Tooling Spotlight: Diamond Routers

In our tooling spotlight, we break down what you need to know about our most effective tooling solutions. This MVP is our line of Diamond Routers.

The Tool:

Leitz Diamond Routers perform at high processing speeds, equal to or more than comparable solid carbide tools–offering greatly improved service life.

Recent advancements in tool design and construction have allowed Leitz to expand the small diameter diamond routing and nesting tools to 2+2 and 3+3 wing design.

Available in diameters as small as 3/8″ and in various cutting lengths, Diamond Routers will greatly enhance most CNC nesting and sizing applications.woodworking tools, diamond tooling, routers, tooling, leitz

What makes it better:

  • A wide variety of specifications available
  • Technical and economic superiority in critical tests with leading machining center manufacturers
  • Significantly longer tool life
  • Fewer tool changes
  • Optimized machine throughput

When to use it:

With CNC and other precision machining. Optimize performance with the Leitz ThermoGrip™ heat shrink tool holding system.

Diamaster PRO Z1+1

 

·       Entry level for lower production requirements

·       Useful for all company sizes

Diamaster PRO Z2+2

 

·       Economic solution for increased performance requirements

·       Optimum price to performance ratio

Diamaster PRO3  Z3+3 – Nesting

 

·        High-performance tool for nesting applications

·       True 3-wing router bits provide continuous cut quality

Diamaster PLUS Z1+1

 

·       Recommended for composite materials

·       Ideal for various non-wood applications

Diamaster QUATTRO Z2+2

 

·       Standard tool for most industrial applications

·       Ideal for both pre- and finish cutting

Diamaster PLUS Z3+3

 

·       Standard for industrial users with high-performance requirements

·       High feed speeds with excellent finish quality

Diamaster PLUS3 Z3+3 ·       The choice for industrial pre- and finish cutting

·       True 3-wing design for continuous cut quality and maximum performance

The results:

All the benefits of Diamond Tooling, including longer tool life, fewer tool changes, and optimized machine throughput, combined with a wide variety of cutting lengths and size options results in increased performance, cost savings, and a tear-free and chip-free finish.

Add this MVP to your line-up:

Download our Diamond Routers brochure.

Take advantage of our current promotion on Diamond Routers and ThermoGrip™, now through the end of 2018.

Contact your local Leitz consultant at (800) 253-6070, or fill out the form below, and we’ll get in touch.

Tooling Spotlight: ThermoGrip® Tool-Holding System

In our tooling spotlight, we break down what you need to know about our most effective tooling solutions. This month’s MVP is ThermoGrip CNC Tool-Holding System.

The Tool:

The Leitz ThermoGrip® heat-shrink tool-holding system offers unrivaled precision. The one-piece chuck design eliminates excess tool run-out common to collet and hydro tool-holding systems. Heat shrink technology allows for higher machine output, while yielding optimized cut quality and significantly extended tool life.

Heat shrink chucks offer the simplest and most rigid link between the machine spindle and cutting tool. Heat shrink chucks are inexpensive, one-piece tool holders, without moving or mechanical parts to wear or maintain.leitz, thermogrip, tooling, woodworking toolsThe ThermoGrip® tool holding system uses an inductive heating concept to provide stronger, more concentric tool clamping. This leads to increased tool life, better surface finishes, and improved cost efficiency.

What makes it better:

  • Highest torque transfer; essentially a one-piece tool and HSK-F63
  • Safe, rigid balanced to 36,000 RPMs
  • Optimized tool performance, finish quality
  • Increased cutting speeds (by 30%)
  • Improved machine productivity
  • Compact, solid design with no wear parts; right or left rotation
  • Easy cleaning/maintenance; unlimited lifespan
  • Reduced tooling costs; fast tool changes

When to use it:

With CNC and other precision machining.

The results:

The annualized savings utilizing Leitz ThermoGrip can be astounding. You will reduce tooling costs by a minimum of 25% and increase machine and operator productivity by at least 20%. ThermoGrip users have noted annualized savings of at least $15,000 per shift, with expanded production capacity. The ThermoGrip system generally pays for itself within months, and the maintenance-free chucks provide virtually unlimited service life.

