Click here to watch Tutorial Videos >

B@LANCE+DOCTOR

The B@LANCE+DOCTOR from HAIMER offers a range of balancing services for many tools related to the manufacturing industry, particularly as it is related to CNC machine tools. Many of the tools that the B@LANCE+DOCTOR can service include toolholder assemblies, cutting tools (endmills, face mills, boring heads, special tools, indexable cutters, modular cutting tools, etc.), grinding wheels and grinding wheel packs, to name a few. In some cases, actual parts can be inspected at the B@LANCE+DOCTOR in order to see what condition parts-such as those for machines like bearing rings, journals, spindles, chucks, fixtures and gears-are in. The B@LANCE+DOCTOR utilizes the dynamic balancing machine from HAIMER to inspect the condition of the tool or part to be balanced and identify the position of unbalance. Then, as a service, the B@LANCE+DOCTOR from HAIMER can make a correction on the tool or part being-inspected in order to help ensure a consistent and reliable production at the end user.

"Sometimes, balancing is a necessary callout on a print of a particular part," said a company spokesperson. "However, in many cases, it is something often misunderstood. At the B@LANCE+DOCTOR, we help answer the common questions about the importance of balancing, especially those related to toolholder assemblies."

1) Longer Cutting Tool and Insert Life of Cutting Tools

On average, balanced toolholder assemblies net 15-25% more tool life than unbalanced assemblies do. In cases where balance is particularly poor (face mills, boring tools, form tools and Weldon flat tooling), 50-100% tool life improvements are not uncommon.

Example: If you spend $100,000 per year and are running unbalanced assemblies, you may be throwing away $25,000 every year!

2) Enable Higher Metal Removal Rates

The fact is that unbalanced tooling creates vibration, often unnoticeable, that leads to any number of issues, including poor finish, poor sound and unacceptable tool life via premature chipping or tool breakage. The most common solution to these problems is a reduction in cutting speed, feed or depth of cut, all of which decrease productivity.

With balanced assemblies, these sacrifices in productivity become unnecessary, allowing you to realize the true potential of your machine and cutting tool assembly!

3) Reduce Spindle Wear on The Machine

The same forces that create vibration affecting machining performance are also having a negative impact on the spindle bearings of your machine. The relationship between speed and spindle forces is exponential, meaning if you are unbalanced and double your RPM, the amount of force placed on your spindle bearing quadruples. In high-speed applications, unbalanced tools can cause a spindle to fail in a matter of months or even weeks!

This is why all leading machine tool builders recommend all tool holder assemblies be balanced to the ISO1940-1 standard of G2.5 at the maximum spindle speed of the machine tool.

Protect your investment and avoid the incredible cost of unplanned machine downtime.

4) Increase part accuracy

We all know that runout of cutting tools impacts dimensional accuracy of the finished part. However, did you know that at higher speeds, unbalance induces runout where none was measured statically?

You do not necessarily have to reduce your speeds (and productivity) to get the accuracy you need. Instead, try balancing the full assembly to improve dimensional stability.

5) Ensure a Better Surface Finish

Unbalanced tooling generates vibration that causes chatter, which is a killer when it comes to achieving the finest part surface finishes. Do not let harmonics and chatter slow you down via slower speeds or secondary polishing operations!

6) Less Variability

Lights-out machining, Industry 4.0, automation-all rely on the fundamental ability to perform machining operations with the utmost repeatability. No unplanned tool changes, no machine crashes or failures, no part deviations (scrap), no variance.

Simply put, running balanced tool assemblies eliminates a maze of problems that often occur during machining processes that are otherwise untraceable to the root cause (unbalance). Integrate balance into your process, and you will eliminate a host of other issues that just seem to keep coming back.

There are many myths about the topic of balance, but the truth is balance matters at any speed. Even though we may not hear or see the residual effects of unbalance, they are still there. Be it more wear on spindle bearings, faster edge wear on cutting tools, or unexplained failures during machining.the impacts of unbalance are always present in one shape or form.

You balance your car tires, right? Why would you not do the same with your toolholder assemblies?

B@LANCE+DOCTOR can often balance your tooling assemblies tighter than the G2.5 standard designates when finish, part accuracy or tool life are absolutely critical!

Contact the B@LANCE+DOCTOR from HAIMER to see how we can help increase your productivity and assure a reliable, consistent machining in your shop.

Authored by HAIMER USA

For more information contact:

HAIMER USA

134 E Hill Street

Villa Park, IL 60181

630-833-1500

haimer@haimer-usa.com

www.haimer-usa.com

< back