Case Study: How a tool producer keeps its edge

10% cycle time reduction, 4 times better surface quality

Myles Tool Company, Sanborn, NY, since 1977 has specialized in producing standard and special carbide cutting tools for the aerospace, automotive and medical sectors. A one-stop shop for standard tools, regrinds, and special tools made to customer requirements, Myles has grown by investing in new machines and high quality equipment.

VIDEO

View video supplement looking at how an ANCA MX7 Linear CNC tool grinder helped reduce cycle times. Video courtesy ANCA.

Looking for a way to reduce grinding cycle times and improve cutting tool quality in order to satisfy customer requirements, Myles most recently invested in an ANCA MX7 Linear CNC tool grinder with linear motors. Over the years the company purchased a total of 13 ANCA CNC tool and cutter grinding machines. Seven of these machines are the MX7 model.

Joe Adams, plant manager of the grinding shop at Myles Tool, is very knowledgeable in cutting tool design and production. He knows the process and the machines in detail.

The ANCA MX7 Linear CNC tool and cutter grinder improved flute surface finish from 0.8 R_a to 0.2 R_a. Images courtesy ANCA.

“We were looking for capacity and an ability to produce a polished finish on the flutes of one of our aluminium tools,” Joe said. “The MX7 Linear CNC grinder was delivered a few months ago and has been producing tools of exceptional quality to tight dimensional tolerances without any problems since its first day of operation. Normally, I prefer not to buy first-generation machines, but after talking to ANCA and seeing the machine in operation, I was confident it would grind to the finishes I was looking for.”

Asked about any differences he has noted between the MX7 ballscrew and linear motor machine, Joe commented, “When using the same grinding wheels, tool file, feeds and speeds, the surface finish is better on a tool ground on the MX7 Linear when compared to the tools ground on an MX7 ballscrew machine.”

Joe believes the MX7 Linear machine is superior to a machine driven by a ballscrew, “because you do not have to deal with wear, backlash and the transition is smoother. Ball screw wear is a big factor to us because we run a 24/7 operation. We cannot have any failures or unacceptable parts.”

The flute face from a tool ground on the MX7 ballscrew machine can be as low as 0.8 R_a (roughness average), but the flute face measured on a tool ground on the MX7 Linear measures even lower at 0.2 R_a.

“We are seeing much better finishes with the linear motor machine than we could achieve with the ball screw machines, especially for our aluminium tools,” Joe said. The product is an end mill range with variable helix and variable index, two- and three-flute. Joe added a secondary fluting operation to polish the flutes for improved chip flow using an 800-grit wheel.

Range of carbide tools by Myles Tool.

This final grinding pass, although an added move, adds no time to the cycle.