A battery of Walter Helitronic tool grinders and Walter Helicheck tool measuring machines are playing a key role in the continued success and growth of tooling specialist, OSG UK.
The Basildon (Essex) based company is using its four Helitronics – including the more recently installed Helitronic Vision tool grinder and Helicheck Pro tool inspection machine - to maintain its leading reputation for tool regrinds, primarily of own-brand tools, to a wide customer base throughout the UK, Ireland and Europe.
Importantly, too, the Walter tool regrinding and measuring technology is also helping to ensure OSG’s superlative levels of back-up for its market-leading range of own-brand tooling, in particular its high-precision carbide tools for the aerospace industry.
Based on OSG’s worldwide technical relationship with Walter, the Helitronic Vision tool grinder with robot loader and Helicheck Pro tool measuring machine are the latest additions (installed in 2012) to the UK company’s portfolio, and these form an integrated cell.
The multi-axis Helitronic Vision features a mineral cast machine bed and gantry design, and provides a massive 30 kW of spindle power. Coupled with sophisticated drive technology plus synchronous linear motors for its linear axes and synchronous torque motors for the rotational axes, the machine generates unrivalled grinding times and superior surface finishes.
The machine’s Fanuc LR Mate 200iC/5L robot loader can handle workpieces 250 mm long and weighing 1.5 kgs, and it operates in conjunction with a four-pallet system that provides a storage capability of up to 1,500 workpieces (capacity can be optionally increased to 3,500 workpieces with eight pallets).
This is coupled with the four-axis Helicheck Pro measuring machine which has a repeatability of +/- one micron and a measuring resolution of 0.25 micron. The machine can accommodate tools measuring 200 mm diameter by 300 mm long.
The Vision-Pro cell is used mainly for processing small batches of specials and is linked with the Helicheck for immediate feedback of measurement data and, where appropriate, real-time corrective action.
Supplied by Walter Ewag UK, part of the United Grinding group, these machines sit alongside a Helitronic Power Regrinder and two Helitronic Powers, all fitted with cylindrical pallet loaders able to accommodate 280 tools, depending on diameter.
“The loaders are a big asset,” says Production Manager, Mick Brown. “We can put several different batches of parts on the loader – all we do is instruct the machine where each batch is located and the rest is automatic. It means we can run the machine overnight and therefore make savings.”
Fully utilising the robot/loaders, the Walter machines constantly run unmanned and through the night producing batches of up to 30-off. Around 5,000 tools are reground every month.
“Lots of people can easily go wrong with regrinding, where repeatability is everything,” continues Mr Brown. “It is therefore key that the right machining technology is operated by suitably skilled operators to ensure that the reground tool matches the customers’ demands exactly. Our strength as OSG is that we have access to all our original geometries, which means when we regrind tools we can get back to 100 per cent tool life – at least that is always our aim.
“This is where OSG UK continually scores,” he adds. “Because we successfully combine high-technology machining on the Helitronics with our in-house tooling expertise, we are confident that in many cases our regrinds are even better than many other alternative originals.”
OSG UK’s continual progression – it currently employees 45 people, including two apprentices – also depends heavily on its ability to immediately supply a comprehensive range of cost-effective tooling from an extensive in-house stock.
Indeed, orders for standard tools taken up to 5pm are despatched on the same day. The whole operation is underpinned by a sophisticated ERP system.
The company has also recently acquired PN Tools of Atherstone, Warwickshire, an established manufacturer and regrinder of carbide and HSS tools.
The renamed OSG PN Tools is already investing in its future with Walter Ewag UK via a Walter Helitronic Mini Automation multi-axis tool grinder being ordered at the behest of Tony Cooper, OSG UK’s Sales Director and a Director of OSG PN Tools.
“To meet increasing demand, the new Helitronic will reinforce the quality of PN Tools’ production to customers in industry sectors that include aerospace and automotive,” says Mr Cooper.