About Aggregates / Angle Heads
What will an angle head do for my machine and my business? The possibilities are endless. And here at BENZ, we have over 60 years experience in the design an manufacturing of angle heads for all applications; boring, routing and sawing. Our angle heads are suitable for panels, solid wood, MDF, aluminum, slot wall, plastics, metal and many more materials.
In an effort to assist our prospective customers to decide IF they need an angle head and, if so, what configuration would best suit their budget and application, BENZ offers some basic points relative to the advantages of using angle heads on a CNC machine. To get the ball rolling, we begin with some basic points regarding the use of angle heads with existing CNC machines.
Have a question about our angle heads? See questions and answers below.
Will an angle head fit on ANY CNC machine?
YES, with a few minor exceptions. Some of the important issues to consider are as follows: Spindle motor size – absolute minimum 5 HP. Spindle motor connection type: HSK 63F, HSK 63E, ISO 30 (also known as SK 30), BT 30, BT 35 and BT 40 are among the most common connections. It is also possible for us to supply an angle head for a spindle which is equipped with a “nut and collet’ style connection.
Can an angle head be placed into a tool change carousel and be programmed for an “automatic tool change”?
This is determined by the size and configuration of both the tool change carousel and the angle head itself. In most cases this is not only possibly but also – the most efficient way to use an angle head. The average weight for most of our angle heads is approx. 8 to 10 lbs. Please refer to the maximum weight capacity of your tool carousel. This information is available from either your machine manual or directly from your machine dealer. If you are unable to determine this information from either of these sources, contact the Original Equipment Manufacturer. When placing an angle head in the carousel, it is not uncommon that the tool holder position on either side of the angle head may be lost. It is also very important to be sure that there is ample clearance around the tool carousel so that the tooling used in the angle head does not make contact with any part of the CNC machine when the carousel is rotating. Please note that we offer several angle heads which are simply “much too heavy” to place in a tool change carousel. These aggregates can be manually inserted into the spindle motor or you can contact your OEM for a more custom solution, which will still allow for an automatic tool change. I.E. Independent aggregate “garage” – typically located at one end of the machine table.
What are the primary advantages of using an angle head versus the standard machine spindle?
In simple layman’s terms…an aggregate tool is a “right angle” gearbox (with numerous variations). How many times have you programmed your CNC router to machine a component only to realize that it would be far more efficient if you could use a cutter head in a horizontal position rather than a router bit in a vertical position? A good example of this would be the process of “V-grooving”. When a “V-bit” is used in a standard router spindle, the infinite point of the tool has absolutely no rim speed – a tooling function that is critical for good quality machining. This will surely result in less than perfect cut quality. In addition, a much greater feed speed can be achieved using a V-grooving cutter head on a right angle head reducing your overall machining cycle times – making your machine more profitable. What about horizontal machining? How many times have you finished the vertical machining of your work piece on the CNC machine and then had to take it to another station for any/all horizontal machining applications? Any CNC machine can be programmed to perform unlimited horizontal machining operations when an angle head is utilized. Furthermore it is important to note that you are not limited to machining at 90°. BENZ right angle heads can be manufactured with fixed angles other than 90° for operations such as beveled edge machining on entry doors. A commonly used BENZ aggregate is the adjustable right angle head. This unit can be preset from 0° to 100°. If your machine is equipped with an interpolating “C” axis, the addition of an angle head turns this machine into a true 4-axis router. By program, all four sides of a work piece can be machined with a single outlet aggregate tool. Other variations of angle heads include: Floating heads – these angle heads are designed to “float” along the top surface of a work piece which may have thickness tolerance and are used for consistent depth cutting for inlay machining, engraving applications or even profiling of work piece edges. Small and Large Molder heads – these angle heads will hold planer and profile type cutterheads for strait milling and profile cutting applications. Tool size (length) for these heads ranges from 20 mm (approx 1”) up to 120 mm (approx 4 _”). When used with a “C” axis, these heads will provide you with the ability to machine a full range of curved moldings. Undersurface Trimming Unit – with this angle head an elevated work piece can be machined from underneath up to 6” in from the edge. Corner Notching Unit – how do you make square corners with a round tool? After machining a square opening in an elevated work piece with the standard router spindle you are left with radius corners. This angle head, which utilizes a small rotary cutter head, plunges from the top and “squares” the corner. Machine must be equipped with “positioning” or “interpolating” C axis in order to square all 4 (four) corners of the cutout. Minimum cutout size 4” X 4”. Multi spindle gang drills – these angle heads, available in vertical or horizontal configurations are designed to produce row holes in a single pass. 3, 5 or 7 spindle units are available with 20 mm, 25 mm or 32 mm center-to-center spacing. The spindles are NOT individually selectable. Speeders – increase or decease your maximum and minimum output speeds from your spindle motor for engraving or sanding applications.
What if a customer has more than one brand of CNC machine – must an angle head be purchased for each machine?
With the new BENZ modular design for flexible application, a customer can use the same angle head on more than one brand of machine IF the machines are equipped with the same type of spindle output connection (e.g. HSK 63F, ISO 30, etc.) Each brand of CNC machine has it’s own unique spindle connection specifications for angle head tooling. The connection mechanism on all BENZ angle heads is a removable device, which we refer to as the “torque arm”. Each “torque arm” is unique to a specific brand of machine. If a manufacturing company operates multiple brands of CNC equipment – all equipped with a common spindle output connection, they can purchase one common aggregate with a number of “torque arms” – one for each brand. The torque arm is easily changed and also provides users the flexibility of rotating the orientation of the angle head from 0° to 360° on the horizontal plane. This is an ideal function for those machines not equipped with “C” axis.