Set-Up for Success with Cutting Tools

Jeremy Bunting grew up in the cutting-tool industry, getting a hands-on education and work experience that he has used to start to start his own business — Facet Precision Tools, headquartered in Ganderkesee, Germany.

"I started designing my first tools at age 14, in America, as part of the family business, using manual grinding as well as conventional grinding to manufacture tools," he recalled. He also learned how cutting tools are applied (e.g., "feeds and speeds"), and later worked for different tooling manufacturers in Europe, seeing different approaches to manufacturing and precision tooling.

"I started Facet Precision Tools in 2015 primarily to service the aerospace and automotive sectors," Bunting explained. "Both these markets require special tools with distinct needs."

Facet Precision Tools produces PCD, carbide cutting, and coated-carbide tools, which are supplied through distributors and direct to customers.

"It's challenging starting a new business. We had a market and products in mind and were in a unique position where we could decide… 'If these are our target markets, what machinery and equipment do we need?'

"When we entered the market, I wanted to have high-quality equipment, robust manufacturing processes, and to be producing market-leading cutting tools," the tooling executive explained. The manufacturing center he planned and outfitted now exhibits his choices and expectations.

Facet Precision Tools invested in a range of ANCA CNC machines for the shop that Bunting planned, including two MX7 Linear tool grinders with 38-kW (51 HP) permanent-magnet spindles for high torque at lower RPM, recommended for carbide grinding and other applications.

"We use the MX7s primarily for automotive tooling, as they work well when grinding tools with larger diameters of 20, 25, and 32. We also run a lot of pocket grinding for PCD cutting tools on this model," Bunting said. "The MX7 has a lot of horsepower that allows us to grind these tools in a very stable way."

Among other CNC machines and equipment, Facet Precision also operates an FX7 Linear tool grinder, and an EDGe tool erosion and grinding machine for producing PCD tools.

"We use the FX for high-volume carbide tooling. As an extremely rigid and thermally dynamic, stable machine, I can rely on it to grind highly repeatable cutting tools.

"On the MX7 we have an ANCA spindle speeder that allows us to achieve higher RPMs. We worked with ANCA to adjust the software to be able to provide a better stable pocket and more accurate pockets in our grinding process.

"On the EDGe we manufacture PCD tools," Bunting noted. "In the past couple years we have been developing PCD vein tools with our own blanks and cutting tool designs, working through and refining our processes. The EDGe has allowed us to have a high degree of accuracy when trying to grind a lot of the geometries. I found that as a process, erosion enabled the repeatability and the quality we were looking for," he detailed.

"We also added a vision camera system on the EDGe, allowing for a quick inspection inside the machine, to get higher repeatability and better quality versus taking it out of the machine, and putting it back in…"

Bunting's choices went beyond CNC machines to auxiliary process supporting tooling development and production — a primary example of which is the ANCA 3D Simulator software.

"Up to 95% of the designs and problem-solving are done on the simulator," he observed, "testing the grinding process, reviewing, and modifying before you go into a machine. It is our strongest tool to increase efficiency and reduce waste and that is a major help to our profitability.

"For example, carbide is extremely expensive, where you can be paying from €400 ($475.00) for a 32-mm standard rod," Bunting emphasized.

"The simulator also shows estimated grinding times, which has been a great tool for us to reduce cycle times. For example, last time it took us 20 minutes to make this tool, but after considering a new idea or different approach we can reduce that time to 18, 17, or even 15 minutes, all through experimenting in a simulated grinding environment.

Facet Precision Tools has had touch probes installed on all the machines in its shop, allowing operators to change wheel packs easily, qualify the wheel, and start production again quickly.

"It also allows us to remove human error and ensures a higher finished quality," Bunting said. "To be able to dress and probe the wheel, picking back up where you left off without having to change the setup, is very advantageous.

"One of the main reasons we love the ANCA machines is because of the software," the tooling manufacturer said. "We have found it to be extremely flexible, and at Facet we don't use a lot of the standard ANCA programs and designs, but instead do a lot of our work in profile editor, changing angles and profiles to meet the tool designs that we need."

Building on experience and developing new expertise, Jeremy Bunting is using Facet Precision Tools manufacturing center to shape and promote the future of the business.