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Without accurate, repeatable workholding, the best machine tools will fail to deliver the performance required, regardless of past size. The challenges are different according to size, shape, material types and machine type, but all processes need careful planning that takes into account the requirements for clamping parts accurately and securely, the various types of fixtures for milling applications and the various types of chucks for turning.
“Fixturing for machining centers involves using tombstones or modular systems with hydraulic or manual clamps to hold multiple prismatic parts stationary during machining, while workholding for CNC turning and multitasking machines involves choosing from a wide array of available chuck styles,” says Joe Kraemer, corporate accounts manager at Mazak Corp., Florence, Ky.
“One of the very first considerations is usually manual versus hydraulic clamping. Manual clamping is less expensive, easier to build, but it’s not as repeatable, requiring operator attention to tighten down bolts and clamps. It could be beneficial to use a programmable torque wrench to ensure consistent clamping operator to operator, for example. Manual clamping is also slower. For applications where cycle times are fairly short and part loading and unloading speed are important, as well as loading repeatability, hydraulic clamping, though more expensive, is a better choice,” Kraemer says.
When it comes to chucks for multitasking machines, such as Mazak’s Integrex machines, there is a wide variety of chucks to choose from, including 2-, 3- and 4-jaw chucks, hydraulic and manual collet chucks, pullback chucks, and compensating and self-centering chucks. For twin-spindle, multitasking CNC lathes with a milling spindle, you might have an OD collet chuck on one head and an ID chuck on head number two.
“Choices are application dependent, starting with the material that is being machined. If you’re machining aluminum, which is free cutting, you wouldn’t need as large and strong of a chuck that you would need for machining the harder metals like steel, nickel alloys or titanium,” Kraemer says.
“The main considerations would be how heavy the parts are and how heavy the cuts are and how much clamping force is needed to properly hold the part during machining operations,” he continues. “Other things to consider are the number of jaws and the types of jaws. For example, jaws with teeth that dig into the part for heavier types of cuts.”
Machine tool builders and distributors are an important source of information about workholding solutions, whether for buying new machine applications or bringing new jobs to legacy machines. “That’s where we come in,” says Kraemer. “We have upwards of 80 application engineers in the U.S. that we can call on for workholding solutions. Their job is to look at the parts and make machine and processing recommendations that we can take to the fixture and chuck suppliers so they can provide the proper solutions.”
The mix of workholding product requirements at SMW Autoblok Corp.’s Commercial Division, Wheeling, Illinois, has swung away from the standard 70/30 ratio—special workholding to a 75/25 split in favor of specials to standard, according to President Larry Robbins. That trend has important ramifications for SMW’s U.S.-based customers, as well as for the company‘s product offerings.
“Our customers benefit from the ability to take a standard product and create application-style specials with special touching features or tooling mounts to the faceplate. The disadvantage, of course, is that in the event of a crash the waiting time for replacement can be 12 to 16 weeks versus two to four weeks to replace with off-the-shelf chucks.”
Robbins recommends putting as much flexibility as possible into the shop’s application to meet the change in part families. “Development of electric actuation and data capture is bringing workholding into the 21st century,” he says. “Electronics enables us to get feedback about jaw position, input and output pressure, travel distance and all the variables associated with a job. The reports that are generated enable us to replicate setups from the past because you’re going back to the exact same position every time and you don’t have to probe the part.”
Robbins explains that digitalization in keeping with the objectives of Industry 4.0 IoT allows the shop to have total connectivity between its machines, machine control and plant operating system.
SMW Autoblok provides a range of workholding systems from full hydraulic or pneumatic setups all the way down to manual clamping. For example, the company’s new mechanical, hydraulic and pneumatic vises for stationary workholding are completely configurable in the field. They include the IMG vise, Sintex vises and the SP5 2G vise as well as pneumatic and hydraulic power vises. The SP5 2G system gives the ability to put pins in a part, vise, or fixture and mount/dismount those parts over again, Robbins says.
SMW-Electronics’ product line features non-contact inductive coupler systems that transfer energy and data (up to 1,500 W) via an air gap within a maximum of 20 mm. Products include the new F180 ethernet remote axial coupler that provides wireless transmission between moving and stationary components with a high-speed power transmission of up to 400 W, and 20-mm transfer distance.
The company also produces a line of intelligent sensor systems, including the LPS 4.0 position sensor that identifies the exact position of a sensor element wirelessly with accurate repeatability. The LPS 4.0 is also protected to IP67 and offers EMC properties.
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SMW Autoblok’s new Mag Autoblok division includes a line of permanent electromagnetic chucking systems for workholding on horizontal and vertical milling machines, vertical turning centers, FMS systems, grinding machines and EDMs. A line of magnetic lifters is also offered.
