PRECISION CNC GRINDING MACHINES Advantage Through Knowledge Vol. 65

ROTARY TRANSFER GRINDERS ( RTG ) PRODUCE COMPLETE & PARTS 4 TIMES FASTER! FOR THE AUTOMOTIVE, AEROSPACE, MEDICAL & CUTTER INDUSTRY.

ITM Design & Manufacturing Facility 5 Industry Drive Palm Coast, Florida USA 32137 Tel.: 386-446-0500 Fax.: 386-445-5700 FLUTE SERIES | PEEL SERIES | ROTARY SERIES | THREAD SERIES | FILTER SYSTEMS

FEATURE ARTICLE ITM RTG Rotary Transfer Grinder & AFS -8-200 Filtration System Focus: Production of HSS Step CUSTOMER INFORMATION Company Name: Giess & Quanz GmbH (EXACT GmbH & Co.) Contact Name: Mr. Reiner Quanz Address: Ehringhausen 46 a-b Postfach 16012 42859 Remscheid Germany Phone: + 49 (0) 2191.36250-0 Fax: + 49 (0) 2191.36250-16 Email: [email protected] Internet: www.exact.info

Rotary Transfer Grinder Allows German Tool Manufacturer To Reduce Tool Production Costs

How do two medium size manufacturers (one of Cutting Tools and the other CNC Grinding Machines) survive and thrive in a worldwide market place dominated by larger competitors? Answer: Innovation!

Giess & Quanz GmbH has been in business for over 60 years and is a manufacturer of cutting tools such as taps, dies, countersinks, and specialized step drills for thin materials. The company is headquartered in Remscheid, Germany. They have grown steadily over the years and are known for designing and producing innovative cutting tools. Many of their tool designs are patented.

International Tool Machines (ITM) has been in business for over 30 years and designs and manufactures computer controlled grinding machines and oil filtration systems. ITM is headquartered in Palm Coast, Florida USA. They have grown steadily over the years by supplying innovative and productive CNC grinding machines and oil filtration systems to a worldwide customer base. ITM also has many patented machine designs.

Back in the early 1990’s, due to increasing demand for their step drills, Giess & Quanz purchased their first ITM Grinding Machine and AFS-8- 200 ITM Filtration System. The machine was a 5-axis Series UGG Universal Grinder equipped with automatic cnc loading and wheel dressing. The UGG CNC Grinder replaced older less productive, and less flexible, mechanical grinders. STEP WITH PATENTED “EDGE BREAKER”

2 Advantage Through Knowledge FLUTE SERIES | PEEL SERIES | ROTARY SERIES | THREAD SERIES | FILTER SYSTEMS

Rotary Transfer Grinder Allows German Tool Manufacturer To Reduce Tool Production Costs During the 1990’s, Giess & Quanz saw it’s step drill business continue to grow. They continued to introduce new and innovative step drill features such as spiral flutes, and a special burr removal zone called the “edge breaker”. By the late 1990’s they needed to manufacture more step drills than the first ITM grinder could produce, so a second ITM 5-axis grinder was purchased.

By early 2002, Mr. Reiner Quanz, President and owner of Giess & Quanz, was again in need of more step drill production capacity. Once again, he contacted ITM for a solution. This time around, Karl Giebmanns, (the late President of ITM), suggested to Quanz that he consider one of ITM’s Multi Station Grinders for the production of his step drills.

Multi Station Grinding

ITM developed its first Multi Station Grinder in the mid 1990’s for the production of hss twist drills. Since then, the concept has been expanded for the production of a large variety of tools such as hss step drills, medical drills, routers, burrs, carbide twist drills, carbide endmills, and other ground parts.

According to Mr. Giebmanns, “mechanical multi station tool grinders have actually been around for years”. But, according to Mr. Giebmanns, the old multi station grinders “are as big as a house and take too long to set up”. “What was needed was a compact ROTARY TRANSFER GRINDER RTG 6/3 multi station machine that sets up in minutes instead of days”.

A result of this new machine design, with up to 5 grinding stations and loading/unloading at the same time, is a cycle time that only reflects the longest grinding operation plus the time for one tool index from station to station (4 seconds). One machine produces a complete tool, which usually requires three or more conventional machines. This reduces set-up and cycle time as well as operator involvement and tools are produced with the highest level of quality. It also means that the feed rates for the shorter grinding operations can be reduced to match the cycle time for the longest operation, which increases wheel life and tool quality, because finer wheels VIEW INSIDE MACHINE CABINET RTG for Step Drills may be used to achieve higher surface finishes.

