The Official Toolmex Technical Blog
Insights from the Toolmex Team into our Products, Technology and Industries
To Buy or Not to Buy?
May 18, 2010 — by Chuck Toolmex
The other day Ark Kielb, the President and CEO of Toolmex, asked me if we were selling chucks of what the chuck holds. I paused and thought about what the typical response might be, and then I took the complete opposite tactic, and said, "We are selling what the product holds." Right answer!
Lots of companies sell chucks and tooling products, and everyone will tell you why their products are better, but they never tell you if there is added value to purchasing their workholding and tooling. At toolmex, we offer you a lot. We have a 2-tier testing system, ensuring that our chucks and tooling are quality products. We have a great customer service team, and of course, let's not forget that we have been in business for over 40 years, so we know what we are doing!
By now you must be wondering where this is going. Is this the same old pitch you've heard time and time again? Absolutely not. I want to talk about the benefits and advantages to buying a new chuck versus repairing and/or reconditioning your existing chuck.
We all know that chucks can last for years and years. However, there will be a time, sporadic or not, when a jaw cracks or may be wearing unevenly. This is when you will need to make an informed decision—do you repair, recondition or buy a new chuck?
In all circumstances, safety should be your first priority. Next, decide whether the chuck will be operate for only a short period of time, or whether you expect to get a longer period of trouble-free use. And, most importantly, decide how much the cost difference of repairing and/or reconditioning versus getting a new chuck will affect your purchasing decision. The difference may not be as much as you may expect, and the benefits to ordering a brand new chuck may outweigh it.
Let's look at the reasons why you might need to repair or replace your chuck:
- Does the chuck visibly appear to be worn?
- Has an accident broken something in the chuck?
- Has the chuck begun to lose its gripping force or its accuracy?
- Is the chuck design incapable of holding a part to meet your part process and tolerances?
REPAIRING or RECONDITIONING YOUR CHUCK
Usually, this is the least expensive option and the quickest way to get you back into production. If there is a broken master jaw or a broken jaw activator caused by an accident, then replacing the broken part and cleaning up some damaged surfaces may make the chuck serviceable at very little expense. However, what happens when the broken part is a special part? It may now need to be reverse engineered and manufactured, which is more time-consuming and costly than if you called your local distributor and asked about the best chucks they have to offer. Some chucks today are technologically different than older chucks, and are better engineered with better tolerances.
The repairing procedure may provide a very serviceable chuck, returned almost to its original condition prior to breaking. However, the repaired chuck is still a somewhat worn chuck with a warranty that is typically good only on the replaced parts. A final consideration is that replacement parts may not have the same fit with worn parts, which, in turn, may not provide the best situation for holding parts. You then need to ask yourself what kind of service will you get with the repaired chuck, if any, and if there is someone that you can call and ask for a new chuck to be sent to you overnight as a replacement? Any problems and/or deficiencies inherent to the old design and any desired changes usually require replacement.
REPLACING YOUR CHUCK
Quite often, the cost of reconditioning exceeds 60% of the cost of a new chuck or it's simply time to update and replace it with a newer model chuck. The new chuck will have all the advantages of the latest designs and materials. This is especially beneficial if your operations have changed and you require redesigns to improve performance.
In addition to receiving a full 1-year factory warranty, considerations for selecting new chucks are:
- The need to operate chucks at a higher RPM, which the newer chucks will do unlike their older counterparts.
Today's selection of coated carbide tooling requires much higher speeds and feed than ever before. Current designs take high speed into consideration, using counterweights and counter centrifugal mechanisms.
- The additional travel required in master jaw strokes.
The usual stroke of a standard power chuck is 3/8" per jaw which in most cases is quite substantial. However, with the long stroke chucks, this can be up to 1" per jaw. This permits gripping parts where a flange may have restricted gripping to only a certain area, which may not be the ideal situation. Also, the longer stroke will allow the gripping of more part diameters with the same set of jaws, thus reducing setup time. With automation, the long stroke chuck allows parts to be loaded easily, and also permits chips to escape more effectively.
