Transcript Multi Station Grinders - ITML

Multi Station Grinders
International Tool Machines of Florida Inc.
5 Industry Drive
Palm Coast, Florida 32176
Tel: 386-446-0500
Fax: 386-445-5700
[email protected]
www.itmfl.com
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ITM Multi Station Grinders
ITM Company History
Mr. Karl H. Giebmanns, the founder and President of ITM, began his
career in 1969 working as a chief designer for a German grinder
manufacturer. He has also worked as plant manager and chief
engineer for a U.S. manufacturer of grinding machines.
Armed with many forward thinking ideas, and eager to design and manufacture his own line of grinding machines,
In 1981 Mr. Giebmanns established ITM in Westport, Connecticut. ITM was founded with the purpose of supplying
application driven, high value, production grinding machines to a worldwide customer base. ITM’s customers have
been primarily well known companies from around the world, which are leaders in the tool & cutter industry, medical
industry, automotive industry and others.
In 1992, ITM moved its design and manufacturing facility to Palm Coast, Florida. The new larger facilities gave the
company room to grow as its customer base continued to expand. The Florida location, with its year round mild
climate, good schools, and low cost of living, provides the employees of ITM with a high standard of living. The
attractive Florida location has also made it easier to recruit new talent from around the world. Palm Coast is located
5 minutes from the Atlantic Ocean and offers numerous recreational activities such as boating, fishing, golf, tennis,
motorcycling, biking trails, hiking, equestrian sports, live shows, and many fine restaurants. ITM is also located less
than 1.5 hours away from three international airports. The city of Palm Coast, Florida provides an excellent base
from which to operate. In fact, the company has seen it’s sales triple since moving to Florida!
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ITM Company History
ITM Recipe for Success
ITM uses a small and effective staff, coupled with aggressive and
focused leadership, to design and manufacture its machines. This
allows us to respond quickly to an ever-changing marketplace and
special customer requirements. Some new machine designs have gone from concept to completion in under three
months. ITM currently holds over 30 patented machine designs. By using a building block concept, in conjunction
with the latest computer technology, machines are easily tailored to the customer’s exact needs. The innovation of
these machines is that 80 percent of their components can be applied universally to a range of tasks, while only 20
percent of the machine must be customized to suit specific tasks. ITM can also develop proprietary machine
designs for customers giving them a distinct advantage over their competitors.
ITM designs the machines, develops software, assembles the components, and installs all the machine electronics
at the Palm Coast facility. The machined and fabricated components are outsourced to carefully selected vendors
in Florida, Connecticut, and Germany. Many of our vendors have been with ITM since the beginning of the
company. By outsourcing these components, we are able to respond quickly when large multiple machine orders
are placed and at other times of high demand.
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ITM Company History
Another key ingredient in ITM’s success is the accumulated grinding
knowledge that has been gained by ITM personnel from diversified
exposure to a large number of industry markets. We believe that the
best grinding machine is no good without the correct grinding technology.
ITM offers turnkey solutions with the most productive and cost effective
grinding wheel technology and coolant systems. In order to overcome the
AFS-8-200 Filtration System
limitations of existing coolant systems, ITM developed its own coolant filtration system.
The correct grinding technology and a consistent coolant supply is one of the keys to producing high quality parts
in the shortest time possible. Including the Multi Station Grinders ITM offers a total of 6 various Production Lines.
A Few Success Stories
ITM was the first grinder manufacturer to develop a machine and automatic grinding process for producing stainless
steel hip broaches used in hip joint replacement surgeries. Prior to purchasing ITM machines in 1985 , the hip
broaches were ground by hand using a labor-intensive process that required 11hours to produce a complete broach.
With the new ITM process, the cycle time was reduced to 20 minutes and part quality was greatly improved!
ITM developed a new machine and process for producing large high quality thread rolls. Prior to the purchase of the
ITM grinders, the customer averaged 20 hours to produce one thread roll. With the ITM grinders, the customer was
able to produce a complete thread roll in 50 minutes!
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ITM Company History
For a manufacturer of carbide drills, ITM built machines for preparing
the carbide drill blanks that, with the use of high speed peel grinding,
reduced the average cycle time to produce a complete blank from
25 minutes to 5! One of ITM’s greatest success stories has been the
development of our ever-expanding line of Multi Station Grinders.
Multi Station Grinders divide up the operations to produce a complete
part over up to 5 grinding stations. The end result is a high quality part at very high rates of production.
