When investing in a CNC machine from a supplier such as DMG MORI, a worldwide leader of machine tools for turning and milling, you’re expecting it to produce high precision, high-value components. To enable it to do this requires high-quality solutions for tool management. “It's very important that if you've invested a large amount into a 5-axis machine, you need to get the tool to perform the best way possible,” says Philip Morris, the Haimer Group’s Regional Sales Manager.

In a cooperative partnership struck up in 2017 between DMG MORI and the tool holding manufacturer, Haimer, the latter acquired DMG MORI’s Microset pre-setting technology, which now operates under the name Haimer Microset. This acquisition complements Haimer’s existing portfolio of high-precision shrinking and balancing technology, enabling it to offer a full tool management solution from shrink fitting and balancing to presetting.

The first is the Power Clamp shrink-fit technology, which comes in a range of machines from a basic model with one shrink-fit station and no cooling to the high-end Premium Plus machine that is equipped with rotary table, integrated contact cooling and system cart. Key to these machines is the patented coil technology in conjunction with the intelligent power electronics.

“On this particular machine, we have a 13kW coil that will heat up the holder to around 350 degrees C in about four seconds. We can then change the tool over, pop it onto the cooling station and cool the holder down in about 30 seconds from 350 degrees C to 30 degrees C, so they're a safe handling temperature,” explains Morris.

However, with all this continued heating and contraction, will it reduce the life of the tool holder? Not at all, according to Morris, who claims that if a Haimer tool holder is used in conjunction with a Haimer machine, many thousands of cycles are possible. Overheating is not possible and the condition of the holder will repeat for many years.

“Quality steel with a yield point of around 550oC is used for the holder whilst the NG coil can reach a temperature of 330 to 350oC, which means we are not taking the material passed its point of elasticity,” he confirms.

The next stage in the tool management solution is the balancing of tool holders and Haimer offers a series of Tool Dynamic balancing machines. High-precision balancing provides for fewer vibrations, reducing wear of the spindle and tool, ultimately leading to a longer-lasting machine tool, and also offers a better surface finish.

“There are three ways to balance the tool. We can either add mass with carefully weighted screws that we add once we go through the cycle of balancing, the machine will then tell us where to put the correct weighted screw in order to bring about a correct balance. Another method that we can use on longer overhangs on tools is using balancing rings. These can withstand rpm of around about 50,000 revolutions per minute and, again, the machine will tell us where to do that. Lastly, we can also take mass away by drilling or milling within the holder,” says Morris.

Once the tool has been shrunk in and balanced, the last stage in the process is tool presetting, carried out by a range of Haimer Microset Tool Pre-setters depending on the customer’s needs, which correctly positions and gathers accurate measurements for the tool in order to put it into the CNC machine as quickly and as accurately as possible. As well as streamlining the user’s tool setting processes, Haimer Microset tool presetting equipment also stands out for its absolute ease of use, uncomplicated software (anybody can use it with very limited training) and stable base construction, which is made of cast iron, not aluminium.

“All of our bodies are made from cast iron, which means that you’ve got a better coefficient of linear expansion as opposed to using two different types of materials. This keeps it in a better condition with changing temperatures in the atmosphere, so we can always maintain and guarantee the highest accuracy levels possible,” says Morris.

Following the use of this collective tool management solution from Haimer, manufacturers will stand to benefit from quality tooling and superb component results. “Using these three items in conjunction with a quality machine like DMG MORI, you can maintain its accuracy of the tool going in, speed of the data going into the machine and also you’re going to protect the spindle and your expensive investment,” concludes Morris.