05.02.2020

Makeover for forming tools

Heavy metal becomes the perfect forming tool with Haas Multigrind® software. 

Forming tools: Best future prospects with technology from Haas Schleifmaschinen

A forming process is basically the brute use of force. The tool is pressed with massive force into the starting material until it yields to the desired profile. Physically, there is a lot to be done. Forming tools are subject to strong dynamic stress and are subject to high wear at certain neuralgic points. If it is possible to significantly minimize wear and extend tool life, this has a direct impact on the unit costs.

Really Heavy Metal: Forming tools are expensive, often made of hard metal. Carbide grinding is already the first choice today, as customer requirements have increased and continue to increase in terms of complexity, dimensional accuracy and reproducibility. In addition, production must also be much more economical.

An ideal task for the inventors from the Black Forest to develop something groundbreaking with Haas technology.

Hightech for high-performance: allrounder Multigrind® CA

Haas Technology 1 - The Multigrind® CA: a grinding machine that stands the test of time

The Multicube design principle gives the machine maximum rigidity, stability and accuracy, which is essential for machining precision forming tools. All guides are symmetrically aligned and their supports are partially cast into the mineral casting bed. Force overhangs, vibrations and expansions, which can have a negative effect on the grinding process, are reduced to a minimum. This and much more enables an enormous spindle power of an impressive 30 KW and thus high cutting capacities can be achieved. 

Everything is possible: producing contours, grinding squares, interpolating run-out, aligning surface, tip radius and chamfer grinding - even complex forming tools can be machined in just one clamping in the familiar Haas precision. For very long workpieces, a tailstock ensures vibration-free machining; if necessary, a steady rest provides support. The Multigrind® CA, the heart of high-precision, repeatable and economical results.

Haas Technologie 2 - Multigrind® Styx: A visualization tool that shows the way

Multigrind® Styx is the first visualization software to show the final grinding result. All grinding processes and the workpiece data are displayed with pixel accuracy. Errors are detected early and easily corrected by the operator. Multigrind® Styx is an integrated, cloud-based component and an ideal supplement to the proven Multigrind® Horizon user interface. More power, more efficiency with less computing power. New, brilliant and productive. Save even more time and money before the grinding operation starts.

Haas Technology 3: A software that thinks ahead and takes control

Our proprietary development, the Multigrind® Horizon software, is the most important component in the grinding machine. It thinks along with you instead of prescribing and makes a Multigrind® grinding machine your individual specialist. As a forming tool manufacturer, you benefit directly from the maximum flexibility, endless possibilities and outstanding precision. For example, different forming tools, such as punches, can be processed chaotically in one job. The orders are programmed into the web shop and processed in line with the Industry 4.0 standard. Thanks to individual combination and parameterization, you will be able to produce exactly the forming tool you currently need - faster and more precisely than before. No matter how often a grinding process is repeated, the result always remains within the tolerance range. Even if general conditions change, e.g. due to temperature fluctuations. Because software, workpiece and machine are in constant dialogue with each other, deviations on the abrasive are brought back into shape in good time. The "Closed Loop Process" enables highest precision in series up to batch size 1. In short: The Multigrind® Horizon software increases and sustainably secures the product quality of forming tools.

 

Simply book automation, we have already thought out your strategy

Haas Technology 4: An integrated measurement process that never loses sight of the target value

Outstanding grinding performance in the manufacture of forming tools cannot be achieved without sophisticated measuring technology. Maximum accuracy in the µm range can only be achieved if all requirements are coordinated in a collaborative process. The combination of high-precision measuring technology and intelligent software takes place in a "closed loop". The compensation measurement on the reference surface of the workpiece is carried out via the sensitive touch probe. The measuring machine imports real data and measurement results into the Multigrind® Horizon software, which processes the data ultra-fast. The results of the continuous compensation measurement of the workpieces are thus used for the automatic fine correction of the grinding track and implemented precisely. Even the slightest deviations from the nominal profile of the forming tool are detected and compensated to the nearest µm. The quality remains constant and error-free, from the first to the hundredth workpiece.

 

Haas Technology 5: With Haas automation strategies the future is under control.

With the intelligent Multigrind® Horizon software, automation becomes controllable and the future becomes part of the present. Once the pallets are loaded, the robot, precisely controlled by the Multigrind® control software, takes over loading and unloading fully automatically. Meanwhile, the Multigrind® CA competes with the external robot unit. If the precision clamping device has to be changed, this is done at record-breaking speed. All the necessary contour-accurate grinding and cutting tools are available in the tool magazine, so that they can be changed in no time at all. If the integrated tool changer is not sufficient, the large tool magazine is used. With up to 70 grinding wheels with 250 mm diameter and 20 coolant protection devices, you can grind everything that is currently in demand. With both solutions you are fit for productive unmanned operation. Precision in the µm range and an increase in productivity that makes the investment pay off in a flash. Maximum flexibility with which you can safely plan your future, no matter which tools are currently in demand. Just in time production without expensive warehousing becomes an economical alternative.

 

Conclusion on the Haas technology: More precise, faster, more economical and more flexible.

Convince yourself of the new production strategy for forming tools. The Haas application engineers will configure a complete turnkey solution exactly according to your current requirements and will also take your future ideas into account.

You can make an appointment via our Homepage. 

The author

Zita Bader

Zita Bader works in the marketing and communication department of Adelbert Haas GmbH.

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