The first ITM multi station grinder was developed for the production of HSS drills. One customer who selected ITM
to be the sole supplier of its HSS drill grinding machines purchased 41multi station grinders over a 2-year period.
The machines were purchased because of their small footprint, greatly reduced manpower requirements, and
increased throughput. Throughput is increased by eliminating the scheduling headaches associated with performing
separate operations on multiple stand-alone machines.
A customer who manufacturers carbide drills on an ITM multi station grinder was able to reduce his cycle time to
produce a complete high performance carbide drill from 10 minutes down to 2.5 minutes!
An ITM customer who manufactures HSS routers produces a complete router every 7.5 seconds with their multi
station grinders. This compares to over 60 seconds before the purchase of the ITM multi station grinders!
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ITM Company History
Finally, an ITM customer purchased a multi station grinder to produce
carbide, diamond cut, ball nose routers. ITM worked closely with this
customer to optimize the machine and grinding technology for the
production of these tools. Prior to delivery, the machine ran production
for 3 months at ITM 24 hours a day, 7 days a week “lights out” and
unattended operation overnight and on weekends. The machine is
EMO Trade Show Germany -September 2001
equipped with an automatic system to notify an attendant via telephone
in the event of a machine alarm. With the ITM multi station grinder, a complete part was ground every 72 seconds,
and during the 3 month period a total of 85,000 parts were produced! During the same 3-month period, the
customer’s existing machine could produce a maximum of only 16,500 parts in a two shift five day operation!
Moving Forward
ITM is an application driven company. Our grinding machines are designed to provide our customers with the best
possible solution to their manufacturing challenges. We are experienced at the efficient utilization of our resources
to design and manufacture very forward thinking, cost-effective, and innovative machines. We operate in an
organized way that creates an environment where things get done right the first time. We strive to stay focused on
our goals and achieve them in the most efficient way possible. We are not afraid to question the way things have
been done in the past. By doing these things, we are able to deliver high quality, high value machines to our
customers in a profitable way.
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Overview
Multi Station Grinders
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ITM’s Multi Station Grinders are
production grinding machines for
the manufacturer of HSS and
Carbide Cutting Tools, round
shank and square (carbide inserts).
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The RTG “Rotary Transfer Grinder” resembles a
compact grinding cell consisting of up to 5 precision
grinding stations connected by a high speed rotary
transfer mechanism.
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Benefits of Multi
Station Grinders
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Optimum part per person output ratio
Reduction of cycle times
Increased Uptime
Reduced Changeover/ Set-up time
Reduced Production Scheduling time
Reduced floor space requirements
Reduced wheel cost
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Machine Features
& Specifications
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Up to 5 Grinding stations and
1 Load/Unload station in one
compact machine cabinet (68 sq ft)
Up to 50 HP spindle drives
Integrated dressing at each station (usage of low cost
conventional wheels, CBN and Diamond wheels possible)
Integrated blank oversize check (prevent machine damage
and reduce downtime)
Integrated quality control of critical tool dimensions
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Machine Features
& Specifications
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Easy to use “open structure”
Software, menu driven with graphical support
CNC control with Networking and Internet capability
for Online Monitoring and Support
Large capacity loaders for up to 50 hours of
unattended production
HSK quick-change wheel flanges for reduced
set-up times
ITM Multi Station Grinders
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ITM Multi Station Grinders in Service
As of May 2003 ITM has installed 68 Multi Station
Grinders in the United States and Europe.
Applications include:
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HSS Drills
Stainless Steel Medical Drills
High Performance Carbide Drills
HSS & Carbide Endmills
HSS Drywall & Fiberglass Cutters
HSS Sheet Metal Step Drills
HSS Center Drills
HSS Spade Drills
Diamond Cut Carbide Routers & Burs
ITM Multi Station Grinders
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ITM Reference List
USA
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ALLIED MACHINE & ENG.
AMERICAN SAW
AMERICAN TOOL (Wisconsin)
AMERICAN TOOL (Nebraska)
BALAX
DEPUY
G.K.N.
GREENLEE TOOL
IMPLANT INNOVATIONS
ITW
JASCO TOOLS INC
J.I. MORRIS
JORE CORPORATION
KENNAMETAL NC (Asheboro)
KENNAMETAL NC (Weldon)
KENNAMETAL MA
KENNAMETAL GA
MASTERCUT TOOL CORP
NIAGARA
ONSRUD
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OTHY INC
PFAUTER MAAG
QUINCO
REED RICO
ROBERT BOSCH TOOL CORP.