Add this MVP to your line-up:

Check out our current promotion for the ThermoGrip Tool Holding System. Offer valid now through December 31, 2918.

Download our ThermoGrip PDF.

Contact your local Leitz consultant at (800) 253-6070, or fill out the form below, and we’ll get in touch.

Intelligent Tooling Driving Production

By Mike Lind

How intelligent tooling will operate in the smart factories of the future, starting today.

The Connected World and the Internet of Things

The world we live in is more connected than ever before. You may have heard the term ‘internet of things’, which generally means the internetworking of all things around us, from devices to buildings, to vehicles. We have refrigerators that can offer recipe tips based on the products within them. We can change the temperature in our homes with thermostats that can be adjusted remotely, and almost every late model vehicle has an on-board computer that provides on-demand system performance information. Smart devices are everywhere these days; even the meat smoker in your backyard can be monitored from your cell phone.

Industry 4.0: Linking the Panel Processing Industry

Today we are using cyber-physical systems, the Internet of things, and cloud computing to develop the basis for the “Smart Factory”. The current trend of automation and data exchange in manufacturing technologies will, sooner rather than later, become the norm in manufacturing.

In fact, there is already a huge amount of market presence in our wood products industries related to Industry 4.0. Trade shows and industry conferences are themed under the Industry 4.0 banner–most recently at Ligna in Hannover, Germany, our AWFS show in Las Vegas and the Holz-Handwerk Fair in Nuremberg, Germany. Each of these events had an inescapable Industry 4.0 presence. The smart factory is a highly focused topic for large companies who are the drivers and facilitators of the technology. And in our industry, the equipment manufacturers are putting a huge emphasis on Industry 4.0 through various platforms, touting the benefits it should provide.

We are seeing office furniture producers, kitchen cabinet giants and other market segment leaders as the early adopters of the technology. However, it is important to recognize that the smart factory, while rapidly evolving in the wood products industries, is still very much in the developmental phase. For everything to come together all the parts–including machines, software, and tools with embedded devices and readers–must work in concert together.

Managing the Data

The processes in woodworking are becoming more intricate and sophisticated. The increasing diversity of materials and surfaces (various species of wood and combinations of wood, aluminum, plastic, etc.) have very specific machining requirements. Batch size 1 production or new approaches for individualized mass production are ramping-up the need to understand what is happening in the machining environment at all times. Machines and the systems that run them are becoming more and more complex.

The probability of mistakes is more present than ever, and the impact and severity are heightened as process demands increase. Despite publishing information for proper cutting speed, feed rates and the like in catalogs, literature, and even in user guides provided with the tools, we still see evidence of improper tool use every day from customers around the world.

We are coming to the limit with the operator skill required and mind power available to manage the data in front of us and to manage it in a way that produces the desired products in an optimal and safe environment.

The Role of the Tooling Manufacturer in the Integrated System

Tool makers like Leitz are playing a role in enhancing the overall system. Through Embedded Chip Technology, RFID devices, and integrated QR codes, the tool becomes the gateway to a central database of information that improves process efficiency and reduces mistakes.

The basic results include:

  • Cataloged tool specifications and running parameters that remain with the tool always.
  • Real-time information captured during the operation of the tool and maintained as a quasi-database throughout the life of the tool.
  • Mistake-proofing of applications and programs through simulation and warning indications when a tool runs outside of design parameters.

The key concept with intelligent tooling is to make information available without the need to open the instruction manual. Every tool has a unique serial number; once you know the serial number, all the necessary information to run the tool is at hand for both man and machine.

leitz intelling tooling with QR codeRFID chips can contain a 3-D model with the exact geometry and dimension of the tool, so the machine software can simulate the machining process, ensuring safety during tool changes, and preventing crashes due to incorrect programming. Process-specific information can be kept as part of the tool data, facilitating set-up, increasing spindle up-time and decreasing the possibility of creating expensive scrap.

