A unique guide pad system eliminate tedious fine tuning. Good in dimension accuracy and roundness in finishing of the valve spool bore in interrupt machining.
- Diamond tool required no adjustments
- Cycle time reduction by one-shot tool
- The integration of rough-finishing process by combination tool
No more need for adjustable PCD’s!
With the unique UM DANDIA™ guide pad system, fine adjustments of the PCD’s are no longer necessary to maintain size and roundness in valve spool bore finishing – not even in interrupted cuts. Our tooling solutions are designed specifically for your application and will allow for firm and constant support throughout the entire bore. Thus, you’ll experience vibration-free machining and extra-round bores. In addition, there is no need for fine PCD adjustments each and everytime you replace a tool.
Effective in machining centers or legacy transfer line environments
Whether you are machining valve bodies in brand-new machining centers or in a legacy transfer lines, UM DANDIA solutions have proven effective for machining smooth and round spool bores. In machining centres, We recommends that the PCD tools be used in conjunction with the UM DANDIA™ adjustable holder to provide one additional level of robustness to the machining process when the spindles begin to loosen. And for the transfer line environment, we will recommend and supply carbide bushings to properly support the tool in the cut.
PCD tools and coolant
Our PCD tools are suitable for traditional coolant and MQL (Minimum Quantity Lubrication). Several complete valvebody lines are running production using MQL and UM DANDIA™ reamers.
WHY COOPERATE WITH KYOCERA UNIMERCO?
The innovative partner
In a very close partnership, we transfer the ideas/new requirements from the market into high performance PCD tooling solutions that benefit our customers in different ways. An example is the MQL solutions which were developed in close cooperation with customers and machine tool builders.
Increased product quality
The unique guide pad system and the very narrow tolerances in the our tools cause less vibrations and thus less friction. Your benefits include better roundness, more accurate coaxiality and a second-to-none surface quality of holes.
Optimised geometries and tool designs made according to the actual application enable the end user to operate the KYOCERA UNIMERCO tools at higher rpm and feed rates. Increased cutting parameters provide a shorter cycle time, reduce friction, increase lifetime and reduce down-time. The result is greatly increased productivity.
Very short delivery time
Why wait more than 12 – 16 weeks on new tools when you can get a tooling solution designed specifically for you much faster from us? And, of course, we are able to make in-house tests, which we document in a report for you. Your tools will be delivered “readyto-use”.
Professional technical back-up
With highly qualified tooling technicians working in close cooperation with the end user, we are ready to help you find the right cutting tools and also the best complete machine environment. In other words, we optimise the tool performance until you get the expected output.
Not only regrinding but “RE•NEW®”
We regrind your tools with the same attention to detail as when we manufacture new tools. Original tool geometries are secured in our RE•NEW® process. We also RE•NEW® other tool brands with very good results – often better than when you received the new tool.
But of course not even KYOCERA UNIMERCO tools can run forever. Due to a unique internally developed norm system and a highly developed drawing database, we are able to continuously deliver cutting tools with the exact same geometries throughout all future deliveries, regardless of the place of production.
OPTIMISATION IN THE AUTOMOTIVE INDUSTRY – SPOOL BORE MACHINING
KYOCERA UNIMERCO has customers who refer to UNIMERCO spool bore tooling solutions as “out-of-the-box performance”. In short, this means that in cases where the machine spindles are in good order, the toolholder assembly can be taken right out of the box and placed on the machine spindle, and the first part produced will be a good part. We supply the toolholder assembly pre-balanced, gauge length preset and with assembly set runout within 0.002mm.
Adjustable holder system
The UNIMERCO adjustable holder provides an effective userfriendly method of dialing in tools. Dialing in tools on a machine spindle becomes necessary when the machine spindle is worn or when the part tolerance is very narrow. The UNIMERCO adjustable holder can be set within a matter of minutes, maintaining 0.002mm or better runout. In the long-term, this will improve tool life and robustness, resulting in consistent part quality.
Life-long traceability of a tool
The UNIMERCO tools/assemblies are delivered in protective wooden boxes with foam surrounding the tools/holders. Additionally, the box contains a measuring report that provides valuable information for the end-user as well as KYOCERA UNIMERCO . We use this information to track tools for quality and rework purposes. For you it provides traceability, thus assuring repeatable performance from the new and renewed tool.
Simple and unique design
The user-friendly UNIMERCO tooling requires a minimum of setting-up for the end user. The tool design results in a consistent quality over the entire life span of the tool.
The tooling is designed with two cutting edges, thus allowing for higher feed per revolution – in turn lower RPM is required for meeting cycle times. Lower RPM is also beneficial to the total life of the spindle.
Depending on the design of the part, clamping, etc., it may be necessary to use a robust process. We consider a robust process one that if certain variations are introduced from castings, coolant, etc., the process will still produce a good part, hence a robust process. The robust process consists of the following:
- Plug drill for core pin flash (optional, MQL and x D dependent)
- Pilot tool – used to create a round target for the start of the semi-finish and finisher
- Plug drill and pilot tool will often be combined in one.
- Semi-finish – removes core diameter stock and leaves necessary stock for finisher to generate final features.
- Finisher – generates finish diameters.
Producing bores in one or two passes
Within UNIMERCO tooling designs, it is possible to produce bores in one or two passes. The following needs to be considered for a two or single pass process:
- The machined feature tolerance
- The cast core prior to machining
- The diameter length ratio of all diameters on the machined feature
- The number of diameters on machined feature
- The rigidity of the part structure
- The rigidity of the fixture
- The type of coolant, wet or MQL.