January 2008 Edition
IMTS readers' choice
Tooling & Production has invited IMTS 2008
exhibitors to share their latest innovations with readers
before the doors of Chicago's McCormick Place open in
September. This month, T&P focuses on workholding and
toolholding products.
In the coming months before the greatest show in
manufacturing, T&P will feature cutting tools, inspection
products, software, laser and waterjet marvels, abrasive
machining products, and the best in turning and machining.
Use the Rsleads addresses at the end of each listing
to receive more information directly from the company. T&P
will gage the level of interest in each product and
determine the Readers' Choice winners, which will be
featured in the big August pre-show issue.
Quick-clamping vise
The
Dapra T-REX vise boasts adjustable gripper studs embedded
into the workpiece, allowing safe and quick clamping of raw
parts, thermal cut parts, and sawn-off material. It has a
movable pivot jaw that accommodates different workpiece
shapes. It is also designed for easy operation with a
mechanical power intensifier.
The top and bottom sides are ground, and the bottom side
has accurate aligning slots and a positioning hole. The
spindle of this vise is entirely closed and nitrated,
ensuring high reliability, protecting against contaminants
and chips and minimizing cleaning time. Dapra Corp.,
www.rsleads.com/801tp-169
Pull-down chuck
SMW
Autoblok's TX pull-down chuck features repeatability of up
to 4μm (0.00015") and is designed to operate under
aggressive cutting conditions. The TX chuck is ideal for
secondary machining operations in which high levels of
accuracy and parallelism are required.
Designed to operate with less wear than any other
pull-down chuck, the TX chuck disperses cutting forces over
an increased area. This is especially important for
applications with heavy tool loads (such as in milling or
interrupted turning). It also allows the chuck to hold its
accuracy over an extended period of time. Furthermore, the
master jaws are pinned to the chuck body, providing
additional rigidity and allowing the TX chuck to work
effectively in milling as well as turning operations.
The TX chuck is completely sealed and will run six months
in around-the-clock operation without additional
lubrication. This ensures less maintenance, more spindle run
time, and more consistent part gripping. It will be
initially available in 8", 10", and 12" sizes. SMW
Autoblok Corp.,
www.rsleads.com/801tp-170
Hydraulic toolholders
Schunk
Inc. introduces new features to its hydraulic toolholders,
modifying its bestseller TENDO to be able to clamp different
types of cutting tools with cylindrical shanks directly in
the toolholder without using intermediate sleeves. This
makes this toolholder even more universal during its
application of various tasks. Torque transmission capacity
has also been increased by up to 15 percent.
A steel sleeve surrounded by hydraulic fluid performs the
clamping of the cutting tool. When initializing the clamping
process, an internal piston forces the hydraulic fluid into
a cavity surrounding the steel sleeve. The high pressure
uniformly forces the sleeve around any cutting tool shank.
Cutting tools with different shanks are held with great
concentricity of less than 0.002mm. The enormous clamping
pressure displaces oil or grease into the TENDO groove in
the clamping bore. Clamping areas remain dry and high-torque
transmission is guaranteed at all spindle speeds. The
hydraulic system also absorbs vibrations inherent in the
cutting or grinding processes. The results are very high TIR
accuracy and repeatability of less than 3 microns
(0.00012"), tool life is extended up to four times, and
greatly improved surface quality of machined parts.
The toolholders are suitable for high-speed and fine
milling, heavy-duty milling, wood machining, high-speed
machining, internal grinding, boring and chamfering,
precision reaming, and precision tool grinding. All TENDO
toolholders are completely closed systems that operate free
of dirt, coolants, lubricants, and chips to ensure low
maintenance and high operating lifetime. As an option, TENDO
toolholders are available with a radial length adjustment
allowing micro-precise adjustment to guarantee higher
process performance. Schunk Inc.,
www.rsleads/801tp-171
New master plates
New master plates from Carr Lane are ideal for machining
large thin-walled parts. Made in three sections that mount
on a chuck similarly to top jaws, the plates accept a wide
variety of machinable jaw segments.
