TOOLING

Preset for productivity

Though not a much discussed technology, the latest tool presetters can bring a multitude of benefits to
a manufacturing business, as Steed Webzell discovers

W hile it is easy for many to suggest

that the days of the tool presetter
are numbered, the number of suppliers
still in the market testifies to the
continuing demand.
Tool presetting is all about saving
time and money. The catalyst for the
development of the first generation of
presetting machines was the
introduction of qualified tooling.
Through greater tool shank/holder
accuracy and the use of precision inserts,
repeatability of location became assured,
and by extension, the dimensions of
tools set off-line became guaranteed.
Industry’s adoption of qualified
tooling prompted the introduction of
what is now a well established principle
of off-line presetting. For many years,
more forward thinking machine shops
have made use of various devices to set
their tools to a known size before loading
them into the machine tool.
The benefits of off-line presetting are
numerous – it negates the need for trial
cuts, slashes scrap levels and releases The Parlec ParleVision
produces a series of images
and answers at the touch of
a button. As well as tool
length and diameter
measurements, operators
can produce insert wear
comparisons, calculate tool
run-out, view instant
geometry displays,
calculate precise geometric
measurements of radii or
angles, produce angle
comparisons and check
arcs

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 TOOLING
valuable production time.
A respected UK market player is
Bowers Metrology, which represents the
Trimos range of presetters. Bowers says
that a company wishing to increase
productivity by the purchase of a further
CNC machine tool, can often gain the
same extra capacity by investing in a
relatively inexpensive presetting
machine.
The latest offering from Trimos uses
advanced embedded technology and a
new vision system. All new Optima
models (pictured) have an integrated
tool management system and a user
friendly digital/graphic control
panel/display interface.
PAYBACK IN MONTHS NOT YEARS
According to Bowers, production cells in
large manufacturing plants benefit
hugely from the implementation of
tool presetting regimes, with
investment payback periods often
measured in months and not years.
Off-line presetting enables
manufacturing cells to operate at peak
efficiency and minimises downtime
with the instant availability of pre-set
tooling as part of a job kit issuing
system, or when used in conjunction
with the application of progressive
philosophies such as Kaizan.
Most presetters, including Optima,
are now capable of sending data from
each of their measuring axes to label
printers, tool management software or
into machine tool control systems.
Aside from the previously cited
benefits, users also report significant
reductions in expenditure on
consumable tooling. This is due to
presetters allowing inserts to be set to a
common diameter, thus ensuring each
insert is sharing the
machining task
equally – significantly
extending their
working life.
So exactly how
much machine
downtime can be saved by
using a tool presetter?
According to Roland Schmidtt,
34
manager at Zoller UK, the answer is 12
per cent per machine per shift.
“Presetting off the machine and
transferring the data results in three
minutes less machine downtime,” he
says. “Based on an average of 20 tool
changes over an eight hour shift, the
total downtime saving equates to 12 per
cent for each machine.”
Zoller’s predominant range of
presetters is the Venturion, which is
suitable to accompany machining
centres or turning centres. Available in
semi or fully automatic variants, the
Venturion comes with a vision system
and an electronic tool management
function.
Venturion is simple to operate
thanks to photo-realistic input prompts
and automatic cutting
edge detection in all
four monitor
quadrants – even with
cutting edge shapes
greater than 90°. Five
measuring results are
obtained at the push of
a button: length,
diameter, radius and
two angles.
Gewefa also has
considerable experience
in the specification,
installation and
maintenance of tool
presetting systems,
representing Parlec in
the UK.
“The compelling argument for off-
the-machine tool setting can be summed
up in two words – productivity and
profitability,” Andy Barnett, Gewefa’s
tool presetting expert explains.
“With the capital investment and
high running costs associated with
today’s highly sophisticated machining
centres, it really does not make sense to
be setting tools on the machine.” He
adds: “Modern presetters such as the
machines in the Parlec TMM series work
quickly to produce highly accurate and
consistent tool measurements that are in
most cases, more accurate than those
achievable on the machine tool.
Remember, a dedicated presetter is just
that – dedicated. So the toolholding and
measuring software has no
compromises and is developed
specifically for the processes of
presetting and tool measurement.
OFF MACHINE PRECISION
“Tasks such as adjusting boring bars,
setting chamfers, examining inserts for
wear or breakage and checking the
accuracy of tool geometry can all be
undertaken far more precisely off the
machine. And while the operator is
performing his checks, the machine tool
is earning money because it is still
cutting metal,” he adds.
As Mr Barnett continues, the
majority of modern presetters now use
digital imaging. “The days of projection
machines are disappearing and state-of-
the-art measuring and inspection
techniques such as the Parlec ParleVision
system can produce a series of images
and answers at the touch of a button.
Using ParleVision, as well as tool length
and diameter measurements, the
operator can produce insert wear
comparisons, calculate tool run-out,
view instant geometry displays, calculate
precise geometric measurements of radii
or angles, produce angle comparisons
and check arcs.
For higher end machine tools where
greater detail is necessary, Mr Barnett
says that the ParleVision system allows
the operator to detect and gauge insert
defects and damage while highlighting
November 2006 www.machinery.co.uk
 TOOLING