ITM Machines are Designed for 24 Hour Production…7 Days a Week 3 FLUTE SERIES | PEEL SERIES | ROTARY SERIES | THREAD SERIES | FILTER SYSTEMS

Rotary Transfer Grinder Allows German Tool Manufacturer To Reduce Tool Production Costs RTG Improves Productivity

After visiting ITM for a demonstration of their Multi Station Grinders, Mr. Quanz ordered a 4-station RTG Rotary Transfer Grinder and an additional ITM AFS-8-200 Filtration System. Before the purchase of the Rotary Transfer Grinder, Giess & Quanz average cycle time to produce a complete hss step drill (p/n ST-BO 6-30) was 5 minutes. With the RTG Rotary Transfer Grinder, they produce the same drill in 1.5 minutes.

The added productivity of the RTG is made possible for a number of reasons. Dividing the operations up to produce a complete tool (load/unload, flute grinding, o.d. step grinding, and point grinding) over four simultaneously operating stations is the largest contributing factor. However, according to Mr. Giebmanns, “high production grinding is not possible without rigid tool support, high pressure coolant, and the correct grinding technology for the application”. The RTG is available with a variety of tool supports depending on the tool to be ground and the operation being performed at each grinding station. For step drill production, the machine is equipped with a programmable bushing support and tailstock at the fluting and o.d. grinding stations. The pointing station is equipped with a programmable full bushing support that follows the vertical movement of the tool as the point geometry is generated. The programmable supports also act as the mounting platform for the wheel dressers. This allows conventional and dressable CBN wheels to be dressed automatically in the machine.

Multi Station Grinding

Clean and temperature controlled coolant, delivered at up to 500 psi pressure, is another key ingredient when producing high quality step drills in the shortest time possible. Many years ago, ITM developed its AFS Series Filtration System to eliminate the problems associated with poor grinding performance do to an inadequate coolant supply. According to Mr. Quanz, “the ITM filter is easy to operate and delivers clean oil at consistent temperature”. Another advantage of the ITM Filtration System is their unique sludge dryer. It removes 99% of the oil from the sludge, returning the grinding oil to the machine and leaving behind a dry “cake” or powder. This is especially important in Germany and other parts of the world AFS-8-200 FILTRATION SYSTEM where disposal is closely regulated. Solving the Space Problem

The RTG Rotary Transfer Grinder was also appealing to Mr. Quanz because of the compact design. The Giess & Quanz factory is located on the side of a hill in a mountainous part of Germany. Centuries ago, many manufacturers chose this area because of its abundant rain fall and rushing streams that could be used for powering grinding

4 Advantage Through Knowledge FLUTE SERIES | PEEL SERIES | ROTARY SERIES | THREAD SERIES | FILTER SYSTEMS

Rotary Transfer Grinder Allows German Tool

Manufacturer To Reduce Tool Production Costs ITM MODELS Solving the Space Problem (Continued..) PPG machines and other equipment. Building a new factory meant that first you had to blast out a terrace in the side of the hill. Expanding a factory can also be a difficult and expensive proposition – one that Giess & Quanz was as their business continued to grow and prosper. However, with the compact footprint of the RTG, they were able to get the additional productivity of three machines into the floor space required for one conventional grinding machine. UFG Another problem related to space also had to be overcome. After making a few measurements of his factory, it became apparent to Mr. Quanz that the RTG was not going to fit through the door! So, since it was not practical to install a larger door, ITM redesigned the machine cabinet making it 8” lower to fit through the existing door.

ITM has been building Multi Station Grinders for over 15 years and has over 180 UFGG Multi Station Grinders installed worldwide. The RTG Rotary Transfer Grinder is the latest addition to their growing family of Multi Station Grinders. According to Mr. Quanz, “We’ve had a long successful relationship with ITM. We’ve been looking for a compact machine that will give us more capacity and help us lower our manufacturing costs. The RTG machine was a natural choice.”

RTG

Building Quality Machines – Since 1981

• Made with Quality Components o From Germany, Japan & USA • Assembly Facility in Palm Coast, FL. USA • Pre-assembly Procedures AFS-8-200 • Assembly Procedures • Machine Calibration • Test Grinding o Pre Acceptance at ITM o Final Run Off at Customer’s Facility

ITM Machines are Designed for 24 Hour Production…7 Days a Week 5

from a variety of industry markets such as precision cutting tools, medical instruments, aerospace components, and the automotive industry. ITM designs the machines, develops software, assembles the components, and installs all the machine electronics at the Palm Coast, Florida 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 Assembly Area ITM since the beginning of the company. By outsourcing these components, we are able to respond For over 30 years, ITM has been producing a variety quickly when large multiple machine orders are of CNC grinding machines for worldwide customers placed and at other times of high demand .

