Toolholders Fuel Setup Time Reduction

印第安纳州印第安纳州格林纳的精密技术（IPT）一直是1988年开始运营自本田美国的精密汽车零部件供应商。在其精密加工产品中，它是本田公民，Quancs和V6体育用途车辆的燃料进气歧管。IPT在工作日24小时内生产4,000个歧管，模具铸造了这些歧管，并完成了所有饰面加工和在内部测试。

The company was looking for a way to reduce its setup time on the diamond reamer used to machine fuel rails in automotive fuel intake manifolds. The fuel rail port through which fuel is injected in these intake manifolds requires a 3.2-micron surface finish to provide accurate fuel flow for top engine performance. Although the machining was achievable, the problem occurred when tool replacement was needed. Accurate tool resetting would take anywhere from an hour and a half to eight hours of trial and error to get the diamond reamer to produce the desired finish. With 28 CNC machining centers, IPT’s volume requirements for the manifolds grew, and tool setup time loomed as a problem.

“We became interested in命令工具系统（Ramsey，Minunsota）新的收缩款式工具持有者技术作为我们的刀具持有人经销商介绍了我们的促进产品的解决方案，“IPT的Rod Humphries说。“David Dolen and Command的代表，Marty Welch，据镜头们认为，由于我们的高度和体积要求，指挥的热锁刀架测试可能会显着减少跳动时间并消除钻石铰刀的繁琐工具设置。”

IPT的持续改进计划需要关于主要设备收购的一年回报。Humphries先生认为，刀架开关可以实现设置时间减少和延长刀具寿命。如果成功，刀架交换机的投资将在IPT为12个月的回报要求内下降。

为了开始进行测试，汉谟先生购买了四种定制BT30热锁刀架，两个保持了85毫米/长的扭转钻头，用于点击燃料轨道和两个以保持160毫米/长度的金刚石铰刀进行整理操作。（扭转钻头内直径为12毫米。钻石铰刀内直径为13毫米。）汉普里斯先生运送扭转钻头和铰刀以命令装入新刀架。这是必要的，因为需要在保持器中正确进行电动加热机。

与传统的刀架不同，该刀架具有用于拧紧的固定螺钉或夹头，加热带收缩器技术的命令热锁刀架以加载和卸载切削工具。他们没有套装或夹头。相反，它们相对于使用的切削工具略微略微尺寸。当放置在特殊的加热装置中时，阀门内直径的鼻子膨胀以接受切削工具。冷却时，保持器鼻子内径缩回到其原始的下尺寸。结果是在保持器/切割工具界面的全长上夹持电力。该收缩拟合方法提供了刀架中的理想总指示器读数水平（TIR）和360度同心抓握电力。要删除该工具，安装过程简单地反转。

收到IPT的扭转钻头和钻石铰刀后，命令将新的BT30刀具持有者放在其中一个感应工具更换器中，使得适当的电源设置选择，发起加热循环并将工具插入指定的长度。在几秒钟内，工具被锁定到位并准备发货。

IPT使用四种不同尺寸的定制Thermolock BT30刀柄在所有班次上六周的测试。重要的工具 - 钻石铰刀 - 以4,300 rpm运行，座位进料速率为每分钟473毫米。

汉弗莱斯先生说:“结果是优秀的. “Using the conventional collet chucks, we averaged 16,500 parts with three holes in each over a 13-day period. With Command ThermoLock toolholders, for the same three-week period, we averaged 92,500 finished parts. We basically tripled our tool life on the diamond reamers. We found the perfect toolholder with the most repeatable machine interface. Both of our tests were done within what we consider a ‘safe zone.’ In other words, we actually change tools before they are dull or fail. We calculate their life based on manufacturer information, previous usage and experience. Then, we backup 15 percent from that. It gives us a ‘safe zone’ so that we don’t damage tools or make scrap unnecessarily. It also allows us to make the tool changeover at a convenient time such as at the end or beginning of a shift.”

According to IPT, the setup time issue became a moot point because the toolholders were set accurately at Command with an induction heating machine. IPT’s operators only needed to load them into the magazine and turn on the switch, and runout was accurate from the beginning. Mr. Humphries says he and his management were satisfied with the test and its cost/payback projections, which they calculated at less than 6 months.