Small tools, big challenges

Customer requests for quicker delivery of microscale specials caused Tom Greene, owner of Greene Tool Systems Inc., Dayton, Ohio, to look for a grinder that could help the toolmaker meet that demand.

The technologies incorporated into the FX7 Linear tool and cutter grinder from ANCA Inc., Wixom, Mich., captured Greene’s attention at IMTS 2014. Already an owner of two larger ANCA machines, Greene said his business is under constant pressure from customers to meet tighter tolerances, and he was receiving a growing number of requests for small-diameter tools.

Previously, the company couldn’t produce tools around 2mm to 3mm (0.079″ to 0.118″) in diameter, Greene said. Now, he added, thanks to the responsiveness of the linear drives and “everything else, we can do drills down to around 0.050″ (1.27mm).”

The grinders’ LinX cylindrical linear motors have no mechanical moving parts, so there’s no loss of machine accuracy over time because of wear, ANCA reported. Being cylindrical, the motor is designed to be fully sealed and impervious to contaminants.

Greene said linear drive technology is “awesome because I don’t need chillers to chill the drives, and the machine’s ability to flute and give us good finishes is incredible.” The drives are “just excellent for a smaller machine. They’re accurate and they’re repeatable.”

In addition, not needing a chiller reduces energy consumption and minimizes any change in the ambient temperature. “One of our challenges with lights-out manufacturing is the change in ambient temperature causing part size changes during loader runs,” Greene said. “It’s not a good day when half of a loader run is scrap because the temperature drastically changed in the plant during the off shift. ANCA’s linear drive system does not generate excessive heat.”

Tom Greene (left), owner of Greene Tool Systems, stands with Plant Manager Steve Mader in front of one of the toolmaker’s two ANCA FX7 Linear tool and cutter grinders. Image courtesy ANCA.