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The most recent developments have been those created by machine tool builders and control manufacturers to allow simplified programming at the machine, these systems are gaining momentum and others will follow suit in the near future. Recent developments in at-machine and remote (CAM-based) programming solutions have made HDT and Freeturn as simple to use as any other turning technology. While using a single tool to complete multiple turning operations may seem complex, nothing could be further from the truth. Similarly, the same FreeTurn can be used on both main and sub-spindles as the rotation of the spindle, whether clockwise or counter-clockwise is compensated for by positioning the tool above or below the component centreline. Machining efficiency is also improved as by using the axis of the machine milling spindle the approach angle of the FreeTurn can be optimised as, unlike other systems the FreeTurn approach angle can be adjusted, in-cut, ensuring correct chip thickness and maximum metal removal at all times.
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With HDT and FreeTurn fully automated production is created and machine availability is now 24/7. Compare this to the conventional turning tool in a turret, where the machine must be stopped and the operator manually index the insert, more production time lost.
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Each FreeTurn insert has three cutting edges, which can all be used for roughing or finishing, so a simple machine controlled index of the tool presents a fresh cutting edge, without any manual intervention. A further benefit is the elimination of ‘traditional’ sister tools. Therefore, eliminating just two tool changes can greatly reduce cycle times. For example, on some machines, with non-optimised positioning of tools in a chain-type tool change carousel, chip-to-chip times can be as high as 10 seconds when tool changing. This brings significant efficiency gains as time-consuming tool changes are eliminated. Using the milling spindle of these machines, one FreeTurn can achieve the same result as multiple turning tools would have done previously.
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The key benefits of High Dynamic Turning (HDT) and the associated CERATIZIT FreeTurn system of turning tools are well documented, but in brief it allows the full potential of multi-tasking machine tools to be realised.