(Vermont American)
S.G.S.
SOSSNER
TIVOLY INC
TRIUMPH TWIST DRILL
TRW OH
TRW TN
UNION BUTTERFIELD
VITRAMON
WALTER VA
WILSON TOOL
WELDON
ZIMMER
Customer in the state of NY wishes not to be named
Customer in the state of IN wishes not to be named
ITM Multi Station Grinders
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ITM Reference List
Worldwide
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SUTTON TOOLS
DORMER TOOLS SA
INT’L MINICUT
SHANGHAI CUTTING
CESKA ZBROJOVKA
CLOU
JANIN
BOSCH
MAGAFOR
BALTRUSCH U. MUETSCH
AUGUST BECK
BDS MASCHINEN
BUDERUS
EUGEN DUERR
FETTE
GIESS U. QUANZ
IFA
LEITZ
LINIG
PROTOTYP
RUKO
SMAT
TITEX PLUS
WALTER TUE
MILLER CARBIDE
Australia
Brazil
Canada
China
Czech Rep.
Denmark
France
France
France
Germany
Germany
Germany
Germany
Germany
Germany
Germany
Germany
Germany
Germany
Germany
Germany
Germany
Germany
Germany
Germany
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TITEX
ROTHENBERGER
SILMAX
DORMER TOOLS S.P.A.
F.I.U.M.
MASTER TOOLS S.P.A.
VERGNANO
OSG
NACHI
HITACHI
Y.G. 1 TOOL CO. LTD.
CABRE S.A.
IZAR
DORMER TOOLS AB
WEBA
CHARPILLOZ SA
HWA FENG
HO HONG TOOL
MAKINA TAKIM
CLARKSON OSBORN
DORMER TOOLS HOLBROOK
DORMER TOOLS WORKSOP
India
Ireland
Italy
Italy
Italy
Italy
Italy
Japan
Japan
Japan
Korea
Spain
Spain
Sweden
Switzerland
Switzerland
Taiwan
Taiwan
Turkey
United Kingdom
United Kingdom
United Kingdom
As of May 15, 2003: 313 machines in Service
ITM Multi Station Grinders
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Reliability with “Top of the Line”
Machine Components
Control system: GE-Fanuc (Japan)
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Latest control models – currently 16i
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Highest machine tool productivity and best uptime in the Industry
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Average 14 years between failures
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2 year warranty standard, extended maintenance contracts available up to the lifetime of the
machine eliminating any part or labor cost for control components
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Nationwide technical and parts support 24x7 through 1-800-GE-FANUC
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Servo motors are air purged to prevent contamination
Spindles: Fiege (Germany)
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High Performance direct driven watercooled motorspindles with HSK quick-change flanges
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Preloaded bearings with ceramic balls for longest lifetime cycles and highest precision
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Air purge system to protect the spindle from contamination with grinding residue
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Maintenance free lubricated for life
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Automatic monitoring of spindle coolant temperature in control with warning messages
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Spindle components are constantly quality checked during the manufacturing process.
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Final inspection and performance test with protocol for each spindle before shipment
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Reliability with “Top of the Line”
Machine Components
Fully Automatic Central Lubrication System: Vogel (Germany)
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Models are used with Gear Pumps for operation with highest reliability
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The Oil Reservoirs are equipped with float switches. If a switch detects a low level situation a message is
displayed on the control screen to notify the operator.
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A switch monitors the pressure of the central system. If low pressure is detected a warning message is
displayed on the control screen to notify the operator
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Lubrication is automatically controlled by a timer
Linear Rails: THK (Japan)
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Model Type “SHS-SS” with ball retainers designed for longest lifetime cycles with maintenance free operation
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All rails are sized and designed to exceed 30 year lifetime expectancy
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Contamination protected by End-, Side- and Inner Seals
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Positive oil pressure from central lube system inside the shoes guarantees efficient lubrication and supports
contamination protection
Ball Screws: THK (Japan)
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Precision ground, preloaded Type “BIF” for longest accuracy life of screw and nut
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Preload is achieved by CNC ground Nut lead offset instead of conventional oversize ball preload method
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Each screw is connected to the Central lubrication System (maintenance free)
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Bellows are used to protect the screws from grinding residue contaminating the system
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