The plates are available for chucks from 10" to 60"
diameter, in standard height and extra high. Made of
aluminum alloy, the plates' mounting pattern is machined to
the chuck's specifications when the customer specifies make
and size of chuck when ordering. Carr Lane Mfg. Co.,
www.rsleads.com/801tp-172
SG design system
Emuge
Corp. offers the System SG expanding-bush design workholding
solution. Emuge's System SG is used in many machining
operations such as hobbing, shaping, and shaving for gear
production, as well as milling and inspection.
System SG design is based on a series of short tapers,
which expand or contract when acted upon by an axial force.
System SG can be designed for ID or OD clamping, allowing
for expansion and contraction. A key benefit of the SG
design is the large surface area contact with the workpiece,
which securely holds almost the entire diameter of the
clamping area.
System SG expanding-bush is also designed to give the
workpiece a slight axial movement toward an end stop, adding
rigidity to the operation. The result is a clamping solution
which is very rigid, accurate and repeatable. In addition,
System SG is capable of handling higher transferable torque
values experienced in today's machining operations while
maintaining its mechanical reliability. Emuge Corp.,
www.rsleads.com/801tp-173
Grinding chucks
SAV
North America, the recently established subsidiary of Spann
Automations Normteiletechnik (SAV) GmbH of Nuremberg,
Germany, is launching several new workholding lines in the
United States, Canada, and Mexico. The first of these is a
series of fine pole transverse electromagnetic chucks for
surface, or reciprocating, grinding applications.
Of particular interest to users is the pole orientation
of these chucks is 90° to the grinding forces. This
orientation provides stronger holding power than similar
designs on the market. Further, an increased number of
magnetic circuits result in improved performance over other
chucks in this class. The number of circuits is relational
to the size of the chuck.
The SAV surface grinder chucks offer consistent, uniform
holding conditions over the entire work area. The nominal
holding force is 145lb/in2
(100N/cm2). Their low profile design
increases machine capacity. This design is also available in
permanent and electro-permanent variations. Standard sizes
are available from stock at the Connecticut facility. SAV
engineers can also design and build custom sizes for special
applications.
SAV North America,
www.rsleads.com/801tp-174
Clamping system
The
Unilock Clamping System from BIG Kaiser Precision Tooling
Inc. helps reduce setup time and part-processing time.
Unilock's simple clamping concept provides a comprehensive
system to position and clamp workpieces for the most
efficient part loading. Unilock's clamping mechanism
utilizes spring pressure to drive wedges against a tapered
wedge lock (clamping knob). Air pressure is used to compress
the springs, releasing the wedge lock.
Unilock can be used on workpieces of any size or weight.
For small part machining, the system eliminates the need for
repeated clamping and unclamping, minimizing unnecessary
labor and the chance for errors. For large work, a crane can
be used to position a heavy workpiece into an exact position
in minutes.
The system can be used in any configuration and in almost
any process. Multiple receiver sizes are provided so the
system size can be matched to the process. A simple load,
lock, and cycle start scenario cuts down time. BIG
Kaiser Precision Tooling,
www.rsleads.com/801tp-175
Magnetic chucks
MagVISE
EEPM (electro-permanent) chucks are used for normal and
heavy-duty drilling, milling, and boring operations on
medium- or large-sized workpieces. Rough and uneven stock is
no problem to hold. Simply use the sliding pole extensions
to support uneven workpieces. A minimum of four alternate
poles contact is necessary for optimum magnetic holding
power. Minimum thickness of job is 3/4".
EEPM magnetic workholding chucks drastically reduce setup
time while maintaining uniform electro-permanent holding
power over the entire workpiece. Since workpiece distortion
does not occur, tool chatter is minimized and surface finish
and tool life are improved.
No electricity is needed to keep the EEPM chuck on; the
magnet keeps on holding tight even during a complete power
loss. Earth-Chain Inc.,
www.rsleads.com/801tp-176
Magnetic solution
Tarus
Products of Sterling Heights, MI, recently introduced a new
heavy-duty compound angle deep hole drilling machine with
the ability to drill deep holes at almost any angle at any
orientation in steel mold blocks. The machine combines a
tilt drill head with a rotary table – almost complete
compound angle capability in a single setup. In developing
this new machine, workholding became a major factor. The
solution for achieving absolute access proved to be a
magnetic table.
