Tool Management

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TOOL MANAGEMENT

By – Avinash V. Kale
Roll no. - 153556

TOOL MANAGEMENT
Tool management is required to provide the right
tool to the right place at the right time
 Management and co-ordination of the wide
variety of cutting tools is possible with the help of
proper tool management system
 Tool management take care of following elements


 Replacement
 tool

of tool

storage
 tool life monitoring
 reconditioning and present condition
 broken tool detection and other factors

AREAS OF TOOL MANAGEMENT
Tool room service
 Tool Delivery
 Tool Allocation and Data Flow
 Fault Sensing
 Mass Exchange
 Tool Sharing
 Tool Migration
 Assigned tools
 Tool preset identification and data transfer
 Tool monitoring and fault detection


TOOL ROOM SERVICE
Dealing principally with preparing, servicing,
organizing and controlling the vast array of
perishable tools, inserts, tool holders and tool
components
 Control of idle tool assemblies along with
determining tool disposition
 Actively maintaining machine tool data for the
remaining tool life of returning and idled tool
assemblies


TOOL DELIVERY
function relative to moving the tools between the
tool room and the various tool magazines of each
machine tool in the FMS
 includes transporting the tools to and from the
machine tool requiring those tools
 loading and unloading the tool magazines
 variety of part mix is high enough then complete
automation of the tool delivery and distribution
function may be necessary


TOOL ALLOCATION AND DATA FLOW
Tool allocation is essentially assigning and
controlling the total number of tools required for
each machine to process the previously defined
FMS part spectrum
 Controlling the tool data flow relative to the
allocated tools requires that the MCU
 It is based on specific part process plans,
machine programs and machining methodology
along with the varying part mix and volumes


FAULT SENSING
Fault sensing is monitoring and detecting cutting
tool problems at each machine
 involves electromechanical and optical sensing
and detection of worn and broken tools along
with absence of tools or misplacements
 Each tool is offset to a contact and non-contact
sensor
 validate tool presence, correctness and condition
 Replacements should be available for the broken
tools.


MASS EXCHANGE
The mass exchange strategy is removing all the
tools in each machine tool matrix at the
completion of specific production
 and replacing them with the new part required
for tooling
 Mass exchange permits tool exchange control to
be minimized at the expense of an increase in
tool inventory


TOOL SHARING
sharing of tools within the framework of affixed
production period and workpiece requirements
 Common tooling among the fixed production
requirements is recognized, identified and shared
among the various parts to be manufactured in
the fixed production period
 a new set of tools for the next production is
loaded and common tooling is again identified
 The tool strategy requires computer software to
implement due to merging of tool lists and
matching requirements to identify the common
tooling.


TOOL MIGRATION
consider the workpiece to be manufactured
within the fixed production period and tool
matrix capacity available to support it
 Tool migration exchanges must be done in an
effort to minimize spindle interruption
 Tool delivery is accomplished through various
means such as AGV
 sophisticated computer software and decision
logic required in order to determine the removal
of tools, adding of this tool


ASSIGNED TOOLS
manufacturing operation forces consideration of
production schedule changes, machine
breakdowns, tooling and material unavailability,
flexibility among processing equipment becomes
high priority
 assigned tool strategy can address the need for
increased flexibility among a set or group
machine tools
 identifies the most used tools
 assigns permanent residence to those tools in
each machine tool matrix for the full production
run


TOOL PRESET IDENTIFICATION
Automated identification systems are important
because they are reliable, save time and reduce
human error
 The most common of these identification systems
are


 Bar

Code Scanning
 Radio Frequency Identification
 Optical Character Recognition
 The Microchip
 Machine Vision

DATA TRANSFER
Once cutting tools have been assembled, gauged
and identified the associated tool dimensional
data must now be transferred to the host
computer for application use
 tool-preset operator assigns an identification
number to the entire physical collection of tools.
 If an electronic tool gauge is being used, the
gauged values of tool length and diameter are
automatically read from the gauge and
transferred and stored in a tool collection file on
the FMS computer


TOOL MONITORING AND FAULT
DETECTION
Cutting tools can be monitored in stand-alone machine
cell and FMS application for tool life
 the time during which a cutting tool produces
acceptable parts in a machining operation
 Tool monitoring therefore becomes a comparison of how
much useful life should exist on a given tool measured
against the actual cutting time of the tool
 End of useful life when any of the following occur


 Losses

of dimensional part accuracy due to cutter wear of
deflection.
 Loss of required surface finish due to tool wear
 Tool breakage of chipping due to excessive wear
 Excessive torque from increased feeds and speeds heavy
stock removal application.

TOOL MONITORING AND FAULT
DETECTION


When the actual cutting tool time as tracked by
the host computer in FMS application expires,
perform one of the following actions;
 Select

a duplicate and redundant tool, continue
operation and notify the FMS computer.
 If no duplicate tool has been provided stop the
machine in a “feed hold” condition and notify the
FMS computer.
 Flush the part requiring that specific tool from the
active machine queue and go on to another part

NEED OF TOOL MONITORING AND
FAULT DETECTION
By monitoring tools, you can get more parts per tool
 Tool costs are lowered because you are using the tool properly and
sharpening it only when needed
 This will also reduce machine downtime
 tool inventory can be reduced
 You can also get faster new part process development. If you have a
history of tooling from a monitoring system
 With tool monitoring, labor can be reduced, because fewer tool
inspections and changes will be needed
 Lower skilled operators can watch the machines, because the tool
monitor alerts them to tool changes
 Scrap can be significantly reduced because dull tools that produce
scrap have been taken out of service before they can cause problems
 comparison to see if the new tool is cost effective over old one.
 higher overall efficiency along with improved part quality


THANK YOU

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