For this approach to be successful, an integrated system of tool, machine, measuring instruments, sharpening equipment, and data must work together. Starting with tools with chips or QR codes installed on machines, the machine then reads and utilizes the running parameters and programming information. Information is fed into computer systems or cloud computing networks. Alerts are sent to mobile devices when problems arise (e.g. machine parameters are exceeded). When the tools are removed from machines and sent for service, the event is logged into the database (location of tools can be determined). Relevant tool information (specifications, drawings, service instructions) can be accessed at the service center. When the tools have been serviced, any changes in specifications (diameter, reference points) are added to the tool database. The tool is reinstalled on the machine. Updated tool specifications are read by the software on the machine, and the cycle starts over. When the tool is serviced, key information can be synchronized with the company ERP system, including service tickets, on-hand inventory, and running status of tool life cycle with the ability to alert and send an order for new tools. And, we can monitor this entire process with an app like those that we use in our daily life.

 “Synchronizing Process Components” or something that communicates the orchestration that has to occur for the desired end result.

The tooling alone is not the driver. The process is only efficient and stable if all the parts – machine, tool, software, operator – are in accordance through proper communication. When expertly implemented, intelligent tooling offers several advantages:

  • Production quality improvements from optimized settings
  • Simplified tool set-up that is expedited due to information available on-demand
  • Process reliability because all the steps are verified and adjusted prior to running parts
  • Increased availability of resource = optimized utilization – not more, not less
  • Energy efficiency – dull tools are replaced at the right time, requiring less power consumption
  • Process know how
  • Expert system
  • “Learning-in” material and tool combinations
  • Every service and sharpening recorded as “tool history”
  • Sharpening procedure is documented and stays with the tool so that no mistakes are made in the service shop
  • Easy tracking and monitoring of tools, reducing the amount of capital employed
  • Automatic tool ordering, decreasing administration and paper

As our world rapidly changes around us, new business approaches and models are required. Owners, managers, and stakeholders need the freedom to concentrate on producing wood and wood-related products without process headaches. Intelligent tooling in the smart factory environment offers solutions that allow for a focus on the business at hand – producing doors, windows, furniture, cabinets and other products, in the most efficient way possible.

Leitz at IWF 2018 – Solutions in New Dimensions

In addition to displaying new and innovative tooling solutions, Leitz Tooling is driving home the important message of Right Tool, Right Service at IWF 2018. As a thought leader in the tooling space, Leitz is helping manufacturers maximize their investment in tooling by ensuring the right tool is selected for the machine and the application, and that the tool is properly serviced for optimized use and longevity. 

“Tooling selection, especially in today’s smart manufacturing landscape, is a 360-degree decision. You need to have a tooling partner that has your ongoing best interests and desired outcomes in mind,” comments Michael Lind, Leitz CEO. “The right tool results in quality and productivity; the right service ensures long-term success.”

Leitz educates manufacturers on what to consider when selecting a tool, how to improve the partnership between the tool and the machine, and the best service practices to get the most from their tooling investment.

Visit the Leitz booth #5752 at IWF 2018 to learn more.

Want to chat before the show? Fill out the form below and we’ll be in touch:

Tooling Spotlight: WhisperCut Cutterhead

In our tooling spotlight, we break down what you need to know about our most effective tooling solutions. This month’s MVP is PCD WhisperCut Pre-Mill cutterheads. leitz whispercut edgebander woodworking woodcutting wood manufacturing tool

The Tool:

Leitz WhisperCut is the premium low-weight PCD jointing head for edgebanders, and the first to utilize field replaceable/sharpenable precision diamond inserts.  The light-weight aluminum alloy cutter body reduces machine spindle wear while damping cutting noise by as much as 5dB(A).  WhisperCut technology provides the most efficient and economical pre-milling solution available.

