For powRgrip users, any degree of runout is unacceptable. That’s why they chose a toolholding solution with a total indicated runout (TIR) less than or equal to 3 µm at 3xD. But even a tiny chip floating in coolant swarf that has dried onto a toolholder’s taper can create serious issues with the security of the interface between spindle and toolholder. At low spindle speeds, this may not be a problem, but at high speeds, those tiny issues are magnified until they become big issues, resulting in scrapped parts, catastrophic failure or even an accident.
To prevent that, REGO-FIX recommends regular cleaning and maintenance for powRgrip toolholders, which ensures that the holder is properly seated at full taper contact. With holders held and positioned accurately – along with a properly functioning spindle and effective tool geometry – a machine’s full power and tolerance capabilities are safely transferred to cutting tools, reducing runout and vibration for superior part surface finish quality.
REGO-FIX suggest shops adhere to five critical tips that will keep them from running into toolholder runout.
- Shops should clean and inspect toolholders and spindles after every job. The tool and holder should be completely disassembled and cleaned, particularly when using synthetic or semi-synthetic coolants that are prone to leaving behind a sticky surface. An oil-dissolving cleaner can be used to clean any coolant residue from toolholder and spindle surfaces, while automatic power-brushes or ultrasonic cleaning systems will be effective to keep tapers clean.
- Spindle cleaning should take place on a regular basis, as with all planned maintenance. Any issues with spindle performance should be identified and corrected as soon as possible, a process that is much easier with quarterly use of a “ForceCheck” device to ensure that the spindle’s pulling power is still effective.
- In addition to the toolholder and spindle, the tool itself can be responsible for runout. Be sure that you are using the correct type of solid or indexable tool for your milling operation and material type. For new processes, a microscopic system for analyzing tool wear can be key in diagnosing possible issues and ensuring the security of processes by only putting effective tools in the cut.
- If possible, a tool crib manager or designated tooling person should manage toolholder maintenance. As jobs are completed, and tools are returned to the crib, cutters and holders should be completely disassembled and all components cleaned manually or in an ultrasonic system, then reassembled.
- A coat of protective light-penetrating oil is sufficient to prevent rust and contamination of toolholders while in storage, but before using a toolholder or installing them into an automatic tool changing (ATC) system, visually inspect the taper and spindle to ensure they are free of any defects. Professional re-grinding may be necessary to correct defects in the spindle taper socket.