- The ability to mount locators on chuck facings.
Newer chuck models allow Locators or Locator Bungs to be mounted on the face of the chuck, which provides a stationery repeatable flat surface for the part to locate. Usually the locating face is on the moving top jaw and may yaw when clamping, causing inconsistency from part to part.
Today, in order to stay competitive, many companies have to run "Lights Out" with robots or automation, which requires a great deal of sophistication throughout the whole processing, including the chucking. Monitoring the chucks' actions is critical to preventing a problem which could shut down the process. Feeding air pressure through the locating surface is a common way to detect whether or not a part is located properly. A drop in air pressure signals that the part is not seated properly, and is allowing air to escape. Air may also be fed through the spindle to blow off chips from the mounting surface and part. Today, sensors can be used to indicate clamp/unclamp, part location and clamping pressures.
No matter what you decide, making the right decision—whether you buy new, repair or recondition—is critical, and it is extremely helpful to ask the assistance of a knowledgable vendor for guidance. Naturally, the final decision is yours and must be based on what is functionally and financially the best solution for your individual situation. Each recourse has its place.
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Eliminate Poor Power Supply Performance Issues with Drive Isolating Transformers
May 18, 2010 — by Greg Micinski
Most machine tools in the United States require simple 230-Volt or 460-Volt 3-Phase 60Hz power supply. However, current requirements of power quality, due to electronic devices, are elevated. There are many situations were power quality can deteriorate or suffer distortions, thereby reducing your CNC machine tools with Variable Speed Drive (VSD) performance. Guide standard IEEE 519-1992 was developed to help avoid voltage distortions in power networks since VSD can be both a source of distortion as well as a victim of it. Voltage and current waveform distortion can be corrected using filters and reactors. Drive Isolating Transformers (DIT) can also be installed to help minimize and smooth out distortion and electrical disturbances, allowing users to operate their machine tools for optimal performance. Additionally, DIT separates the machines from power primary source since the transformer's secondary windings are electrically isolated from primary windings.
THE BENEFITS TO INSTALLING DRIVE ISOLATING TRANSFORMERS ARE:
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Call Toolmex at 800-992-4766 or 847-301-3700 to order a Drive Isolating Transformer, and ensure that your machine tools are getting the full advantage of an optimal power supply and quality.
ADD TOOLMEX TO YOUR IMTS OUTLOOK CALENDAR
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Do More.
Faster and Easier with Toolmex TUR Manual Plus CNC Technology
April 12, 2010 — by Greg Micinski
Check out some of the other useful functions available* on Toolmex TUR Manual Plus CNC Lathes:
* NOTE: Toolmex offers a variety of controls to fit your application requirements. Features are not limited to the above, and not all the features listed within this blog are available on all machines or controls. For detailed information, call Toolmex Lathe Sales at 847-301-3700 x120. |
Now more than ever today's competitive plants from machine shops to job shops to toolrooms require technology that makes building parts on the fly easy and affordable. The Manual Plus CNC platforms available for Toolmex TUR-MN lathes help shops do that and more with technology that saves time, is user-friendly and flexible, and provides skilled machinists an easier entrance into CNC machining without requiring extensive G-code knowledge and programming.
Manual Plus CNC technology combines the best of both words—some of the simplicity of Manual lathes and the enhanced productivity and much better accuracy and finish of full CNCs.
For simple Manual machining, the CNC monitor can be used as an intelligent DRO (Digital Readout) showing the lathe operator not only the axes position, but also functional information like feed rate, spindle speed, spindle load, and more. Additionally, thanks to the adjustable feed rate and spindle speed override rotary switches, key cutting parameters can be adjusted on the fly during machining.
TUR-MN Manual Plus CNC technology is also exceptionally conversational with a user-friendly programming editor that is simple to program, operate and learn for non-skilled G-code programming operators. Programs can be built using the Free Contour Programming Editor and/or by using simple cycles (canned cycles) such as turning / boring, taper-cutting, grooving, threading (taper thread cycle combined with thread run-out is a great feature for threading API - oil country threads), center drilling cycles, and more. (See our full line of Indexable Carbide for your machining needs.)