After reviewing various options, Tarus chose to partner
with Wen Magnetics of Raleigh, NC, to build the magnetic
system directly into the machine's rotary table. While
placing standard magnetic chucks on top of the table is
possible, the integral solution yields optimal strength and
stiffness without consuming machine envelope and allowing
for full integration with the machine's control.
The final design uses a 50mm square pole magnet system
integrated into the rotary table with a full metal face for
durability – no exposed resin. The electrical connection is
permanent using a rotary coupling – no connectors – and the
control unit is integrated with the machine control.
With 120 magnetic poles covering the rotary table, the
workpiece is secured with up to 45 tons of pull force – more
than enough to hold it in place – and all in a matter of two
seconds. Wen Magnetics,
www.rsleads.com/801tp-177
Production vises
Jergens
Inc. announces a new series of hydraulic-powered production
vises. The vises combine an innovative compact design with
jaw changeovers taking less than a minute to provide
significant flexibility to workholding. Internal hydraulics
provide up to 4,700lb clamping capacity.
Three base styles are available. The Ball Lock Mounting
System style features an interlocking "jigsaw" pattern,
which permits multiple vises to closely nest together,
maximizing workpiece density on a fixture while
simultaneously allowing changeover of entire vises in a
minute. The universal base style mounts directly to machine
tables. The narrow base style is designed for stand-alone
fixture plate mounting while providing high-density
capability.
The vises have many other advanced features to help speed
production – all jaws are fully machinable and reversible,
providing more flexibility for each jaw set; steel rails are
hardened and ground for accuracy and repeatability; a
flow-through base lets chips and fluids escape; and a fully
sealed lead screw assembly reduces maintenance.
Jergens Inc.,
www.rsleads.com/801tp-178
Collet blocks
Hardinge
collet blocks can be used horizontally or vertically on mill
tables, flat or angled fixture plates, tombstones, or rotary
trunnions. Sizes are available from the 1C micro medical
machining industry up to the 35J mid-range automotive and
aerospace industries. Modular collets blocks are compact
with a low profile for increased axis travel and for maximum
layout of the workspace. A collet can provide certain
advantages over a jaw chuck, vise and other clamping
methods.
A collet automatically centers the workpiece for reduced
setup time. Centers remain fixed when the fixture is removed
from the machine table. A collet provides equal gripping
pressure around the circumference of the part unlike a
standard vise or a three-point contact jaw chuck. Thin-wall
parts or delicate materials may crush or distort in a
standard vise or jaw chuck. Collets ordered with serrations
can add additional gripping power to prevent push-back and
radial slipping. Extended-nose collets can provide
additional tool clearance. Some collet blocks accept
expanding collets to grip a part at the internal diameter.
Hardinge Inc.,www.rsleads.com/801tp-179
Steady rests
LNS
America has developed new steady rest configurations for a
variety of applications that allow precise machining of
exceptionally long workpieces used in oil drilling and large
truck drive shafts.
These systems can also be used in any application in
which the length and stiffness of a workpiece makes it
difficult to machine without distortion or deflection.
In addition to a broad assortment of quality steady rest
components, LNS devotes extensive applications experience,
3-D design capabilities, and nationwide service and support
to every steady rest project.
LNS America Inc.,www.rsleads.com/801tp-180
Rotary table
The
Tsudakoma RTV-202 is a direct drive, ultra-high-speed,
super-precision rotary table. The RTV-202 features a top
speed of 150rpm and indexing accuracy of ±5arc sec. A FANUC
servo motor powers the gearless RTV-202 generating zero
backlash.
Koma Precision Inc. is the exclusive North American
importer of Tsudakoma rotary tables, Alberti angle heads and
live tools, JauchSchmider EDM rotary tables, Koma Z+ angle
heads and live tools, and Romai specialty tooling.
Koma Precision Inc.,
www.rsleads.com/801p-181
Five-axis clamping
The
workholding answer to five-axis machining operations is the
new five-axis clamping system. It allows continuous
five-axis cutting motion of complex pockets, sculptured and
contoured surfaces, and intricate 3-D features with
repeatable high-precision accuracy. Called the Kurt VB 5X100
Schenke 5.1 Clamping System, this system provides a clamping
force up to 8,992lb (40kN) for obstruction-free, high-speed
machining in all five axes. Where conventional workholding
limits a five-axis machining center to just three-axis
operation, the Kurt VB 5X100 Schenke 5.1 Clamping System
extends the operating range of the machining center to its
full output potential.
