handling

1

2

3

4

PLUS post process operationsFor example: finish polishing / brush hone / customisation /

barcode reading / QA measurement / packing...

5

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Blanket Grinding on the TXcell directly addresses the pressure points of any tool manufacturer.

Your Pressure Point Traditional Production Line Blanket Grinding Process

Reduce inventory and stock holding costs.

Cost of maintaining stock blanks maintained for hundreds of different types of catalogue tools. Stock held in WIP for longer periods of time.

Hundreds of different catalogue tools can be manufactured from common bar stock. WIP is dramatically reduced and tools move through your factory more quickly.

Respond to customers requirement for smaller order quantities in less time.

Time to setup sequential machines means a traditional manufacturing line is not well suited to manufacture of small batches of tools. Each machine in the process introduces more delays.

Flexibility of TXcell means setup time between batches is virtually eliminated. Reduced processing time from start to finish means faster turn around of customer order.

Reduce labour costs. Labour for transfer of parts from one machine to the next, and setup of each sequential machine.

Parts handling between processes eliminated. Labour for machine setup between batches dramatically reduced.

Reduce capital and operating costs.

Multiple machines duplicate costs. Each machine in the production line consumes capital, power and floor space. Requires supporting equipment (coolant systems) and annual maintenance.

Overall the TXcell is a smaller capital investment. TXcell consumes less power, occupies less floor space and has just one coolant system.

Increase tool accuracy. Multiple tool holding between machines introduces inaccuracy to the tool.

Single chucking for all grinding operations ensures maximum accuracy and minimal tool runout.

20 tool batch comparison of contributing factors

Conventional Process

Blanket Grinding on TXcell Saving

Cost per tool# $23.48 $20.41 13%

Total labour time usage (for part handling and machine setting)

115 minutes 20 minutes 83%

Cumulative processing time for Batch

499 minutes 328 minutes 34%

Cost of capital (lease) 73 cent/min 43 cent/min 41%

Total floor space occupied 18.5 sq.m. 11.9 sq.m. 36%

#Per tool cost comparison considers: Labour costs for part handling & setup time of each machine. Overhead costs of machinery (floor space, power, maintenance schedule). Cost of capital of machinery and relative utilisation.

ANCA’s new TXcell with 21 wheel packs, and 4 tool pallets is ideally set up for Blanket Grinding. Utilising the power and precision of the TX7+, combined with the flexibility of a robot for process automation; the TXcell offers the possibility to perform operations from blank preparation through to final tool grind and post process finishing across varying tool diameters in a single setup.

To find out how Blanket Grinding can address the pressure points of your manufacturing process contact your nearest ANCA representative

Dramatically reduce set up time from tool to tool

Comparison of Conventional1 and Blanket Grinding2 ProcessTool Type: Carbide Step Drill

Details: 12mm (shank) – 6mm (pilot diameter), overall length 90mm

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Number of Tools in Batch

Actual cost per tool comparison 12mm - 6mm step drill

5 2010 30 40

20

10

30

40

50

50

Per T

ool C

ost (

$)

Sequential Machine Process

Blanket Grinding Process