What Makes it Better:

Features Benefits
Field replaceable/sharpenable PCD inserts ·         Replace inserts instead of heads, at a far lower cost

·         Significantly reduced tooling inventory, replacement knives only

·         Send knives for service instead of heavy steel cutterheads

Light-weight body ·         Reduced spindle bearing weight

·         Jump spindle moves smoothly in and out of cut

·         Absorbs and reduces cutting noise -5db(A)

·         Safe, easy handling

High shear (Edge Expert) versions available ·         Optimal cut quality due to dramatically reduced cutting pressure

·         Exponentially longer tool life due to reduced cutting pressure

·         Exceptional cut quality in fragile or textured laminates

·         Reduced or eliminated plucking of loose core material

DFC gullets ·         Improved chip evacuation and reduced knife wear/damage

When to Use It:

For pre-milling in preparation for edgebanding, on both classic and CNC based edgebanders.  Custom versions are available for jointing, rebating, v-grooving and angular cuts in abrasive materials.

Suitable Raw Materials:

  • Particleboard, MDF, and abrasive materials
  • Uncoated, veneered and laminated materials
  • Paper-coated, fiber reinforced plastics (glass fiber reinforced, carbon fiber reinforced plastic etc.).

The Results:

Exceptional finish, tear-free edges, and a straight edge on double-sided laminates.

Add this MVP to Your Lineup:

Download our WhisperCut PDF.

Contact your local Leitz consultant at (800) 253-6070, or fill out the form below, and we’ll get in touch.

Cutting Edge Furniture Making – Haworth & Leitz Tooling Solutions

Haworth’s sustainable manufacturing practices help give the contract furniture giant an edge in the marketplace.

One of the top three U.S.· based contract furniture manufacturers, Haworth Inc. is renown worldwide for its quality office furniture and innovations. Founded in 1948 in Holland, Ml, by G.W. Haworth, it remains a family-owned and privately-held company serving markets in more than 120 countries through a global network of 650 dealers and 6,500 employees. 2014 net sales for the furni­ture giant were $1.8 billion.

Spurring the company’s success is its focus on research and design, which help drive the company’s deep understanding of agile workplace needs, said Haworth spokesperson Ryan McCall.

“Globally, Haworth improves workplac­ es with award-winning furniture, interior architecture, and technology solutions to help customers achieve business goals and transform culture, as well as support collaboration and innovation,” said Mc­ Call. “Haworth is committed to protecting and restoring the environment, creating economic value as well as supporting and strengthening its communities .”

As part of Haworth’s sustainable manu­facturing efforts, the company made changes to the production of its furniture and components. Among the technology upgrades in the panel processing area was the implementation last year of Leitz tooling to the edgebanding line.

“We upgraded our double-sided edge­ bander with the Leitz WhisperCut EdgeEx­ pert milling head program,” said McCall. “We were looking for a sizing tool on the edgebander that would greatly increase finished cut quality and greatly decrease the frequency of tool changes.

“Before developing this tooling program, machine operators were spending an aver­ age of 45 minutes every shift changing carbide insert tooling to maintain a quality cut. When we implemented the Whisper­ Cut EdgeExpert program, the PCD milling heads dramatically decreased the need for tool change frequency,” he said.

Feedback from the lead operator on the double-sided edgebander indicates he is now changing the diamond-tipped knives every six to eight weeks, McCall added.

“Work surface production was specifically targeted with this tooling development. We manufacture over 1,200 rectangular work surfaces per day with standard color offerings or a customer’s own material,” he said.

In addition to the edgebanding pro­cess, a number of machines are integral to the production of Haworth’s wide range of products. Among the workhorses in use at the company’s factories are beam and angular saws for cutting panels and sheet goods to size. Laminating is done in-house, utilizing a hot platen press. CNC routers and machining centers are also used extensively within the production area as the furniture manufacturer continuously looks for ways to improve the productivity and profitability of its products and processes.

The Leitz Tooling program is an integral part of this goal. “The WhisperCut EdgeExpert ROI is well under a year based on labor savings alone,” McCall said. “We have had great success with this tooling program.”

