Savings from the use of tool monitoring

Main potentials

 

Tool cost reduction

Base functions of the Tool Monitor

 

  • Extension of the tool change interval based on the ability to detect wear early.

  • Ability to economically re-sharpening because of timely tool changes.

  • Avoiding of tool breakage.

  • Option of hazard-free experimentation with different tool types and grinding specifications.

  • Ability to use more economical tools as premature tool life ends is indicated as appropriate.

Savings

 

  • 02 - 08%


  • 00 - 05%

  • 00 - 03%

  • 05 - 15%


  • 10 - 20%

 

Increase in use of the machine tool (resulting in the need for fewer machine tools)

 

  • Ability to have unsupervised runs during breaks or production in a semi-supervised 3rd shift.

  • Lower machining cycle time because higher feed rates are possible.

  • Operation with few disturbances through avoidance of breakage and “clearing” on the following stations.

  • Reduction in air cutting: reduction in machining time through the use of higher feed speeds until cutting begins (is especially common for grinding).

  • Gap elimination: Lower machining cycle time because higher feed rates are possible before first cut initiating.

  • Measurement curve display covers premature switchover points from high-speed to working feed speed.

 

  • 02 - 08%


  • 00 - 05%

  • 05 - 15%


  • 10 - 20%



  • 00 - 03%


  • 00 - 07%

 

Avoiding of scrap production and re-touching work

 

  • In-process work piece dimension control with pneumatic measurement probes, a lathe tool or the RST as probes (acoustic contact detection via the slide noise on the rotating work piece).

  • Detection of false dimensions by monitoring different acoustic emission.

  • Improvement in surface quality through detection of chatter.

  • In production tool wear and breakage control with immediate stop.

  • The visualization of the process on the monitor often allows detection of irregularities just by looking at the measurement curve.

 

  • 00 - 05%



  • 00 - 05%

  • 00 - 02%

  • 00 - 02%

  • 00 - 03%

 

Machine cost reduction

 

  • Avoiding of machine fires (when using cutting oil)

  • Protection of the machine when large tools break or during a crash

 

  • 00 - 03%

  • 00 - 03%

 

Avoiding of complaints about sorting out bad parts

 

  • Detection of short pieces due to other process irregularities and sorting them out with control of a scrap gate.

 

  • 00 - 05%