Greater precision, less setup time with »venturion«

KM Optimizes Manufacturing with ZOLLER

It has been about 10 years since KM Co., Ltd., a manufacturer of machine parts in the Hiroshima region, introduced the ZOLLER »venturion« tool presetter into its parts plant. How has this high-precision tool presetter—which has been in continuous use for so long as an indispensable part of the manufacturing process—contributed to improving machining accuracy and reducing costs? Interviews with on-site employees revealed its true value.

Background and Challenges 

Prior to the introduction of this system, on-site machining was carried out under considerable “uncertainty.” There was no option to perform measurement of specialized, complex-shaped tools, so the correct procedure was not known until the actual machining process began. The “radial run-out” of the reamer itself impaired the accuracy of the finished drill hole. There was always a danger of machine collisions due to errors in the input of tool data. Once it occurred, such an accident resulted in significant repair costs and production downtime.

Quality Assurance for Special-Shaped Tools 

Until now, there were no measurement methods available for these complex, costly shaped tools, where angles and step lengths directly influence the results. This created the risk that errors would not be detected until after lengthy machining runs. The introduction of the »venturion« enables the “visualization” of tool angles and shapes prior to machining. Even if a tool delivered by the manufacturer is defective, the system can detect and notify of this before it is used. 

Switch from Reamers to Drill Bars 

What was especially impressive during this visit was the dramatic improvement in the finishing of drill holes. Previously, multi-edged reamers were used for finishing at this location, but there was a persistent problem: the “radial run-out” of the tools impaired machining accuracy. To solve this problem, an exchange to drill bars was considered. However, drill bars had inherent drawbacks. Every exchange of cutting edges required a precise diameter adjustment, and the process of “cutting slightly undersize, measuring, then reworking” had to be repeated multiple times. This procedure was extremely time-consuming, which made the exchange difficult. The solution to this dilemma was the »venturion« with its high-precision measurement capabilities.

Outstanding Measuring Accuracy 

With the introduction of »venturion«, the critical diameter adjustment—the biggest drawback of boring bars—could be performed perfectly during “off-machine setup” before clamping. Since fine adjustments down to 0.001 mm can be made on the presetting device, “one-shot machining” has become possible. This eliminates the need for rework or test cuts, even after installing a new cutting insert. 

Effective Time Savings 

Tasks that previously took over an hour due to concentricity deviations in reamers or the adjustment of boring bars are now completed in about 10 minutes. This corrects the precision concerns associated with reamers while brilliantly overcoming the low productivity of drill rods. 

Less Stress for Skilled Workers 

The repetitive cycle of machining and measurement not only caused downtime for machine operations but also placed a significant psychological strain on the operators. Since »venturion« provides reliable numerical data, operators can now press the start button with confidence, knowing that everything will be done “right the first time.” This ensures both safety and reliable results.

Zero Collision Accidents Through Data Integration 

On the production floor, »venturion« is networked with three Mazak machine tools. The system ensures that the precise tool information measured by »venturion« is transferred directly and reliably to the machines via the “Smooth Tool Management” interface, thereby completely avoiding errors caused by manual input. Without this system, tool collisions with workpieces would have occurred, leading to spindle repairs costing over 10,000 euros and extended machine downtime. This “safety” is one of the points most valued in manufacturing. 

Consistent Tool Life and Cost Management 

In light of ongoing price increases for tool materials such as tungsten, controlling tool runout in the micrometer range is becoming increasingly important. Minimizing radial run-out with »venturion« improves machining stability and extends tool life. This contributes significantly to reducing monthly tooling costs. 

Field Test 

Confidence in »venturion« is so high that even production team leaders make statements such as: Even though they are difficult to quantify, the benefits—including loss compensation through accident prevention, reduced setup times, and psychological safety—“knowing that we can reliably produce high-quality parts”— —are valued so highly that they deliver a return on investment that far exceeds the initial purchase cost. 

Future Prospects 

In the future, this successful model should be expanded to additional production lines and plants. Particularly in the manufacture of core components that require high-precision machining, the »venturion« will continue to fulfill its role not only as a “measuring instrument” but also as the plant’s “uptime guardian.”