Originally published in FDMC Magazine October 2015. Download the PDF here.

Tooling Spotlight: ProfilCut Q Insert Tooling System

In our tooling spotlight, we break down what you need to know about our most popular tools. This month’s MVP is the Profil Cut Q & ProfilCut Q Premium.

The Tool

ProfilCut Q, ProfilCut Q Premium, and ProfilCut Q PCD are the fastest and most precise dedicated profile insert systems available.  The ProfilCut family of tools is designed to optimize process efficiency through perfect cut quality, highest yield, and fastest production cycles.

What makes it better

  • Modular body design offers profile flexibility and economic operation
  • Precision knife locating and retention prevent knife movement due to centrifugal forces
  • All knife changes can be made at the spindle, without disassembly of cutterhead
  • Knife clamping elements are protected from dust & resin build-up for ease of maintenance
  • Longest service cycles with Marathon or TDC (diamond) coated, and RipTec knife options
  • Lightweight aluminum alloy body allows for better balance and, in turn, reduced vibration
  • Certified and approved to operate at knife velocities up to 120 meters per second (50% faster than any competing insert system)

When to use it

  • Five-piece cabinet doors (cope/stick/style/rail/edge detail)
  • Wood interior and exterior doors
  • Wood windows
  • Architectural millwork and mating profiles
  • Miter lock or v-folding applications
  • Finger and glue jointing applications
  • Profiling of non-ferrous metals and advanced materials

Suitable raw materials

  • Soft, hard and exotic wood species
  • Panel materials such as plywood, raw or laminated particleboard and MDF
  • Plastic, foam, resin and composite materials
  • Non-ferrous metals

The results

  • Perfect sand-free finish quality at high knife marks per inch
  • Prevention common defects such as grain plucking, tearing and fuzzing
  • Reduced scrap loss, rework, and post machine sanding and repairs
  • Exact profile dimensions are maintained with every knife change
  • Maximum tool life
  • Multiple profiles can be achieved through simple knife change or exchange of modular cutter disks
  • Reduced machine downtime, with no need for machine recalibration
  • Larger profiles and limited machine spindle wear
  • Lowest possible cost per unit of production

Add this MVP to Your Lineup:

Contact your local Leitz representation by calling (800) 253-6070, or fill out the form below and we’ll get in touch.

Learn More About the ProfilCut Q Insert Tooling System
Contact us for more information.

Leitz Attends the 2018 Fensterbau/Holz-Handwerk Trade Fair in Nürnberg, Germany

With 110,000 visitors and 1,329 exhibitors from 42 countries the exhibition duo of HOLZ-HANDWERK an FENSTERBAU FRONTALE 2018 represents one of the largest wood manufacturing shows in Europe. The show has an emphasis on all things related to window and door manufacturers.

Leitz participated in this year’s trade fair, which took place March 21 – 24, 2018, presenting solutions and concepts that display technical innovation and focus on added value for our customers.

In addition to recent additions to the Leitz program, such as ProfilCut Q Diamond and WhisperCut panel saws, Leitz has also partnered with the hardware manufacturer, Roto-Frank, and other companies, to develop a new, high performance sliding door: Inova. The Patio Inova sliding door and sliding window system is specially designed for use in extreme climates.

Secondly, after an 8-year run, the ClimTrend tilt-turn window/door system has seen an upgrade to ClimaTrend Style, offering a modular design, higher performance,  slimmer sight-lines and more efficient manufacturing.

Learn more at leitztooling.com.

The Role of Tooling Technology in Cabinet & Cabinet Door Manufacturing

By Mark Alster

Kitchen cabinets are a central focus of modern home designs, as the kitchen is perhaps the most used room in the home. We cook, dine, socialize and entertain in our kitchens. The kitchen becomes the centerpiece of the home, and many of today’s open floor plans incorporate the kitchen into the primary living space. The cabinets are a focal point in any kitchen and must be both functional and aesthetically pleasing.  

