Sharon-Cutwell does cutting tool grinding that combines part features or multiple operations onto a single tool to make a complex job simple.  That's often much more cost effective than other solutions, like five-axis machining or multiple setups.  For example, one customer needed to drill and ream into solid ductile iron, plus create several features within the hole.  He was using four tools and seven operations:  two spotting operations, two drilling operations, two counter-boring operations, plus reaming.  The total cycle time exceeded three minutes, including the automated tool changes.  Sharon-Cutwell designed a single cutting tool that machined all the features in only two operations and cut the total cycle time to 20 seconds!  Even though that tool might be considered "expensive" at about $200 and whether it is about milling, drilling or lathe tool grinding, the cost is far exceeded by the obvious benefits of a ten-fold improvement in cycle time. 

But how do you make complex tools efficiently?

As President Jeff Prom puts it, "the more creative you are and the more you're willing to take risks the sooner you find truly game changing solutions."  But to arrive at creative solutions quickly, especially ones that can actually be implemented in the real world, Sharon-Cutwell uses Walter's Cyber Grinding and Helitronic Tool Studio software for tool grinding machines to design the tool and simulate the grind in 3D so that everything is proved out in a virtual - albeit realistic - world.

The wheel changer is also a game changer

Another key investment has been a Walter Helitronic Vision with automatic wheel changer.  One benefit of the wheel changer has been greater design freedom.  That's because some tools are so complex as to require multiple setups on a two spindle machine - even one with six grinding wheels like a standard Walter Helitronic Vision or Helitronic Power - or only after a difficult setup that figures out how to use each wheel without another wheel interfering with another part of the tool or the machine itself.  The wheel changer liberates the operator from the complications inherent in having multiple wheels on a pack, so it's much easier to do one-chuck setups.  Plus the wheel changer actually results in "a better designed tool because the designer is not worrying about the constraints imposed by one wheel interfering with another."  

For more information on solutions created for lathe and cutting tool grinding machines, contact us. We have what you need to improve your cycle timing without interrupting production.