AFB used a whole range of different slot cutters to create grooves in the components for its load handling devices, including many older two- and four-flute tools for which no plates are available anymore. To bring order to the arsenal and to work more economically and user-friendly, the machine builder is now relying on ISCAR's modular HELISLOT system.
"With our 45 employees, we have been developing and manufacturing customized load handling devices for intralogistics in warehouses and production, and everything related to it, for over 50 years," describes Frederic Schneider, managing director of AFB Anlagen- und Filterbau. He leads the family business from Haiger/Hessen in its third generation. "From telescopic tables to autonomous transport vehicles, everything is included," Schneider adds. With its intralogistics solutions, the machine builder generates sales of nearly six million euros.
AFB typically delivers its solutions directly to system integrators, who then implement them in facilities around the world. "Our customers expect absolutely reliable solutions that operate continuously, function 24/7, and provide flexibility and a quick response," explains Frederic Schneider.
To ensure this, AFB produces most components in-house. 1,200 of the 2,200 square meters of production area are reserved for machining. "All steel parts that fit on the four-meter bed of our largest machine come from our house," says production manager Marvin Jung. AFB primarily works with C45 steel and chrome steels that offer high dimensional accuracy and good strength. This results in profiles in different variants and batch sizes between two and ten parts for the load receivers.
"We only achieve larger batches with our chain tensioner housings," explains the production manager. "There we reach around 500 parts per production batch."
Getting a Handle on the Chaos
But back to the profiles – to equip these important components with the necessary guide and roller tracks, AFB previously used a whole range of different screw-on slot milling cutters from various manufacturers. "Since we work 95 percent on a project basis, over the years we accumulated a whole arsenal of standard and special cutters, for which some plates were no longer available," describes production planner Christian Hudel the situation. "It couldn't go on like this."
To get a handle on the chaos with the tools, the AFB team turned to ISCAR.
"On the wish list was a stable and process-safe slot milling system that covers all cutting widths and diameters for both standard and special solutions, is user-friendly, and enables economical and productive machining," lists Rolf Behrendt, Regional Sales Manager at ISCAR. "I didn't have to think long about it. This described exactly our HELISLOT."
Stability Meets Economy
The HELISLOT is ISCAR's efficient disc cutter with square, eight-edged indexable cutting inserts (WSP) for the economical creation of grooves and T-slots. The monoblock tools are available as disc and insert cutters with diameters from 32 to 200 millimeters and for groove widths between seven and 24 millimeters.
The cutters are equipped with double-sided WSP for machining alloyed steel, ferritic and martensitic stainless steel, as well as cast iron from innovative ISCAR SUMOTEC cutting material grades. The dovetail-like clamping ensures a stable insert seat.
The double-sided WSP with eight helical cutting edges and specially twisted chip surfaces contribute to a stable and smooth cut even at high cutting rates. The combination of staggered teeth, positive rake angle, and stable WSP clamping ensures high process reliability and productivity even in challenging machining tasks.
"AFB has been successfully using the HELISLOT in a standard version for several years," says Rolf Behrendt. "I didn't have to do much convincing."
The machine builder uses HELISLOT standard milling cutters with diameters of 80 and 125 millimeters in cutting widths of six and 13 millimeters, as well as special tools with a diameter of 120 millimeters and a cutting width of 35 millimeters.
Expectations Fully Met
AFB can now integrate the two guide and roller tracks into center table profiles with HELISLOT 20 minutes faster and reduce the overall time for the three-sided machining by almost a third. "Thanks to the monoblock tool, we benefit from greater stability and experience less vibration," says Marvin Jung and lists: "This allows us to achieve higher cutting values, larger engagement widths are possible, we have longer tool life, and the people at the machine are happy about quick and easy insert changes."
Production planner Christian Hudel is satisfied: "The new solution has fully met our expectations. With the stably constructed cutter trio, we can now cover all application cases in a process-safe manner and thanks to the eight cutting edges, we can also manufacture more economically and faster." The collaboration with ISCAR has once again been excellent in this project. "We have a long-standing relationship of trust," says Frederic Schneider. "We can be sure that ISCAR stands by us as a competent partner with advice and action and knows what we need."
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