Abstract Core Tip: Cutting tool manufacturer Shape-MasterTool excels in machining traditional cutting tool materials and complex geometries, but needs to achieve breakthroughs on this basis. As cutting tool materials are constantly evolving and presented for processing...
Core Tip: Cutting tool manufacturer Shape-Master Tool excels in machining traditional cutting tool materials and complex geometries, but needs to make breakthroughs on this basis. As cutting tool materials continue to evolve and place higher demands on machining, grinding machine manufacturers must upgrade, otherwise they may fail in the competition. 
Laser technology not only enhances Shape-Master's productivity, it gives it the ability to handle a variety of difficult materials, but it also allows the company to compete with large tool custom suppliers. Thanks to the production flexibility of laser technology, Shape-Master can process from 50 small individualized processing to thousands of annual recurring plans with high cost-effectiveness under the premise of guaranteeing quality and delivery time. Kind of size tool.
After only a few months of training and hands-on learning, Shape-Master began using laser machines to expand the product range and business scope, including rotary tools. At present, a considerable part of the factory's business is derived from rotary tools, and the factory is planning to continue to expand the product range.
Shape-Master's "EWAG LASER LINE ULTRA" laser machine was purchased from the Joint Grinding Group. The machine uses state-of-the-art ultrashort pulse laser technology to process a wide range of high quality cutting tools with complex geometries in a single setup.
The Laser Touch Machining® laser uses a tangential laser beam process to create the edge and geometry of the cutting tool by shaping the tool surface using the outer edge of the laser beam in a very short pulse of 10 picoseconds. These ultrashort laser pulses will directly evaporate the material without producing significant heat. In the repetitive scanning process, the laser scanning unit moves synchronously with the machine's eight CNC axes to create the tool geometry.
The Shape-Master's two LASER LINE ULTRA laser grinding machines are equipped with automation technology. One of them integrates a 6-axis FANUC robot, a 2-in-1 HSK 63 tool holder and a tray. All equipment can be used for automatic production of rotary tools without interruption in a light-free environment. The machine also automates the mass production of indexable diamond cutting inserts.
Shape-Master's other LASER LINE ULTRA laser grinding machine's magazine system adjusts the height of the tray to double the load capacity. When machining shorter or lower workpieces, the eight pallets move up and the palletizing system can carry up to 300 workpieces per pallet. The flexible, automated nature of the EWAG LASER LINE ULTRA laser grinder is the main factor that Shape-Master decided to adopt.
“We have been using EWAG's grinding machines,†says Dan Chambers, application manager at Shape-Master Tool. “We first introduced the EWAG manual machine, and then added the EWAMATIC LINE CNC grinding machine in the 1990s, and it is still in use today.â€
Chambers said that Shape-Master took some time and is now familiar with the operation and function of the LASER LINE ULTRA laser grinding machine. The equipment supplier provides a one-week training at the EWAG headquarters in Switzerland and a one-week training at the factory. But he added that training is an ongoing process.
“The Joint Grinding Group places great emphasis on training and technical support for its equipment,†says Chamber. “Their customer service and support is very comprehensive and timely. They are always willing to help with any questions and answer any questions. Without their support, my processing plant may not be able to achieve the current results.â€
He added that EWAG has developed software based on their CNC grinding machine kit, which allows users to easily program LASER LINE ULTRA lasers. However, with a variety of shafts and laser heads, LASER LINE ULTRA is more like a machining center than a CNC grinding machine.
At the Shape-Master factory, the LASER LINE ULTRA laser scanning head typically has a step rate of several thousand millimeters per minute. When passing through a tool, the incremental step size can be as small as 0.2 microns. Depending on the complexity of the geometry and the size of the workpiece, the cycle time for laser processing varies from approximately 1 minute to 1 hour. Machining near the cutting edge and edge takes up most of the machining time.
“Laser can process geometry, polishing, and edge processing, all of which are difficult or impossible to achieve with a CNC grinding machine,†explains Chambers. “For example, when machining a cutting edge, conventional grinding will produce sharp edges in the 5 to 10 micron range. By contrast, laser machining produces an edge range of only 1.5 to 5 microns. This edge accuracy can be achieved for us. It is a significant advantage."
ULTRA also processes chamfers and other 3D edge shapes.
Customers can use Shape-Master tools to process parts of a variety of materials, including cast iron, depleted uranium, aluminum alloys, and industrial composites for automotive, aerospace, energy, and other applications.
According to Chambers, Shape-Master also produces tools for the space exploration industry and provides components for the US defense system. He also pointed out that many of the company's aerospace customers use composite and novel materials. Chambers believes that this type of material will continue to enter the automotive industry because, like the aerospace industry, the automotive industry also has the need for light weight and energy savings. Therefore, the advanced tools produced by the factory for customers in the aerospace industry will soon be used in the automotive field.
“We have high quality products and services and excellent staff, and our repeat customers help us to spread word of mouth,†Chambers said. “We have invested heavily in technology, inspection equipment and finishing equipment to meet all of our customers' needs and to provide better products than our competitors. This is what our customers expect and what EWAG machines bring to us. benefit".
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