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Advantage Savings in cycle time

 

The cycle time saving for thread machining is 20 – 50% and depends on the operating conditions.

The reduction can be determined by simply changing the CNC program. To do this, reduce the spindle speed by a ratio of 4.412 and increase the feed per revolution. (refer to Kinematics) linked

  1. Measure current thread cycle time
  2. Measure thread cycle time without tool / component with modified program
  3. Increase spindle speed to 2000 rpm (max. Speedsynchro spindle speed = 8824 rpm on threading tool) and record cycle tim
  4. Calculate the savings per component with the ROI calculator

Here is an example of the graphic representation of the cycle time saving for the machining of 15 M6 threads with synchronous and Speedsynchro Modular programming.

Advantage Energy savings

 

The energy consumption of the machine spindle is determined by the acceleration / deceleration to the programmed spindle speed.

The higher the spindle speed, the higher the energy consumption.

By using the Speedsycnhro Modular, the spindle speed is reduced by a factor of 4.412 due to the transmission gear.

This results in a reduction of energy consumption at the machine spindle by up to 90%.

The following diagram shows the energy consumption of the machine spindle during the production of one million M6 threads.

Advantage Reduction of axial force

 

In synchronous thread machining with axially rigid toolholders, it is known that axial forces are generated on the thread tool flanks and lead to increased wear of the threading tools.

To reduce axial forces and tool wear, Emuge has developed Softsynchro tap holders with minimal length compensation.

This technology is also integrated in the Speedsynchro Modular and leads to a reduction of the axial force at the threading tool flanks.

The following diagram shows the process improvement for a rigid spindle M6 thread with Speedsynchro Modular. Link to Tool Details

Advantage Increase in efficiency

 

Using the Speedsynchro Modular significantly reduces the cycle time of the threading process and increases the number of components produced.

On the basis of the machine hour rate, the thread manufacturing costs can be assessed on the basis of tool holder costs, cycle time and energy savings.

For your specific application you can easily calculate the cost reduction based on your application data with the help of a ROI calculator. (linked: advantage cycle time saving)

The following example shows an example for the machining of M6 threads.

ALL ADVANTAGES IN A NUTSHELL

 

  • Reduction of cycle time
  • Reduction of energy consumption
  • Increase of tool life
  • Simple determination of cycle time reduction by simulation of Speedsynchro programming
  • Simple calculation of the ROI based on the hourly rate of the machine
  • Suitable for forming and cutting threading tools in all materials
  • Accurate thread depths as in synchronous machining
  • Low wear in comparison to well-known tapping devices with integrated change of rotation direction, service recommendation 1x per year or every 2 million threads