Rising carbide costs and supply difficulties have been putting pressure on manufacturers of cutting tools and precision components for some time now. When carbide becomes more expensive and availability is a concern, every blank, every grinding cycle and every machine hour has a greater impact on production costs. For many companies, the focus is therefore shifting from sheer output to the cost of each saleable tool. Key factors include shorter cycle times, controlled material removal, less scrap and rework, higher machine utilisation and better use of existing equipment.

ANCA supports this approach with new options for CNC grinding machines, software innovations, the ‘Performance+’ application package featuring feed rate optimisation, process control, advanced measurement systems, automation and application expertise. The aim is to convert carbide, machine time and operator effort more efficiently into finished precision tools.

“Rising carbide costs and uncertainty regarding the availability of raw materials make controlled, efficient grinding even more important,” says Martin Winterstein, Managing Director at ANCA Europe. “With our latest grinding software, ToolRoom RN35, and Feed Rate Optimisation, we use process data to optimise feed rates, ensure more uniform material removal and reduce cycle times. For our customers, this has a direct impact on the cost per tool produced.”

Getting more output from existing production resources

One key focus is reducing cycle time. When floor space, labour or investment capital are limited, manufacturers need to get more output from the machines already in production.

ANCA’s Performance+ programme begins with a baseline analysis of the customer’s process. Building on this, ANCA’s application experts use new features in the ToolRoom RN35 grinding software to identify potential for optimisation. The feed rate optimisation function enables shorter cycle times whilst simultaneously optimising the process. The recommendations may also include software settings, grinding strategies, hardware or consumables adjustments, as well as operator training. If the recommendations are implemented, Performance+ guarantees a cycle time reduction of at least 10 per cent. Significantly higher figures have already been achieved in documented projects.

In addition to shorter cycle times, feed rate optimisation can help ensure more stable grinding conditions by reducing unnecessary process fluctuations. In customer projects, this can contribute to better feed rate control, lower spindle load and fewer wheel dressings. This supports higher machine performance, shorter lead times and lower production costs, without necessarily requiring the purchase of additional machines.

Regrinding: extending the service life of carbide tools throughout their entire life cycle

The reconditioning of used tools is a direct response to cost pressures and availability issues relating to carbide, as it extends the service life of existing carbide tools. If the geometry and coating are correctly restored, the service life of tools can be multiplied whilst simultaneously reducing the effective carbide cost per cutting edge.

Depending on the tool type, geometry and application, a typical regrinding operation can cost around 30 to 40 per cent of the price of a new tool whilst delivering around 85 to 95 per cent of the original tool’s performance, provided the geometry and coating are properly restored. Over several regrinding cycles – often up to three per tool – life-cycle costs can be reduced by up to 70 per cent and carbide consumption minimised.

ANCA supports the regrinding process through specialised software modules, RFID-enabled workflows, tool identification and automated handling. RFID-based dynamic tool management links each tool holder to the corresponding tool file, regrinding cycle, collet and disc set. This allows tools to be loaded in different orders, reduces manual set-up effort and enables the automatic regrinding of mixed batches. Different tools and priorities can thus be processed within a single workflow. In combination with automated software logic or process automation (ANCA Scripting), each scanned tool can trigger the correct grinding instructions and the appropriate handling sequence with minimal operator intervention. This makes the regrinding process more traceable and repeatable.

Flexibility as a cost and competitive factor

Volatile carbide prices and changing order patterns are also increasing the pressure to avoid overproduction and high stock levels. Manufacturers must cope with smaller batch sizes, rush orders and a wider range of tool types without increasing set-up losses.

ANCA supports this with machines and software for shank tools, indexable inserts, profile tools, special-purpose tools and precision components. Specialised software packages such as InsertsPRO for grinding indexable inserts tailor the programming workflow to the specific application. This flexibility helps manufacturers utilise existing equipment for a wider range of applications, including standard and special-purpose tools, indexable inserts and precision components. At the same time, it reduces the need to permanently reserve machines for narrowly defined production tasks.

Improving machine utilisation and process stability

Machine utilisation remains a key factor in the cost per tool produced. Every downtime, every manual intervention and every unplanned adjustment reduces output – which is particularly frustrating when labour and material costs are already a critical factor.

ANCA technologies such as in-process measurement, closed-loop automatic compensation (AutoComp), motor temperature control, Auto-Stick dressing, disc balancing, robotic loaders and pallet automation reduce non-productive time and stabilise production.

The AIMS ecosystem complements digital workflow control, warehouse integration, autonomous pallet transfer, process instructions and production transparency. Reference applications demonstrated 19 days of unattended autonomous operation, a productivity increase of more than 30 per cent compared with a manual benchmark, and labour savings of up to 60 per cent per machine.

These results are relevant to manufacturers because they address both machine utilisation and labour deployment. Automation can also relieve the burden on skilled operators: they can focus more on process control, programming and quality, rather than carrying out repetitive handling tasks.

Integrated efficiency rather than a single upgrade

ANCA’s approach is not based on an isolated product or a single function. It combines machine capability, software, measurement, automation, process analysis and training.

The machine provides the grinding platform. Software supports programming and feed control. Measurement and compensation technologies ensure quality. Automation improves capacity utilisation and workflow stability. Performance+ complements a structured method for analysing processes and identifying specific improvements.

For tool manufacturers and producers of precision components facing cost pressures relating to carbide, this integrated approach can reduce waste

, shorten cycle times, increase flexibility and make better use of existing equipment.

“Customers are looking for measures that can be implemented within their existing production environment,” says Winterstein. “Feed rate optimisation is applied directly to the grinding cycle, whilst regrinding extends the value of the carbide tool throughout its life cycle. Together with measurement and automation, these are practical steps towards reducing the cost per tool produced.”