High-quality/high-precision toolholders are costly, but because they extend tool life, high-quality toolholders can ultimately be profitable through long-term operation. For example, two mills use the same $30 end mill, but different toolholders to mill low carbon steel, resulting in a cost difference of up to 40% over the course of a year due to the choice of toolholders. Why is this happening?
The first company chose a low-precision toolholder that cost $100 and the toolholder achieved only 80% of the end mill's rated life. The second company bought a high-precision toolholder for $150. The cost is 50% higher than the first company, but the tool holder extends the life expectancy of the end mill by 30%.
In a year, the first company needed 120 end mills – a total cost of $3,600, while the second company only needed 70 end mills – for a total cost of $2,100. After subtracting the extra $50 from the precision toolholder, the second company saved $1,450 in tooling throughout the year, about 40% less than the first company.
Of course, this does not mean that the most expensive tool holders are the right choice for every type of machining. The key is to determine the type of tool holder that is most suitable for the relevant processing project (conventional, collet chuck, heat expansion and contraction, hydraulic type, etc.), and then select this type of high quality / high precision tool holder to improve Tool life.
High-precision toolholders generally have a low overall indication deviation (TIR) ​​and guarantee good clamping force, rigidity, balance and repeatability. All of this extends tool life and reduces scrap rates that are directly related to tool life.
Most of the scrap was produced shortly before the tool change and just after the tool change—before the tool change was due to tool wear, and just after the tool change, the tool was not exactly “enteredâ€. Therefore, by extending the tool life with high-precision tool holders, each factory can reduce tool change frequency and reduce part waste.
The tool's damping capacity also increases tool life, especially for plants that use expensive but less durable tools such as PCD (polycrystalline diamond) and CBN (cubic boron nitride). While hydraulic toolholders are seen as a common way to control vibration, other types of toolholders have the same advantages. These holders are equipped with a cavity filled with polymer, which works in the same way as hydraulic fluid damping.
Plants should also understand that by choosing a normal, centering tool holder, they can save money without sacrificing accuracy or tool life. These common toolholders have higher precision, concentricity and balance than in the past, making them suitable for more machining processes.
Knife clamp manufacturers recommend the combination of a common tool holder and a centering tool holder, such as a spring collet or a one-piece tool holder and a high-end tool holder such as a thermal expansion or contraction or a hydraulic tool holder. However, the factory usually buys a high-grade toolholder system for an application, and then in order to make up for the high cost of the system, the system has to be used in as many applications as possible, even in some applications. Don't give up. For example, a thermal expansion and contraction tool holder is only advantageous for a very small number of knives in the tool magazine of a machine tool, and it is suspected of being used in all knives in the tool magazine.
Factories often overestimate the actual torque values ​​required for toolholders, often with the psychology of “the higher the better/the tighter the betterâ€. Doing so may result in a higher cost by purchasing a toolholder system that is more expensive than the corresponding processing item.
As an alternative to high-cost hydraulic or thermal expansion and contraction tool holders, a one-piece or one-piece construction tool holder may be the right choice. The accuracy, balance and maximum torque of a single-piece toolholder are between hydraulic and thermal expansion and contraction tool holders, but at a lower cost. These toolholders include a profiled, non-circular inner diameter hole that relies on spring tension in the steel material of the toolholder itself to secure the tool. They work similarly to thermal expansion and contraction tool holders, but do not require heating: the factory only has to attach the tool holder to a compression unit, squeeze the non-circular inner diameter hole into a circle, attach the tool, and then loosen Open the compression unit. The tool holder is constrained around the shank to hold the tool in place.
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