The Free Contour Programming Editor is similar to integrated simplified CAD with interactive graphic assistance that allows the machine operator to create complex profiles faster than using external CAD / CAM systems. Profile corners with a radius or chamfers can be programmed as transitions so no calculations are necessary. If some information (i.e. dimension, angle, etc.) are missing on a part's blueprint, entering known data may allow the programming editor to calculate missing data. When a program is completed, simulation can help operators to verify the missing information or review the program path before the real part is machined.
Find the Toolmex TUR-MN Manual Plus CNC lathe that best fits your needs.
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All Indexable Carbide Inserts Are Not Created Equal
March 11, 2010 — by Mark Frost
As I began to source our new Tooling products for 2010, a lot of things occurred to me about what is happening in our industry today. We cannot be complacent and think that the old way of doing business will work in the 21st Century — companies are savvy, the internet provides information instantaneously, and as a product manager, you have to be aware of what the competition is doing at all times, what new products are on the horizon, and how Toolmex can make a difference.
The industry is changing faster today than ever before. We need to be ready at all times to ensure that the products we are selling to our customers are not only of the best quality but also application driven. Toolmex strongly believes that customer needs should be taken into consideration as part of our long term strategy and with the introduction of the Palbit Carbide products, we have looked at how the market is changing and how we will source products going forward. The Palbit offering from Toolmex was sourced in Europe at the request of our customers. We listened, and the choice is Palbit.
Not all Carbide inserts are created equal or so they say . . . There are those who believe that if you buy Carbide from one manufacturer over the next, that the products are all the same. We believe that there has to be added value to the mix and with the addition of Palbit Indexables to the Toolmex product line, we are not only offering an extremely high quality product, but we are offering products from a company that has been committed to cutting for over 100 years. Toolmex is a company of like mind. We have an onsite QA Lab to test products, a customer service organization who has been trained on all of our products to ensure you get your questions answered immediately, and skilled technical experts in the field for that value add.
As you start to think about what you want to add to your product line, you start to think about what makes a company great and what sets them apart in a crowded field. Palbit is an old line company with its beginning in the 19th Century at which time their core business was mining Copper and Zinc. As a logical extension of the mining process, they began production of mining tools which lead to the new business model of manufacturing cutting tools. Their strategy made sense then and it makes sense now — stick with your core business and develop it over time to address new business models.
As a customer, what can you expect from the Palbit Toolmex relationship? Continued innovative approaches to developing products for Mould and Die, Automotive, Mining, Oil and Gas, Medical, Aerospace and Heavy Equipment industries with reduced lead times, state-of-the-art coating process and CNC controlled pressing systems. Palbit is a company that returns 25% of their profit back into R&D, thereby continually expanding their offering for you.
You can count on us to continue to sell Turning, Milling and Drilling products as well as some specials as we have always done. Your business demands the best and as a Master Distributor, we are committed to listening, responding and delivering your application needs with superior products and service.
Where are the new products made?
All of the Palbit products are made in Portugal. We have been asked by our customers to source from Europe, and we have responded with this new product line. It is in the best interest of our customers to find the best source whether we source in Europe, the Pacific Rim, or the Americas. Toolmex will always source the best products and then test them to ensure they are right for the job.
What will the new products be called?
The new products will be branded Palbit, Exclusively Distributed by Toolmex Corporation.
How will you transition the current product line to the NEW TMX Indexable line?
There will be an overlap of products while we upgrade the current product line. While we are in transition, we will be available to make onsite visits to demonstrate the newer version of the TMX products to ensure that you will not have any down time in transitioning from one product line to another. We want to ensure that you are pleased with the quality as well as support that you will get with the new products. It is in everyone's best interest that we ensure continuity of all of our products.
How long will you stock the current products that you carry?
