www.anca.com
Press Release - September 2010
Blanket Grinding
New heights of automation
in tool manufacture
Blanket grinding is a new process approach to tool
manufacture where the complete tool manufacture from
blank stock to finished tool is achieved within a single
manufacturing cell. This eliminates the need for separate
sequential machines and processes traditionally required
for the complete tool manufacturing process. This single
setup approach to the entire tool manufacture process
brings with it competitive advantages in production
flexibility, accuracy and bottom line profit.
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2
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Conventional drill manufacture process1
Blanket Grinding process2
5 steps 5 different machines
5 steps using only 1 machine
5 x machine set up and part handling
Bar stock to finished tools in a single setup!
Step 1. Stock cut to length
Step 2. Blank grind (shank chamfer)
Step 3. Blank grind (cone point)
Step 4. Blank grind (step OD sections)
Step 5. Tool grind (flute, OD, Point)
1 Separate machines used for each operation. Blank parting, shank chamfer, cone
point, step OD, tool grind. 2 TXcell wheel packs are fully configured prior to change
over and includes p-axis with arobotec steady, precision multi jaw chuck on TXcell for
blanket grinding
PLUS post process operations
For example: finish polishing / brush hone / customisation /
barcode reading / QA measurement / packing...
www.anca.com
Blanket Grinding on the TXcell directly addresses the pressure points of any tool manufacturer.
Your Pressure Point
Traditional Production Line
Blanket Grinding Process
Reduce inventory and
stock holding costs.
Cost of maintaining stock blanks maintained for
hundreds of different types of catalogue tools.
Stock held in WIP for longer periods of time.
Hundreds of different catalogue tools can be manufactured
from common bar stock. WIP is dramatically reduced and
tools move through your factory more quickly.
Respond to customers
requirement for smaller
order quantities in less
time.
Time to setup sequential machines means a
traditional manufacturing line is not well suited
to manufacture of small batches of tools. Each
machine in the process introduces more delays.
Flexibility of TXcell means setup time between
batches is virtually eliminated. Reduced processing
time from start to finish means faster turn around of
customer order.
Reduce labour costs.
Labour for transfer of parts from one machine to
the next, and setup of each sequential machine.
Parts handling between processes eliminated. Labour for
machine setup between batches dramatically reduced.
Reduce capital and
operating costs.
Multiple machines duplicate costs. Each machine
in the production line consumes capital, power
and floor space. Requires supporting equipment
(coolant systems) and annual maintenance.
Overall the TXcell is a smaller capital investment.
TXcell consumes less power, occupies less floor space
and has just one coolant system.
Increase tool accuracy.
Multiple tool holding between machines
introduces inaccuracy to the tool.
Single chucking for all grinding operations ensures
maximum accuracy and minimal tool runout.
Comparison of Conventional1 and Blanket Grinding2 Process
Tool Type: Carbide Step Drill
Details: 12mm (shank) – 6mm (pilot diameter), overall length 90mm
Actual cost per tool comparison 12mm - 6mm step drill
Conventional
Process
Blanket Grinding
on TXcell
Saving
Cost per tool#
$23.48
$20.41
13%
Total labour time usage (for part
115 minutes
20 minutes
83%
Cumulative processing time for
Batch
499 minutes
328 minutes
34%
Cost of capital (lease)
73 cent/min
43 cent/min
41%
Total floor space occupied
18.5 sq.m.
11.9 sq.m.
36%
handling and machine setting)
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Sequential Machine Process
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Per Tool Cost ($)
20 tool batch comparison of
contributing factors
Blanket Grinding Process
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20
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5
10
20
30
40
Number of Tools in Batch
#Per tool cost comparison considers: Labour costs for part handling & setup time of each machine. Overhead costs of machinery (floor space, power,
maintenance schedule). Cost of capital of machinery and relative utilisation.
Dramatically reduce set
up time from tool to tool
ANCA’s new TXcell with 21 wheel packs, and 4 tool
pallets is ideally set up for Blanket Grinding. Utilising
the power and precision of the TX7+, combined with
the flexibility of a robot for process automation; the
TXcell offers the possibility to perform operations
from blank preparation through to final tool grind and
post process finishing across varying tool diameters
in a single setup.
To find out how Blanket Grinding can address the
pressure points of your manufacturing process
contact your nearest ANCA representative
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