NEW: LaserControl NT detects Micro-wear at the Cutting Edge within Seconds

Safe from Micro-wear

Blum-Novotest, a leading supplier of innovative and high-quality measuring and testing technology, presents at METAV 2010 the LaserControl NT measuring system which has been further developed to monitor tools used in the production of engines and threads. “Micro-wear just in the machining of standard parts result in considerable costs and disrupts the production sequence on a daily basis. Until now it has not been possible to identify this process-related problem in the machining centre. Using LaserControl NT, it is now possible to detect wear contactlessly within the micro range – and in seconds,” emphasise an engineer at Blum-Novotest.

The level of automation in machining production is increasing constantly. To keep the machining time per workpiece as short as possible, many companies use interlinked production lines. However, the machining result is not checked until the end of the line. The consequence of this is that dimensional deviations or poor surface quality caused by micro-wear on the tool cutting edge cannot be detected until a large number of expensive workpieces has been machined. Manufacturers of engines and hydraulic components and companies in the medical field simply had to live with this. Since Blum however introduced a rapid and reliable solution using their LaserControl NT the interest has been great.

In engine production the system is used for example to monitor tools used in the machining of the valve seat blind bores on cylinder heads. Previously a large number of cylinder heads and/or the individual valve seats had to be checked if the post-process measuring machine detected incorrect machining. As the fault was not detected until the end of the production line, many parts had already been machined with the damaged tool. Wear from 5 µm is now detected by the non-contact laser system which scans along the tool cutting edge. If the laser detects a problem, the corresponding cylinder head is automatically discharged and a replacement tool is loaded. Reporting on this issue, a production manager stated that he initially thought the tool simply had to be replaced as a precaution. However, on closer examination he quickly realised that this would bring no improvement on account of the greatly varying service life. After all, the fault occurred sometimes after just 5 machine operations, but then not again until after 5,000 machine operations.

A different type of cutting edge wear occurs during the production of internal threads. If threads are milled into high strength materials such as titanium, the thread milling cutters have a tendency to tooth flank breakage. A breakage which is detected too late may however render many workpieces unusable in series production. Even a post-process examination of the threads is very laborious and can often only be done manually. LaserControl checks for cutting edge breakage along each row of teeth at high speed and thereby automates production considerably. If the system gives it’s OK, the user can be sure that the threads were manufactured correctly. A subsequent inspection of the threads can therefore be dispensed with, which in turn cuts costs.

Despite the harsh working conditions which prevail within a machining centre, the laser system operates absolutely reliably. This is achieved partly by the transmitter and receiver optics which are protected from coolant and swarf by a pneumatically actuated shutter which is sealed during machining. On the other hand, a stream of barrier air ejected during the measurement prevents contamination. Besides, we can now no longer speak of a simple light barrier. Finally, a microprocessor which operates in LaserControl NT reliably masks out interfering factors such as swarf, coolant mist and drop-lets.




Editors´s notes:

Established in 1968 and based in Ravensburg, Germany, Blum-Novotest GmbH is recognized worldwide as a developer of leading-edge measuring and testing technology for international machine tools, aerospace and automotive industries. The family firm has more than 260 employees working in Germany, Great Britain, Italy, France, USA, China, Japan, Taiwan, Singapore and Korea. Together with skilled dealers (due to their technical competence called "system integrators") and regional sales offices they guarantee comprehensive service for thousands of Blum systems applied all over the world.




For further information:
 
Blum-Novotest GmbH
Production Metrology
Postfach 1202
D-88182 Ravensburg
Germany

Tel:  + 49 (0) 751 6008-0
Fax: + 49 (0) 751 6008-156
E-Mail: vk@blum-novotest.com
Web: www.blum-novotest.com