We plan to stock a full line of TMX Indexables as there is not one supplier that we will rely on. We will continue to augment the Toolmex Carbide line of Indexables from leading suppliers.
Are the new products similar to the previous products specific grades and quality?
In sourcing the new Indexable line of products, the number one criteria is product quality, followed by breadth and depth of the product line which includes grades and application applicability. These new products are a complete redesign to ensure that the quality is superior for your business applications.
What are some of the considerations in choosing the right insert for the job?
A majority of all carbide inserts are coated. Coated inserts should be considered for most applications because of their longer tool life and faster machining. Coating broadens the applications of a specific carbide insert. These coatings are applied in multiple layers and vary in thickness. The main carbide insert and cutting tool coating materials are Titanium Carbide, Titanium Nitride, Aluminum Oxide and Titanium Carbon Nitride. It is important that the right speed and feed combination is used to ensure uniform tool wear and predictable tool life.
Is there a hole in the product line and if so, how will you fill in with missing grades, etc?
We are working hard to make sure there are no holes in the new product line. As we all know, there are no 2 companies that offer a full product line so we will indeed have to source products from various regions around the world.
Where will you source the missing grades?
We have been communicating with other companies in Europe that have fantastic products and one in Asia that have unique products similar to the current offering that we have sold for the past few years.
Will the pricing be comparable to the current TMX products?
The pricing will be comparable to the current product offering.
What will the Distributor discount be for these products?
The Distributor discount will stay the same as the current indexable line.
Has the product been tested?
We tested the product with a number of customers in different territories and industries on a variety of applications.
What were the test results?
If you need results, please cotact us at 800-992-4766 and a Product Manager will respond within 24 hours.
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Everyone's Talking Premium Efficiency, But How Many Are Listening?
February 1, 2010 — by Tomasz Gasiorowski
The more I talk to people about 2010 Premium Efficiency Motor Legislation, the more I am astounded by just how little people know, or, more importantly, understand how the new legislation will impact their business.
Just think about it for one second — in less than a year, the most popular motors you currently sell and/or purchase will be bygones to the past. The new law, which goes into effect on December 19, 2010, will require that ALL general purpose motors as specified in MG 1-2006, Tables 12-12 (see figure 1 for an at-a-glance look) meet premium efficiency requirements. Motor manufacturers and suppliers will no longer be able to produce or import these motors for sale into the United States at 12:01 AM on December 20th.
It might seem scary to think about that at first, but there's also a silver lining on the horizon. Check out the summary below for a few key benefits to going green and get the answers to the most frequently asked questions about premium efficiency motors.
Figure 1 — Motors Affected by the New Premium Efficiency Requirements
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- Yes, premium efficiency motors are more expensive than their EPACT counterparts, but there are also significant savings involved. First, you or your customer may be eligible for incentives or rebate. For example, a new $700 million motor rebate bill was recently introduced in the House of Representatives. The new "Crush for Credit" legislation proposes a $25 / per horsepower rebate for replacing existing motors with NEMA Premium motors as well as a $5 per horsepower rebate for scrapping old motors. That's almost $5000 savings for a 200 HP motor! In addition, many utility companies are still offering rebates. Don't forget to check with your utility company to see what is available.
- We've all heard the green buzz and the question about what else we can do as a country to reduce our energy consumption, but did you know this: Based on DOE data, the new NEMA premium efficient motor program would save 5800 gigawatts of electricity and prevent the release of nearly 80 million metric tons of carbon into the atmosphere over the next ten years alone. That's the equivalent to keeping 16 million cars off the road.
- The more the motor runs, the more savings get put back into your pocket, especially in regions of the country where utility rates are the highest. In industrial applications that require continuous duty, energy efficient motors have the potential to pay for themselves in a few years or sometimes in as little as a few months due to energy savings.
- Over the course of 20 years, energy consumption accounts for approximately 97% of the cost to power a motor (with only 2-3% being the initial cost of the motor). That makes the initial cost of the motor practically insignificant, especially when you consider that energy costs are ongoing and can only get more expensive over time.
