Abrasive approaches

Mike Raynor got so fed up with the recession, he decided to do something about it – he ordered another Walter Helitronic Power 5-axis CNC tool grinder, from Körber Schleifring UK (01926 485047). The plan of ongoing investment is, he says, to ensure that Raynor Tool Services (01630 655314) maintains its competitive advantage in being able to turn round tool regrinds and manufacture bespoke new tools on short lead times. "We needed to secure our ability to offer a cost-effective, efficient regrind service on a wide range of tools," he continues. "The downturn did mean reduced volumes, but business has picked up – and continues to do so – and we bit the bullet and invested in our future." The choice of machine was never in question, he says. "We installed our first Walter Helitronic Power in 2004, and this machine and the service back-up provided has been excellent. We always knew we would buy another Walter Helitronic, though this time we have increased the spec, with the addition of a Disc Loader. The ability to run the machine automatically, unmanned, will be especially useful for our growing manufacturing business and will enable us to keep costs down. "The plan was to invest in 2008, but we held back, and earlier this year we knew the timing was right." Image: Raynor Tool Service installed its first Walter tool grinder in 2004, another Walter Helitronic Power 5-axis CNC tool grinder has joined it SHORT LEAD TIME Commenting that the initial Walter Helitronic Power enabled the company to competitively manufacture and regrind tools with very short lead times, Mike Raynor points out how the continual success of the company since its establishment in 1981 has been based on the provision of a cost-effective, prompt and professional service. "What sets us apart in particular," he says, "is our ability to regrind and recoat solid carbide drills of up to 20 mm diameter, as well as our willingness to sharpen tools of any style, which means we are working with a wide range of grinding programs." Raynor processes a wide range of tools in solid carbide and HSS, including end mills, face mills, T-slot cutters, ripper cutters and counterboring tools, through to dovetail cutters, spotting drills and taps. Standard tools can be modified to achieve optimum cutting performance through the application of ground ball or corner radii and special surface coatings, and tools can be quickly optimised for machining aluminium, brass and plastics, for example. Many tools that are worn only on the end portion of the flutes can be cut off and have new teeth CNC ground, and worn ball radii can be cut off and renewed. The resulting tools are a little shorter, but of original diameter, and are perfectly serviceable to continue working. Tools that are fully reground are reduced to the next 0.5 mm size down, and all cutters are individually boxed and clearly labelled with their new size, prior to despatch, which eliminates the need for customers to perform inspection tasks, and makes storage clear and easy. On the manufacturing side, Raynor customers frequently require non-standard milling cutters (carbide and HSS in diameters from 4 to 40 mm), for example and, explains Mike Raynor: "We are regularly asked to produce cutters that incorporate, for instance, long and short flutes and shanks, multi-step tools for machining of complex shapes or bores, precision ground ball radii and corner radii. "Some aerospace customers often require tools with flute or shank lengths longer or shorter than commonly available, and the Helitronic Power has been a godsend for this." "We have been more than pleased with our first Walter machine – it helped us take a significant step forward in the market," adds production director Rob Scarlett, who finishes thus. "And we are in no doubt that our latest Walter Helitronic Power will do the same, especially in terms of automated manufacturing." Box item Latest grinding technology developments [] Unveiled earlier in the year, at MACH 2010, was Studer's latest enhancements to its S33 cylindrical grinder. A greater variety of parts can be ground in a single clamping, with a new grinding head having three grinding wheels ensuring that complete machining is a reality. Image: The S33 is also now available with a CNC control with integrated PCFirst published in Machinery, November 2010