The grinding machine manufacturer Okamoto is making the successful lapping system AeroLap a fully automatable high-end finishing solution with an 'Innovation Duo' consisting of the automatic fluid supply system AeroLoop and integrated robotics: With AeroLap YT-300, mirror gloss or the perfect surface treatment in the final production process for cutting tools and components of mold making can now be fully automated
in a low-man operation – without edge rounding, without material removal of the lapped molds and tools, and gives the cutting tools an enormous increase in tool life in later use.
Increasing cost pressures, uncertain global markets, and high demands for resource efficiency currently shape the tool and mold making industry. At the same time, the industry is particularly hard hit by the increasing shortage of skilled workers: Highly qualified activities must be carried out safely, reproducibly, and economically despite a tight labor market.
Technology suppliers like the grinding machine manufacturer Okamoto support the industry in this challenging situation with innovative solutions that simplify, automate, and stabilize processes. An example of this is the proven AeroLap system, which has already provided a surface finish with mirror gloss to cutting tools and demanding mold making components – without any material removal and without edge rounding. With the new AeroLoop system and the optional integration of a cobot, the system now receives an additional performance boost and transforms the previously manually operated, labor-intensive system into a robot-controlled high-gloss finishing solution.
AeroLap: Proven mirror gloss finish without material removal
For many years, Okamoto has set standards in precision finishing for drills, mills, punches, dies, and mold cores with the lapping system AeroLap. The system enables various materials – including HSS, carbide, stainless steel, PVD and CVD coated tools – to achieve mirror gloss without changing geometry.
The decisive advantage over classic polishing systems:
- No edge rounding
- No material removal – not even with coated tools
- No dimensional changes
- Mirror-smooth surface for maximum tool life
Thomas Loscher, Technical Manager at Okamoto: 'This is lapping at the highest level. Even with very hard or delicate or complex geometries, every detail remains sharp and dimensional. We receive a lot of positive feedback from the industry. Some customers report that they achieve up to 80 percent longer tool life with cutting tools and the surface quality produced by AeroLap, as less friction occurs, no build-up edges form, and chip removal is improved.'
AeroLoop: The key to automation
Until now, the lapping process with AeroLap required direct manual intervention from the operator, who had to precisely move the workpieces in the suspension jet while simultaneously monitoring their moisture and consistency. While reproducible quality could be achieved this way, the demand for experienced skilled workers remained high.
With the new development AeroLoop, Okamoto now presents a system that makes AeroLap fully automatable for the first time. AeroLoop ensures continuous circulation of the lapping suspension Multi-Corn or Multi Liquid and keeps its moisture and consistency permanently within optimal tolerances. What the operator previously had to check and correct manually is now taken over by a closed, sensor-controlled system – including automatic hydration of the suspension, constant mixing ratio, elimination of re-moistening or refilling, and a significantly extended service life of the diamond carrier. The result is minimized downtime and consistently high process reliability. Thus, AeroLoop eliminates one of the biggest hurdles for a low-man or fully automated operation of AeroLap.
Fully automated lapping – around the clock
With an integrated cobot, AeroLap is now becoming a robot-guided precision finishing system that can carry out the lapping process fully automatically around the clock.
The cobot moves the workpieces with extremely sensitive, circular and rotating movements exactly as required by the process for optimal mirror gloss finish. This eliminates the need for special lapping knowledge on the operator's side, while the motion kinematics remain constant and reproducible at all times. Fatigue – even with heavier components – or potential for error no longer play a role, and multiple AeroLap systems can be easily operated in parallel with low manpower.
Thomas Loscher: 'This enables continuous 24/7 operation. In companies where, for example, five machines previously required their own operator, the system can now be reliably, efficiently, and with consistently high quality operated with a fraction of the personnel.'
Performance increase for tool and mold makers
AeroLap serves many tool and die manufacturers today as a unique selling point, as they can give their components a 'final performance kick' through finishing – and that without risk to geometry or coating.
Automation elevates these advantages to a new level:
• up to 80 percent higher tool life for drills, mills, indexable inserts
• better sliding properties for punches and mold cores
• ideal for a wide variety of materials such as aluminum, carbide, steel, and stainless steel
• optimal for tool series that must be reliably brought to mirror gloss
• economical even for small series, as no specialized personnel is needed
Thomas Loscher: 'With the new AeroLap, a new era of automated lapping begins. With AeroLoop and integrated robotics, Okamoto upgrades a very successful, proven lapping system: AeroLap YT-300 becomes a fully automated high-end finishing center. This means fully automated, reproducible mirror gloss lapping without geometric changes. The process becomes self-sufficient, stable, economical – and is thus a strong lever against the shortage of skilled workers, production pressure, and quality requirements.'
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