KELCH V9xx-S Integrated Tool Presetter and Shrink-Fit Machine Solution
In aerospace component manufacturing, tool accuracy is directly transferred to the workpiece—whether it is turbine disk dovetail slots, casing mounting holes, or rib contours. Any runout or length deviation of each tool directly affects yield. The KELCH V9xx-S integrates tool measurement, thermal shrink clamping, length presetting, and tool holder cooling into a single workstation, providing an “one-time setup, fully controlled process” tool pre-processing capability for aerospace precision machining workshops.
1. Industry Background and Measurement Challenges
Aerospace part machining is a high-value, zero-tolerance manufacturing process. Difficult-to-machine materials such as titanium alloys and superalloys are extremely sensitive to tool condition. A single scrapped part may result in dozens of hours of machine time loss and tens of thousands of euros in cost. The precision and management level of the tool pre-processing stage directly determine the final yield of CNC machining.
Currently, aerospace workshops face the following core issues in tool pre-processing:
Process fragmentation leads to cumulative errors
After measurement on a tool presetter, tools are transferred to a shrink-fit machine for clamping, then returned to the presetter for re-inspection. Each transfer between the three machines introduces new deviations. Fixture clearance, inconsistent machine datums, and handling impacts are amplified under micron-level tolerances.
Poor consistency in complex tool measurement
Reamers, angle heads, and form milling cutters have irregular cutting-edge geometries. Traditional tool setting relies heavily on operator experience. Different shifts and operators may produce variations of several microns on the same tool, which is sufficient to cause chatter or tool breakage in deep cavity titanium machining.
2. Solution: KELCH V9xx-S
The V9xx-S eliminates accumulated errors from multi-machine workflows through an integrated system featuring a monolithic granite base, fully automatic servo multi-axis control, integrated inductive shrink-fit unit, and EASY measurement software.
Monolithic granite structure ensuring micron-level stability
Traditional tool presetters consist of multiple assembled components, where guideways, base, and floor interfaces all become potential deformation sources. The V9xx-S uses a monolithic cast granite structure widely proven in metrology and precision manufacturing. With high thermal inertia, it is insensitive to workshop temperature variations and internal heat generation. Combined with excellent vibration damping, it maintains sub-micron baseline stability over long-term operation.
CNC servo system + intelligent software for standardized measurement of complex tools
The system is equipped with 5-axis drive and 4-axis CNC servo control, along with a telecentric lens CCD industrial camera, achieving a repeatability of ±2 μm. The EASY software provides Picture Start graphical guidance, allowing users to create automatic measurement programs by simply selecting tool contours. Dedicated measurement routines for reamers and angle heads solve consistency issues for aerospace non-standard tools. The Teach-in function converts complex tasks into standardized programs.
3. Implementation Results
Improved precision
With ±2 μm repeatability, runout and axial dimensions after shrink-fit and presetting are controlled within tolerance, enabling direct machining without trial cutting. First-pass yield of critical operations such as turbine disk dovetail milling and casing boring is significantly improved.
Improved efficiency
A single operator at one workstation completes the entire process from loading to cooled tool removal, replacing the traditional two-machine, three-station workflow (tool presetter + shrink-fit machine). Cooling and measurement run in parallel, significantly reducing batch tool turnaround time and reducing machine idle waiting time.
