Software Plug-ins Enhance Tool Grinding Tasks

Walter has introduced version 1.9 of its Helitronic Tool Studio grinding software, offering new solutions for the production and regrinding of tools on Helitronic grinding machines. These include new features for drills and fluting, new operations such as K-land on profile and wheel dressing, and six new operations to increase flexibility. With the Tool Balancer and Feedrate Optimiser plug-ins, Walter said it is able to offer performance-enhancing software solutions.

Feedrate Optimiser uses Tool Studio's knowledge of grinding moves, wheel model and the tool simulation model to calculate the instantaneous wheel load and machine load, to precisely set the optimum feedrate at any given point in time. At every point, the feedrates are set based on user-specified wheel load and the actual wheel load. Moves with low wheel load are sped up and, importantly, moves that exceed the desired wheel load are slowed down.

For complicated tools, savings of 40 per cent and more are possible, according to Walter. Asymmetric cutting tools, such as unequally indexed end mills, have many desirable properties; however, they pose certain disadvantages at high rev/min. An unbalance force develops and leads to chatter vibrations, gouging, loss of part accuracy, uneven wear of the cutting tool and excessive load on machine bearings.

Walter said Tool Balancer resolves these problems. The tool is automatically varied until it is balanced and key aspects of the tool's geometry (unequal indexing/helix, and so on) are preserved. For instance, the flute length at the back can be changed without affecting the rest of the tool. Balanced tools have longer lifetimes, produce better quality surfaces and reduce wear on milling machines.

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