Kennametal
Kennametal

SOFTWARE ENHANCEMENTS MAKE WALTER’S TOOL STUDIO EVEN MORE POWERFUL

DMG MORI
SOFTWARE ENHANCEMENTS MAKE WALTER’S TOOL STUDIO EVEN MORE POWERFUL

WALTER EWAG

Lantek Sheet Metal Solutions

SOFTWARE ENHANCEMENTS MAKE WALTER’S TOOL STUDIO EVEN MORE POWERFUL

A range of new tool grinding and probing routines, as well as new Wizards and improved features for faster and easier use, means the latest 2.1 version of the Tool Studio tooling grinding and erosion software available from Walter Ewag UK, a member of the United Grinding Group, offers even more possibilities for highly effective and efficient tool production and regrinding with the Walter Helitronic range of multi-axis tool grinding and erosion machines.


Underpinning Tool Studio’s renowned 3-D live ‘on the screen‘ tool production simulation – which displays an exact representation of the grinding result - and collision checking functionality, the enhanced software includes a raft of developments designed to save time and make life easier for users.


For example, a new Wizard creates an easier way to add and configure corner radii on drills, including approach and ‘lift-off’ options for very smooth blends. Also for drills, a new standard point operation (with conical face polishing) enables the production of more extreme geometries - point angles of 60 to 160 deg, clearance angles from 0 to 16deg and gash angles from 30 to 80deg.


The upgraded software has new Wizards for countersink tools (with fan and axial gash) and for the easier configuration of ‘bullet-nose’ tooling. New smart probing for end mills, where parameters are probed and recorded with no manual input required, is complemented by new functionality for the probing of unequally-indexed coolant holes and for the probing of eccentric runout and compensation of a tool or blank.


In addition, the uprated software has a time-saving feature for defining pocket seat operations and for the advanced simulation of special blanks.


This new functionality complements Tool Studio’s existing capabilities to manage, for example, the integration of machine loading systems and automated worktables, as well as for the production of K-Land on profiles – to add to the powerful Feedrate Optimiser and Tool Balancer options.


The Feedrate Optimiser capitalises on Tool Studio’s intricate knowledge of grinding moves and wheel model as well as tool simulation to calculate instantaneous grinding wheel and machine spindle loads, to precisely set optimum feed rates and to manage wheel and machining loads.


At every point, the feed rates are set using user-specified wheel load and actual wheel load – low wheel load actions are therefore made faster and, importantly, moves that exceed desired wheel loads are slowed down.


The advantages here include increased productivity - in some cases, especially with complicated tools, time savings of 40 per cent or more are possible and grinding costs are therefore reduced – and extended wheel life.


Tool Studio’s Tool Balancer functionality eliminates the headache often encountered when high-speed machining with asymmetric tools such as unequally indexed end mills.


The resulting unbalanced force can, for example, lead to chatter vibrations, gouging, loss of part accuracy and uneven tool wear plus, of course, excessive load on machine bearings. Balanced tools have longer life, produce better quality surfaces and reduce wear on their ‘parent’ machines.


Tool Balancer analyses the mass of the tool directly from the program and applies an automatic balancing.  The Helitronic operator chooses his own balancing strategy, for example lengthening the flute or deepening the core of selected teeth to perfectly balance the tool, without compromising the original cutting geometries – including unequal indexing/helix.  


                                            


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