Cutting Tool Engineering
April 2011 / Volume 63 / Issue 4

Gold is the metal; The thinking factory

By Alan Richter, Editor

Increasing the material-removal rate to reduce cycle time using lower horsepower while imparting the specified surface finish is the goal when turning. To achieve that, Ingersoll Cutting Tools introduced the Gold-Duty family of CNMX and SNMX double-sided turning inserts.

The aggressive HB chipbreaker on the inserts lowers cutting forces and therefore lowers a machine’s horsepower requirement, the company reports. The chipbreaker also provides finer finishes when medium to rough turning compared to equivalent CNMG and SNMG inserts. The toolmaker says the new inserts offer performance comparable to single-sided CNMM and SNMM inserts, but with the double-sided economy advantage.

HB Chipbreaker.tif
Gold Duty-2.tif
Courtesy of Ingersoll Cutting Tools

Ingersoll’s new Gold-Duty double-sided insert for medium to rough turning is securely clamped with the toolmaker’s hook lever (bottom).

For example, when test cutting a 4.0 " length of 25 "-long, 0.45 percent carbon steel at 500 sfm, 0.040 ipr and a 0.200 " DOC, Ingersoll’s CNMX 553 HB insert imparted a 8.8µm Ra finish compared to 9.0µm Ra for a competitor’s double-sided CNMG 543 insert and 9.7µm Ra for a competitor’s single-sided CNMM 543 insert.

Instead of having a flat bottom to maximize seating rigidity, Gold-Duty inserts have four resting pads on their concave sides that enable even a used side to be raised above the convex mating seat yet stably contact it, explained Ed Woksa, marketing manager for turning and holemaking products. That further lowers cutting forces and enhances chip flow at the recommended DOC from 0.060 " to 0.315 ".

Woksa added that a hook lever clamping system enhances seating rigidity in the insert’s new H-type holder by exerting a double-clamping force. In contrast, a conventional lever design on a P-type holder pushes the insert in one direction back into the two seating walls. “We’re getting multidirectional clamping force,” he said. “That’s going to be 30 percent stronger than the typical lever lock.”

According to the company, the hook lever clamping system eliminates the need for top clamps, which often wear out because of chip wash.

For more information, contact Ingersoll Cutting Tools, Rockford, Ill., by calling (815) 387-6600 or visiting www.ingersoll-imc.com.

With the integration of cognition sensor networks and computer algorithms, machine tools are entering the virtual world. Within that world, Munich Technical University’s Institute for Machine Tools and Industrial Management is conducting research within the framework of CoTeSys (Cognition for Technical Systems), which is funded by the German Research Foundation. “We aim to use the tripartite requirement of ‘detect, deduce, deliver’ to make machines more proactively autonomous than they used to be,” said professor Gunther Reinhart, director of the institute.

He noted that Cognitive Technical Systems differ from other technical systems in that they perform cognitive control, which includes reflexive and habitual behavior in accordance with long-term intentions. “Cognitive capabilities such as perception, reasoning, learning and planning turn technical systems into ones that ‘know what they are doing,’ ” Reinhart said.

Virtualcooperation.tif
Courtesy of CoTeSys/Kurt Fuchs

Within the CoTeSys framework, virtual cooperation enables a robot and human to simultaneously work on the same workpiece.

To move the research from the “ivory tower” down to earth, the university developed the Cognitive Factory demonstration platform—a factory that thinks for itself. Researchers from multiple disciplines, including mechanical and electrical engineering, informatics and psychology, are working on the project, located at the university.

“The related project CogMaSh (Cognitive Machine Shop) aims at using cognitive capabilities to achieve a balance between flexibility, performance and cost-effectiveness by transforming machines and processes into cognitive ones,” Reinhart said. “As a basis for validation, a flexible manufacturing system is used as a demonstration platform.”

The FMS includes machine tools, assembly robots, a quality assurance area, a storage facility, a pallet transportation system, depth and infrared cameras and sensor networks with radio frequency identification systems. The RFID technology collects real-time data from machines and other shop equipment. The information, such as quality-related data, is measured by external devices, such as a laser scanner, or integrated sensor elements on an RFID transponder, such as a strain gage or temperature sensor, Reinhart explained. “Therefore, RFID provides the basis for a precise image of the real world,” he said. “By combining workpieces with RFID transponders, they become smart products that are enabled to share information with the planning level and other resources on the shop floor through a respective communication infrastructure. Smart products are therefore able to actively influence their way throughout the shop floor.”

For example, a workpiece “asks” machine tool No. 2, “Can you drill a 50mm-dia. hole in the required amount of time or shall I take myself to another machine?” If the machine says “yes,” then the workpiece uses the information on the transponder to book a “factory taxi” and says to the transport system, “Please take me to machine No. 2.”

For more information, contact the Institute for Machine Tools and Industrial Management, Munich, Germany, at +49-89-289-15500 or www.iwb.tum.de. CTE

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