EXTEND THE CAPABILITIES OF YOUR CNC MACHINE

Aggregate heads are special tool holders that can be connected to the main spindle of the router, just like a regular tool. However, they enable you to tackle various machining tasks from different angles and simultaneously add new functionalities. So if you aim to upgrade your machining capabilities and watch your productivity soar, these versatile accessories are definitely worth serious consideration.

We could go on and on about aggregates, although sometimes few words say it all. Here some of the real life feedback from clients who have gone through the aggregate head journey with us:

• "It's opened up a whole new market segment for us that will be worth hundreds of thousands to us over time."
• “We’re now starting to win those projects that were too difficult earlier.”
• “I can't believe the amount of time that it's shaved off the production cycles!”

What is an aggregate?

In essence an aggregate is a specially designed tool holder that allows you to extend the capabilities of your CNC machine. An angular aggregate, or angle head, supports the functionality of a CNC machine and acts as an extended arm of the motor spindle. Also, many standard tools fit without modification to connect to an aggregate.

Depending on your application, you can use aggregates with up to 4 separate tool outlets. Most aggregates can be stored in the tool changer on your machine and connect to the main spindle of the router with an ISO or HSK interface, just like a regular tool. Anyway, some aggregates can handle different tool holders on a single unit.

Here's are the main parts of the set:

1. CNC Motor Spindle
Combining an electric motor, a tool interface, and a tool clamping system, the motor spindle is the heart of the CNC machine. The motor spindle clamps the tools and aggregates and supplies the rotational speed and torque for machining.

2. C-Axis
With C-axis, the aggregate can use the clamped-in tools with different approach angles. Rotations about the Z-axis of the machine are simple and time-saving because the C-axis, can rotate the aggregate by 360 degrees into a preset position.

3. Torque Arm
The torque arm is the part that secures the aggregate against spinning. It prevents the static parts from rotating during machining. It also reduces vibrations, supports the aggregate against acting machining forces. The locating pins specified by the machine manufacturer are built into the torque arm of the aggregate and engage in the machine’s anti-rotation torque support ring, stop block, or C-axis.

A few operation examples

1. Kitchen: In kitchen manufacturing and cabinet making, aggregate heads are essential for tasks such as edge profiling of countertops and cabinet doors, milling of glued edges, as well as drilling holes for hardware installation. Their precision and versatility ensure seamless integration of functional and decorative elements in kitchen designs.
2. Interiors, furniture and fit-out: Aggregate heads play a crucial role in interior, furniture and fit-out manufacturing projects as they deliver exceptional results with minimal waste. Whether creating custom furniture components or architectural millwork, you get an excellent interior finishing, surface and edge processing in wood, plastic, fibreglass and other composite materials. 
3. Stair, door and window construction: In woodworking applications, aggregate heads excel at precision mortising to create hinges or lock recesses. They are also used for tenon cutting, which is crucial for creating strong and durable joints in stair components and door frames.
4. Acoustic wall or ceiling application: Ideal for creating cavities in acoustic panels for sound absorption. Aggregate heads are also used for perforating and V Grooving in foam, polyester or other core soft materials for sound diffusion and mitred corners. The versatility and efficiency of aggregate heads accelerate the product development cycle, allowing for faster time-to-market. 
5. Automotive, aerospace & train transportation industries: From aerospace components to automotive parts, aggregate heads ensure accuracy and consistency in machining composite materials. In metalworking industries, they are also used for aluminium milling to machine parts for vehicles, aircraft, and trains.
6. Medical Device Manufacturing: Aggregate heads play a crucial role in smooth surface finishes on medical device components, where precision and quality are paramount. From surgical instruments to implantable devices, aggregate heads ensure compliance with stringent regulatory standards and exacting specifications in manufacturing processes.

Cooling and lubricating

To ensure optimal performance, it is important to keep any aggregate cool and lubricated, because how you keep the aggregate cooled is critical to the longevity of the aggregate. Keeping it as cool as possible while it's in use is the goal.

Excess heat is a result of excess torque on the gear set, often caused by excessive feed speed, too much chip load or insufficient RPMs. However, heat can be controlled by monitoring the temperature of the aggregate. Most aggregates come with a temperature strip fitted on the side of the body and it is up to the operator to keep an eye on the unit and make sure it does not exceed the maximum safe operating temperature indicated by the strip.

Oil or grease lubrication is the most common method of cooling the high-speed gears. It is recommended to use high-quality oils or lubes specifically formulated for the materials as recommended by the manufacturer to cope with operating conditions encountered during machining processes. Factors to consider include viscosity, temperature range, friction reduction properties, and compatibility with machine components.

In general, the CNC machine needs to be powerful enough and suitably configured to fit the aggregate, and the head needs to remain cool enough to handle the load.

LET US KNOW YOUR SPECIFICATION AND YOUR MACHINE MODEL

There's a wide variety of aggregate types available in the market, with each being suitable for different applications such as kitchen manufacturing, interior finishing, furniture production, doors and windows construction, or surface and edge processing. We have access to aggregate connections for a massive range of CNC machines including:

• Anderson
• Atemag
• Auratronic
• Biesse
• Benz
• Felder
• Fooke
• F. Zimmermann
• HolzHer
• Homag
• IMA Schelling Deutschland
• MAKA Systems
• Masterwood
• Michael Weinig
• MKM International
• Multiax International CNC
• Onsrud
• Reichenbacher Hamuel
• Saomad 2
• SCM
• Technowood
• Thermwood Corporation
• and many more

At Tungsten & Tool, we have the expertise and resources to help you choose the best aggregate for your needs, whether you're sawing, drilling, routing, boring, milling, mortising, flat or contour sanding, polishing, cutting, moulding or machining flat panel or contoured material.

Feel free to contact us at 0800 488 647 or sales@tungstenandtool.co.nz for more information on aggregate heads.