Hardwood construction dominates high-end cabinetry, however, European influence and modern laminates provide affordable alternatives that offer an upscale look and feel.

Regardless of the material used, construction quality is of paramount importance, and each presents certain manufacturing challenges. In either case, correct tooling technology will assure the desired finish quality and optimal manufacturing efficiency.

The Challenges

Manufacturing wooden five piece cabinet doors meets the same raw material challenges traditional furniture makers face. The various wood species commonly used in cabinet manufacturing have different hardness ratings and grain structure, which must be addressed through proper tool design and operating parameters. Failure to design or utilize cutting tools, with respect to the cutting characteristics of the various wood species, will result in defects such as plucking, tearing, splintering of the workpiece and significant repair work or scrap loss. Add the fact that door components are generally manufactured across three different machines (moulder, shaper, tennoner), and the various tools must be accurate enough to provide mating joints which are both visually perfect and structurally sound.

Because of the primary components, including particleboard, surface laminates, and edgebanding, and the basic manufacturing process being accomplished using a CNC or saw and edgebander, European-style slab doors may seem easier to manufacture. However, challenges can still arise due to the quality of the particleboard, characteristics of the laminate, and style of edgebanding that is used. Common particleboard with a large-flake loose core can be very challenging to machine without plucking the core and adversely affecting the integrity of the banded edge. Modern laminates feature textured surfaces, made from wear resistance components, which are increasingly difficult to process. Finally, the banding process is becoming more critical, as manufactures strive to achieve a perfect, seamless edge between the laminated and banded surfaces.

The Solution

Using tooling technology, the solutions are relatively simple, and evolve around one key principal; cutting pressure is the root cause of most cutting defects, including plucking, fuzzing, ripped grain, crushed grain and chipped laminates. Cutting pressure can be controlled through the proper application of cutting tool geometry.

The solution must begin with thoughtful tool design, which employs the correct cutting angles for the raw materials being processed. Generally speaking, the harder the workpiece, the lower the cutting angle must be in order to prevent pre-splitting and defects ahead of the knife. Achieving ideal cutter speed and chip-load is critical, as the velocity of cut and amount of material being removed are the keys to maintaining ideal cutting pressure and heat dispersion. Utilizing shear to slice through the workpiece lessens the “chiseling” effect of the knife while reducing cutting pressure and providing better internal support of the material being processed.

Continuous Improvement Focus

Tooling technology continues to increase production efficiency, through improvement in precision, design, sustainability and cutting materials.  Leitz produces precision tooling systems, using advanced cutting materials and designs, which are both flexible and adaptable to meet modern production demands. We apply advanced cutting technologies in a manner which continuously improves the manufacturing process, by optimizing quality output and manufacturing efficiency. Moreover, we work to educate manufacturers as to the availability and proper implementation of current cutting tool technologies. Understanding how tooling can limit or accelerate your manufacturing efficiency is critical, as the investment in cutting-edge tooling technology will always return greater value to your bottom line.

Learn more about Leitz profiling tools.

Download the ProfilCut Q and ProfilCut Q Premium brochure.

Mark Alster has been in the tooling industry for over three decades and is the Central North Regional Manager for Leitz. Mark is passionate about advancing the cutting tooling industry and applies his knowledge and twenty-two years of experience with Leitz to help Leitz customers implement industry-leading advancements. Mark currently serves on the AWFS Board of Directors.

Three Ways to Partner with Your Tooling Provider for Overall Production Success

If you ask the right questions – or more importantly, if the right questions are asked of you – your tooling provider is key to driving success on the manufacturing floor.

Collaborating with your tooling provider throughout your production process, from the purchase of new machines to on-going maintenance, offers significant value to your organization and helps to ensure application success. A knowledgeable tooling provider who offers consultative services can help you save money by implementing solutions with the lowest applied cost, drive efficiency with the right tooling systems and tool management, and reduce downtime and scrap. Continue reading “Three Ways to Partner with Your Tooling Provider for Overall Production Success”