measurements.
John Claxton,
On-machine probing sales manager at
Swiss Precision
According to Renishaw, there are typically three reasons Tooling says: “SPT
for using a tool setting probe on machining centres. First is still sees presetting
a requirement to run additional hours unmanned, thereby as a growth area and
increasing return on investment. A probe can be used to continues to improve
detect broken tools, providing a machine tool with and expand the
‘intelligence’ to monitor its own operations. Second, for products on offer for tool
companies with a small number of CNC machines, it is difficult to setting and presetting.” He
justify the capital outlay for a separate presetter. A probe is a low cost adds: “It is true that many machines
alternative. Finally, even where finance is not a problem, presetting still does not have good setting systems built in, but
take account of errors associated with a tool actually mounted in the spindle. the main issue remains – presetters
Renishaw has a range of products that meet the increasing demand for reduce machine downtime.”
affordable probing on new lower cost machine tools and can be easily retrofitted SPT offers Innotool presetters and
to older machines. tool fix systems. The range covers ‘feeler’
The TS27R is a contact tool setter, allowing cost effective tool setting for all and ‘optical’ types. Top of the range
types of machining centres. Tool length and diameter can be accurately machines have computer links that
measured on the machine: static length setting for drills and taps; rotating length provide software for tool management
setting for face mills and other large cutters; and rotating diameter setting for slot encompassing stock control, machine
drills and boring bars. Detection of broken tools, usually on those where breakage data interface, DNC data information
is likely to occur, is possible by measuring length before use then checking again and tooling lists as well as an extensive
afterwards. measuring program with radius angular
The NC4 system allows fast non-contact tool setting and tool breakage and intersecting point calculation.
detection on machines previously unsuitable for such applications. NC4
comprises compact laser tool setting transmitter and receiver units measuring VERSATILE QUALITY CONCEPT
just 30 mm (diameter) x 35 mm (height). Laser checking at working spindle speeds At PCM Tooling UK, the Toolset presetter
identifies errors caused by clamping inconsistencies and radial run-out of the is a versatile quality concept for user
spindle, tool and toolholders – not feasible with static tool setting systems. The friendly, accurate and reliable tool
NC4 also performs broken tool detection ‘on the fly’ – even at maximum rapid measurement. It has a composite granite
traverse – to further minimise out-of-cut time. base, precision glass scales, special
measurement electronics and a large
two-axis display for measurement
insert wear that could adversely affect centring optics and configurable accuracy and operator guidance.
the surface finish on critical software. The new Parlec 1500 tool Two versions are available: indicator
components. This is achieved using the measuring machine claims to be the clock with anti-shock movement and
optional front light inspection system, most thermally stable construction of ceramic measuring insert; and the
which provides 30x live, high resolution any presetter available today. The design optical projector with an angle and
surface inspection of the tool tip. is based on Parlec’s Symmetry concept radius adjustable template and an
Gewefa insists that presetting can and features a ductile iron base and 80 mm 15x magnification with an option
impact on four areas of metal cutting – column. of 110 mm 20x magnification.
milling, turning, systems integration and The 1500 is available with three Capacity is available for 100 different
shrink-fit technology. In milling (z-axis) column heights – 400, 500 and references and there is an editable
applications, measurements can be 600 mm. Another new feature is a high alphanumeric memory. Selections of
taken of drills, endmills, porting and resolution video camera with smart tool adapters are available for 30, 35, 40,
form tools, face and shell mills, taper and camera technology and CMOS digital 45 shanks, HSK and VDI tooling. All
boring tools and chamfer tools. In image sensor. presetters are fitted with parallel
milling, Parlec also supports a range of System integration and automation interface and printer software and can
applications such as HSK, heat shrink and are achieved by an interface to virtually be supplied with a list printer or a label
multi-axis applications. any cell control or FMS system including printer.
Turning applications are suited to the Mazak, Fastems, Walter, TDM, ProCam
Parlec 1500 platform, which combines and Makino Balluff ID systems, as well as Enter 130 at
travel over spindle centre line, tool the post-processing of total offset www.machinery.co.uk/enquiry

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