Countersinks/Counterbores Burs / Routers Centerdrills Aerospace & Automotive Parts Endmills

Medical Tools & Parts Drills Dies Taps

Stepdrills Hole Cutters Inserts

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International Tool Machines

ROTARY SERIES INTERNATIONAL TOOL MACHINES ADVANTAGE THROUGH KNOWLEDGE – VOLUME 59, V.1

MULTI- STATIONGRINDER ADVANTAGE THROUGH KNOWLEDGE Rotary Transfer Grinder

The RTG resembles a compact grinding cell consisting of up to 5 precision grinding stations connected by a high speed rotary transfer mechanism! The modular design of the RTG allows us to tailor each machine to the customers specific needs. The following schematic describes the variety of available machine models and the distribution of work stations and load/unload station on the worktable:

Machine Model: ITM holds over 30 patented machine designs.

MACHINE FEATURES MACHINE OPTIONS ° Modular Design of each Workstation ° CNC diamond roll dressers at each ° All stations work simultaneously station ° Part Transfer time 3-4 Seconds ° Automatic Wheel Balancing L/U: Load/Unloading ° CNC Wheel Head Angle Flute 0-90° ° Integrated Blank oversize check W-1: Work Station 1 ° Water-cooled direct drive ° Integrated quality control W-2: Work Station 2 Motorspindles, 50HP, 20HP, 10HP ° Automatic Locating Probe W-3: Work Station 3 with HSK quick change flanges ° Coolant Chambers and high W-4: Work Station 4 ° Reliable FANUC Controls pressure coolant W-5: Work Station 5 ° Inch/Metric switchable ° including wheel scrubbers ° Bushing, V-Block or Tailstock Support ITM HOLDS OVER 30 PATENTED MACHINE DESIGNS. © Copyright 2013, ITM

ITM Machines are Designed for 24 Hour Production…7 Days a Week 7 ITM Machines for your consideration:

FLUTE SERIES | PEEL SERIES | ROTARY SERIES | THREAD SERIES | FILTER SYSTEMS

FLUTE SERIES Universal Flute Grinder Universal Flute & Gunnose Grinder • UFG-25, UFG-50 • UFGG UFG UFGG

4 CNC AXIS UP TO 7 CNC AXIS FLUTE GRINDING WITH STRAIGHT FLUTES, RIGHT AND CONVENTIONAL OR LEFT HAND FLUTES, GUNNOSE SUPERABRASIVE WHEELS & CHAMFER

PEEL SERIES

Chamfer Grinder Form Grinder Peel & Plunge Grinder • PPG-250 & PPG-500 UODG PFG PPG

4 CNC AXES MOTORSPINDLES UP TO 30HP GRIND BETWEEN CENTERS TAPS: CHAMFER WITH OR 2 CHUCKS FOR GRINDING HSS, CARBIDE & STAINLESS W/O RELIEF. COUNTERSINKS BOTH PART ENDS MAINTAINS BLANKS GROUND TO & ROUTERBITS 0.01MM CONCENTRICITY HIGH TOLERANCE

ROTARY SERIES

Rotary Transfer Grinder - Multi Station COMPLETE PRODUCTION OF TOOLS & PARTS IN UP TO 5 STATIONS!

• For Automotive, Aerospace, & Medical Industries • RTG Mini (Production of small tools) • RTG-3/2 & RTG-3/3 (Index Table with 3 ) • RTG-6/3, RTG-6/4 & RTG-6/5 (Index Table with 6 Collets)

THREAD SERIES UP TO 5 CNC AXES WITH MOTORSPINDLES UP TO 20HP

• Taps: Thread and Chamfer in the same clamping • Thread Gages & Form Taps • Bone Screws • Thread Rolls with up to 400 starts • General Thread Grinding with or without relief • Multi-rib or Single-rib Grinding

FILTRATION SYSTEMS

• AFS-8-200 Coolant Filtration System • Cleaning rate per filter dome 200-300 l/min (53-80gpm) • Up to 50 bar (800 psi) coolant pressure • Large Oil Reservoir up to 2000 liters (530 gallons) Advanced 55µµµµFiltration • Stand-Alone Sludge Drying Unit • Integrated Sludge Dryer to Recycle & Prolong Oil Usage 8 Advantage Through Knowledge High Precision & High Production Grinding

International Tool Machines

5 Industry Drive Palm Coast, Florida 32137 USA [email protected] www.itmfl.com

Tel.: (+1) 386-446-0500 Fax: (+1) 386-445-5700