The new ANCA MX7 ULTRA can manufacture large volumes of endmills and other cutting tools of the highest accuracy and quality. The minute size of a micron is beyond the human eye, but moving from micrometers to nanometers, the MX7 ULTRA machine’s performance can maintain less than +/- 0.002mm line form accuracy of any profile which includes ballnose and corner radius endmills. New software, hardware, and design features are combined to make significant advances in surface finish, accuracy, and controlled runout, to deliver batch consistency from the first ground tool to the thousandth. The machine was demonstrated at IMTS—Booth #237406. 

The MX7 ULTRA includes:

• nanometer control system,
• new servo control algorithm for smooth motion,
• system and mechanical upgrades enhance stiffness and rigidity, 
• in-process measuring, balancing, and runout compensation for consistent accuracy, 
• Motor Temperature Control (MTC)—compensation for thermal expansion on the grinding spindle, and
• specialist training support in how to grind cutting tools.

Pat Boland, ANCA co-founder says: “The MX7 ULTRA is a significant development in precision machine design and will change the industry expectations for accuracy and tool life. Achieving these outstanding results has only been possible because of our extensive experience working with customers to manufacture the highest quality cutting tools over many years. At ANCA we are always designing and innovating to find better customer solutions and I am very proud of the ANCA team that has developed the MX7 ULTRA.”

ANCA is vertically integrated. This provides a significant advantage as it means ANCA teams can develop and manufacture their own machines from base to canopy—including controls and drive systems, design and simulation software and even machine monitoring software. Owning all the technology means engineers and designers can consider the entire machine as a single system when developing new solutions.

“It has taken years of research and development, and engineering excellence for us to develop this premium solution to grind high-quality tools. In my 25 years in the industry, I believe this is one of the most outstanding innovations we have accomplished that will really change the cutting tool market. We are confident that our customers will be very satisfied with the life and performance of cutting tools produced on this premium machine,” says Thomson Mathew, ANCA product manager for the MX series and software products. 

The MX7 ULTRA performance highlights

Greater control for the velocity and acceleration or deceleration along with machine jerk limits: To increase the stiffness of the C-axis, the MX7 ULTRA combines developments to the nanometer or micro degree resolution in the linear and rotary axis, tuning parameters, several system enhancements, and major mechanical changes. 

ULTRA-fast response to internal or external disturbances: ANCA’s newly designed servo control algorithm allows silky smooth motion of an axis with the use of a unique algorithm and nanometer measurement in the control system. This will create finer cutting edges and eliminate microchips making it more efficient while used in the actual machining of materials.

Better cycle time and higher productivity of high-quality cutting tools: The unique algorithm is key to the performance of the machine and ensures outstanding tracking performance. It also allows ULTRA performance of the servo system without using a complex, complicated, or expensive mechanical system. 

Reduces setup times and scrap: Cutting-edge software has been developed by ANCA to ensure batch consistency in large volumes. LaserUltra is part of the MX7 ULTRA package to maintain consistency and accuracy of the grinding process which includes in-process measurement and compensation to accommodate wheel wear and other external variations during large batch grinding. Its analog capability can maintain less than +/- 0.002mm line form accuracy of any profile which includes ballnose and corner radius tools. 

Increased wheel life and better-quality tools: Tool and wheel performance can be further optimized by the iBalance software, which guides a user to the optimal grinding position and RPM for vibration monitoring and balancing the wheelpack inside the machine. Correctly balanced wheelpacks result in superior surface finish and reduced wheel wear due to the elimination of wheel vibration. 

Consistency in finished tool quality: A major inclusion in the MX7 ULTRA package is the total tool runout measurement and compensation operation in iGrind. When an endmill is in rotation it is important that each tooth hits at the exact same spot along the workpiece for longer tool life and efficient cutting. Every tool in the batch can be measured and compensated for runout to make sure the entire batch is within a tolerance of 0.002mm. It is another piece of assurance that the first endmill will be as good as the last.

Consistent spindle thermal stability: Motor Temperature Control (MTC) is a patented (US PAT. 11,394,331) innovation built into the motor spindle drive firmware. Smart control algorithm actively manages and maintains the temperature of motorized spindles in the MX7 ULTRA. Dramatically reduced machine warmup time means production can start sooner, once the machine has reached thermal stability. This improves productivity and machine use. Consistent thermal stability of the spindle over time regardless of changes in load or speed, or coolant temperature, greatly improves the dimensional stability of grinding results.

Post grinding processes: The smoother, finer cutting edge and surface finish as a result of the combination of all the above including the nanometer control will assist in all post grinding applications like edge preparation and coating. A finer edge that has been properly prepared has greater stability, which reduces the likelihood of it chipping, while also decreasing surface roughness which can cause increased friction between the tool and the workpiece.