In our first blog for our “What It Is and Why It Matters” series, we went over the fundamentals of total indicator runout (TIR), vibration damping and concentricity, which are three essential factors that define machining precision.
For our second installment, we took a closer look at how you can build on the same fundamentals to deliver exceptional rigidity and reduced runout with the unmatched clamping force of REGO-FIX’s powRgrip® tooholding system.
This third blog addresses the use of REGO-FIX toolVibe® sensors and toolholders to measure and analyze the vibrations generated during metalcutting operations. When machining parts with tight tolerances, shops that monitor and mitigate vibration before it causes problems reduce scrap while saving time and material costs. All of which helps maintain part profitably. The toolVibe® system gives these shops one of the most effective ways for tracking and managing vibration at the toolholder level.
| What It Is | Why It Matters | |
|
Vibration Monitoring |
Vibration monitoring systems use sensors such as accelerometers to measure vibrations in a machine tool, tracking both the frequency (how often the machine component vibrates back and forth over a given measurement of time) and amplitude (the distance the component moves, often measured in micrometers). Vibration sensors install on the machine tool or on individual components, like toolholders. |
Excessive vibration leads to poor part surface finishes and increased tool wear. When shops can measure and determine the levels of vibration, they can narrow down the most effective approaches for mitigating or eliminating the problem. Additionally, installing vibration sensors on specific components like the toolholder allow for root cause analysis to determine the exact source of excessive vibration, such as from a malfunctioning machine tool spindle. |
|
Smart toolholders |
Smart toolholders include vibration sensors and data-sharing technology such as Bluetooth to provide shop managers with real-time data on the health of the tooling system. |
Sensors in toolholders let shops precisely measure vibration levels in tooling and where the cutting tool meets the workpiece. Additionally, smart toolholders warn of impending spindle issues so that shops can perform maintenance or repairs before a catastrophic breakdown to prevent scrap and rework as well as unplanned downtime. |
How REGO-FIX Vibration Monitoring Works
toolVibe® Monitoring Technology
The REGO-FIX toolVibe® vibration sensor mounts can be included in the toolholder or standalone sensor that mounts using magnets or a pair of M5 screws. Once installed or mounted, the sensor provides precise measurements from a position close to the cutting zone. the toolholder is as close to the cutting zone as you get, while the standalone sensor can provide reference vibration in the fixturing, spindle or even the part.
The system’s toolVibe® Set interface then allows users to not only analyze the vibrations generated during a single process, but also look at trends over a longer period to identify maintenance issues before they become major problems. This is especially helpful in monitoring spindle health, as increases in vibrations in the toolholder can indicate problems in the spindle. Shops can also set vibration parameters with alarms to alert operators when the vibrations’ amplitude exceeds acceptable limits.
The toolVibe® smart toolholder option incorporates the vibration sensor directly into the body of one of REGO-FIX’s high-performance ER-collet or powRgrip toolholders. These toolholders come in all common spindle interfaces, including SK+, BT+, CAT+, HSK-A, HSK-E and CAPTO. All toolVibe® toolholders are fine-balanced to suit high-precision machining, and they include through-coolant plumbing capable of handling up to 60 bars of pressure, ensuring that the inclusion of monitoring sensors does not come at the cost of quality machining capabilities.
High-Precision Industries
Machine shops supplying high-precision industries like aerospace and medical face tight tolerances, complex part features, and often tough materials. For these shops, vibrations that would go unnoticed on less demanding jobs can lead to scrapped parts, frequent rework and reduced throughput. This is why vibration monitoring – especially near the spindle and cutting tool – is essential. REGO-FIX’s toolVibe® monitoring solutions allow shops to easily and effectively track vibration both in real-time and over a long periods to stay abreast of developing problems without sacrificing the clamping force, balance or coolant needed to machine challenging parts.
Learn more about our toolVibe® product portfolio, here.