The system is adjustable to handle any desired clamping
width and it is limited only by the size of the machine
table. The system's two clamping jaws, one stationary and
one moveable, can be positioned at any desired distance from
each other.
Kurt Manufacturing says its new VB 5X100 Schenke 5.1
Clamping System eliminates jaw deflection and/or part
misalignment during machining operations. By locating the
tension spindle directly under the workpiece, the jaws do
not flare out under tension and the machine table does not
distort. The system handles blank workpieces, machined
workpieces, and round and irregularly shaped workpieces with
repeatable accuracy.
Specifications of the Kurt VB 5X100 Schenke 5.1 Clamping
System include a clamping width from 0.0787" to 9.291" (2mm
to 236mm) that can be extended with optional spindle screws,
a clamping depth of 0.315" (8mm), height above the machine
table of 6.889" (175mm) with extended height options to
7.874" (200mm) and 8.858" (225 mm). The system is designed
to mount easily on standard T-slot tables, location grid
machine tables, or custom fixtures. Kurt
Manufacturing Co.,
www.rsleads.com/801tp-182
VC toolholder
Lyndex-Nikken's new high-performance VC Toolholder,
operating at up to 40,000rpm, offers the ultimate in high
speed, high accuracy and ultra-smooth surface finishes. The
unique design characteristics of the VC result in high
accuracy (runout is within 0.00012" at 4xD) and finishes.
Its slim and smooth profile eliminates noise related to
high-speed rotation, while it reduces the air current
created by the hex nuts and slots on the periphery of most
toolholders. Dampening of micro harmonic vibrations is
achieved with the use of a groove under the nut. What's
more, a thicker wall at the base of the VC and its short
gage length allow for greater rigidity and static stiffness.
As an option, axial adjustment is easily achieved with an
adjustment screw. High-pressure coolant-thru is also
available. The VC design features a TiN bearing nut that
makes greater torque possible by reducing the friction
associated with nut tightening.
The eight-degree collet design of the VC further
contributes to rigidity and gripping torque. The extended
straight portion of the collet pilots and maintains the
concentric placement of the tool.
Easy to use, the VC does not require fixtures or
couplings to install or remove collets from nuts. A GH
handle wrench provides two-way lock and unlock for quick
installation of tooling.
The VC is available in 30-, 40-, and 50-tapers, as well
as HSK and Nikken 3-Lock models. Lyndex-Nikken Inc.,
www.rsleads.com/801tp-183
Adapters
Setup
times can be reduced with the most accurate and flexible
PRECI-FLEX system available today. Adapters are available
for standard mill/drill operations, end milling, tapping and
shell mills. Collet chucks can be adapted to reduce overhang
and tool interference. The basic adapters accept standard
collets in either ER 25, ER 32, or ER 40 pocket
configuration. These economical adapters fit into this
pocket of the basic holder in an axial or radial
configuration for fixed and live tools. Major turning center
OEMs have already exclusively converted to this system to
reduce setup times and are experiencing extremely short
setup cycles by presetting tools off the machine for a quick
changeover on the machine. Repeatability of this system is
in the low microns. Exsys Tool Inc.,
www.rsleads.com/801tp-184
Face driver
LMC
Workholding introduces the new Neidlein FBS MK5 face driver.
The FBS MK5 features a fixed center for high-quality turning
and a near-zero runout designed specifically for hard
turning or grinding operations. The FBS MK5 turns a
workpiece from end to end in one operation and eliminates
drive dogs.
Neidlein face drivers allow the entire OD of a workpiece
to be machined in a single operation, providing increased
productivity, quality, and cost efficiency while eliminating
changeovers. Mechanical face drivers are virtually
maintenance-free and can allow for heavy and interrupted
cuts, turn small and large parts, and increase flexibility
in turning applications for faster cycle times. LMC
Workholding,
www.rsleads.com/801tp-185