When was the law signed?
The law was signed on December 19, 2007 by President Bush and is included in the Energy Independence and Security Act of 2007 (EISA) in public law 140-110. EISA 2007 builds upon the existing EPACT standard.When does the law take effect?
The law goes into effect on December 19, 2010.When will Toolmex offer Premium Efficient motors?
Elektrimax Premium Efficient General Purpose motors from 1-250HP are expected to arrive in Mid-April, 2010. Elektrim Premium Efficient High Performance motors are expected in late 2010.
Can I still buy EPACT motors after December 19, 2010?
Yes, but it depends on the pre-December 19, 2010 availability of your motor supplier. Motor manufacturers and suppliers can still sell through their pre-existing EPACT motor stock. The law siimply doesn't allow any motor manufacturer or supplier to produce or import any new motors into the United States that do not meet applicable premium efficiency requirements where mandated.
Figure 2 —Possible Improvements of EPACT motors to meet Premium motor specifications
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Send to a friend — See Comments (1) — Add a commentWhy are Premium Efficiency motors more expensive than their EPACT counterparts?
Premium Efficiency motors are more expensive than their EPACT counterparts because it requires more and better materials to attain the premium efficiency requirements mandated. Also, premium efficiency motors require a higher quality production process and better components (See Figure 2).What is the energy savings advantage for Premium Efficiency motors versus EPACT?
The energy savings gained from using a premium efficiency motor in place of EPACT varies depending on the motor's duty cycle and energy costs. Motors that run continuously in a high-cost energy market will earn more savings than motors that run sporadically in low-cost energy markets. For your convenience, we have created a simple Excel formatted energy calculator to assist you in determining the energy savings you might expect with Elektrimax Premium Efficiency General Purpose motors.How do I know if a motor is really Premium-Efficient?
You can tell if a motor is premium-efficient by checking the nameplate for notated nominal efficiency and certificate of compliance number: In the case of Elektrimax Premium Efficiency General Purpose motors, the nominal efficiency is notated on the nameplate and meets NEMA Premium Efficiency levels contained in MG 1-2006, Tables 12-12. Certificate of Compliance issued by US Department of Energy certifies that certain basic models of electric motors manufactured or distributed comply with the applicable efficiency requirements contained in federal regulation.How much has the Efficiency improved from EPACT to Premium Efficiency?
The improvement of motor efficiencies from EPACT to Premium varies by motor, from 0.40% to 3%. Generally speaking, smaller HP motors have the biggest increase in efficiency.What about motors not previously covered by EPACT — will they need to meet premium efficiency as well?
General Purpose electric motors not previously covered by EPACT will not need to meet premium efficiency standards. However, they will now be required to meet the energy efficient requirements as defined by NEMA MG 1, Table 12-11. The motors that must now meet the NEMA MG 1, Table 12-11 requirements are: U-Frame, Design C, Close-Coupled Pump motors, Footless motors, VHS motors tested in horizontal configuration, 900 RPM motors, polyphase motors with voltage of no more than 600 volts (other than 230V or 460V) and 201-500 HP Design B motors not previously covered by EPACT.What motors are not covered by EISA 2007?
Motors that are not required to meet EISA 2007standards are Design D, adjustable speed with optimized windings, intermittent duty, integral with gearing or brake where motor cannot be used separately and submersible motors.Are fractional HP and 56C Frame motors included in the new premium efficiency law?
No, the law only pertains to 1-500 HP motors with 3-digit NEMA frame numbers (such as 143T and up) and equivalent IEC frames.Does EISA 2007 require that existing motors in operation be replaced?
No, but you may be eligible for rebates where applicable should you choose to replace motors currently in use with premium efficient motors.How does this affect motors that are export items to locations outside the United States?
EISA premium efficiency requirements do not apply to motors or motors mounted on equipment exported outside of the US. However, the US Department of Energy does require that these motors or their containers be marked as export items. Check with the destination country for their applicable efficiency requirements.