Tool wear is undoubtedly a critical factor in series production and the manufacture of large batch sizes. Achieving maximum tool life with maximum precision remains a key challenge. Constant pressure and competitiveness play just as important a role as the complex introduction of automated machining processes in order to benefit from the constant advance of digitalisation.
With BLUM measuring components for a holistic solution - your productivity is what drives us!
- Applications
The challenges of series production in machining require innovative solutions, such as the use of closed-loop systems for process monitoring and the development of new strategies for process optimisation. Below you will find some of our customers' applications and discover how we support the optimisation of machining processes with our pioneering measurement components.
- Production system with 5 five-axis grinding machines and 5 robot cells
- Grinding and polishing of hard-to-grip all-ceramic clasps that are bent in all directions and whose ceramic is difficult to polish
- Z-Nano tool measuring probe measures the thickness of the felt before each polishing cycle, which guarantees automatic replacement of the felt when a certain wear limit is reached
- Measuring probes enable unmanned operation of the 5 grinding machines and polishing robots
- Challenges: Hardened and coated free-cutting steel, threads, bores and four slightly conical slotted holes with a tolerance of 2 µm in parallelism
- Touch probe is scanned over the surface in series production at a measuring speed of 2 m/min
- Used in large series of 10,000 to 30,000 pieces with materials ranging from stainless steels, heat-treatable steels and free-cutting steel to aluminium
- Production of gears with profile cutters in the turning-milling machining centre instead of special gear cutting machines
- Machining errors are recognised in the original set-up, workpieces are reworked immediately and rejects are reduced (closed loop)
- Automated gear measurement in just 13 minutes, eliminating the need for external measurement on a special measuring machine
- Reliable production processes, enormously reduced delivery times
- Double-spindle turning/milling centre (Doosan MX2600) with robot arm enables the necessary automation in production
- After each robot handling process, the BLUM TC62 measuring probe checks the correct position of the workpiece and the dimensions in order to immediately identify and eject faulty blanks
- Touch probe replaces time-consuming cylindrical grinding
- Turning and milling the rotor on the M40 MILLTURN to the final dimension in grinding quality in automated 24/7 operation
- The high measuring accuracy eliminates the need for extremely time-consuming and expensive grinding on cylindrical and profile grinding machines for compressor rotors
- Pre-machining to a few tenths of a millimetre oversize, followed by a complete scan of the milled profile with shape accuracy and concentricity in the original set-up
- Robots and various automation solutions enable autonomous machine times of 18 to 22 hours - without a night shift
- Morning routine: The graphical display of the FormControl X web client shows whether the tolerances have been met - so you can react immediately or continue production straight away
- Not typical series production - batch sizes range from three to ten units, sometimes less than 100 units
- All dimensions with tolerances of less than a tenth of a millimetre are measured automatically, as are shape and position tolerances
What is an automated machining process?
Automate production processes on machine tools with the help of BLUM measurement technology
The automation of a machining process refers to a production sequence in mechanical manufacturing that takes place using digitalised machines, intelligent robots and computer-controlled systems, primarily without manual intervention. In such a process, technology-leading measuring components from BLUM take on the crucial task of autonomously measuring the tool and workpiece within the machine tool, giving the self-controlled machining process the ability to regulate itself. Particularly in the area of series production, the primary goal is to increase efficiency, precision and productivity while minimising costs and human error. An overview of all the benefits of using intelligent measuring components and measuring and automation software from BLUM:
- Creation of an autonomous production process through in-process measurement
- Closed loop through data feedback to the machining centre
- Automated measurement of workpiece and tool without manual intervention by the machine operator
- Elimination of manual external measurement on the measuring machine thanks to precise measurement in the original set-up
- Statistical process control based on the recorded measured values and reworking in the original set-up