Manufacturers face ongoing challenges meeting demands for low-volume, high-mix production. Tim Wachs, president of Hainbuch America Corp. in Germantown, Wis., emphasizes the critical need for quick changeover capabilities, especially for part lots ranging from 50 to 2,000 parts. This requires flexible machine clamping systems that offer rigidity, accuracy and repeatability in the machining process.
For more than 70 years, the Hainbuch System has continuously evolved to provide time-saving solutions for a range of processes including turning, milling, grinding and drilling. “With the Hainbuch System, you only require one basic clamping device, such as a chuck or stationary chuck, which remains on the machine,” Wachs explains. “Adaptations are available for O.D., I.D., jaw or magnetic clamping or clamping between centers, tailored to the workpiece and application. This significantly reduces setup time, increases flexibility and allows for efficient handling of short-term jobs.”
The Hainbuch System originated with a quick-change clamping head designed to reduce changeover times for multiple-spindle automatic lathes. This clamping head, comprising three separate segments held together through vulcanization with proprietary rubber chemistry, expands and contracts between segments. This design ensures quick and precise changes for different sizes, surpassing traditional collets made from a solid metal piece with slits that might deform over time. These segmented clamping heads remain foundational for Hainbuch’s ongoing innovations.
The Hainbuch System offers two primary workholding variants: SPANNTOP, featuring round clamping geometry for higher holding force compared to conventional 3-jaw chucks and collets; and TOPlus, with hexagonal geometry providing a 25% increase in clamping force over the round variant, along with improved metal removal rates and vibration dampening.
Hainbuch’s workholding solutions cater to diverse industry applications including automotive, medical devices, tool and mold making, micromachining, aerospace, pump and compressor manufacturing. The range of parts benefiting from Hainbuch’s precision workholding spans from hip joints and shafts to brake discs, motor housings, axle housings, pistons, injectors and pump impellers.
Originally designed for quick-change solutions in multispindle automatic lathes, Hainbuch’s workholding systems are equally effective for single- and twin-spindle lathes, standard turning centers and multitasking machines with milling spindles.
“Our workholding solutions are particularly effective in scenarios requiring rigidity, such as when machining flats with a main spindle, subspindle, and milling spindle,” Wachs says. He notes recent advancements in the company’s expanding mandrels called MAXXOS, utilizing the same technology as the separate vulcanized-rubber segments in its clamping heads, resulting in a 25% increase in clamping power.
Hainbuch’s product offerings now include the centroteX and centroteX-S (quick-changeover interface for small spindles), as well as Hainbuch’s centroteX AC automated workholding changeover system. “The centroteX AC stands out as a revolutionary solution in CNC machining for several key reasons,” Wachs boasts. “Firstly, it drastically enhances efficiency by automating the process of switching workholding devices such as 3-jaw chucks to clamping-head chucks on CNC machines, reducing setup times significantly. This automation not only minimizes downtime but also mitigates the risks associated with manual intervention, ensuring smoother operations and higher productivity levels.”
Secondly, the centroteX AC system offers unparalleled flexibility and precision, says Wachs. “Its ability to swiftly adapt to different workpieces and machining requirements enables manufacturers to respond swiftly to changing production needs while maintaining the accuracy and consistency of machining operations. By combining automation with compatibility across a wide range of CNC machines and workholding devices, Hainbuch’s centroteX AC system represents a transformative advancement in CNC machining technology, poised to optimize manufacturing processes and bolster competitiveness in today’s dynamic market landscape.”
Lang Technovation Co., Hartland, Wis, has upgraded its unique workholding technology for milling applications with three advances in technology which continue to reduce setup times and increase machine utilization, according to Jon Dobosenski, general manager. “The Makro Grip FS (full serration) system features a newly revised stamping unit that works hand in hand with a new series of FS vises, which boast an increase in gripping and holding power. In addition, shops working with pallet pools are saving money with Lang’s new rail system as the Quick Point interface between pallet or machine table and workholding device. Finally, we introduced the new small and mighty micro vise to help our customers with small parts.”
The key to Lang’s stamping technology offers an alternative to clamping by form fit. “This three-dimensional clamping enables a significantly higher holding force with comparatively, very low clamping force. In addition, raw parts don’t have to be prepared further, as is the case with dovetail milling, resulting in savings on needing additional machine capacity and time,” says Dobosenski. Lang’s form closure Makro-Grip technology involves stamping indentations on the workpiece to match the gripping serrations of the clamping jaws. A pyramid-shaped clamping serration engages in a corresponding negative form on the workpiece.
“The new form-fit between the continuous holding serration and the matching contour in the pre-stamped workpiece blank increases the holding force by up to 60%, depending on the material and stamping depth. For machining, this means even more reliability and safety in workpiece clamping and, in turn, allows higher cutting performance and ensures faster milling processes,” Dobosenski says.
The FS series five-axis vises are available in all previously known sizes and models as well as a new mini version.
Customers who already use the Makro Grip 5-Axis standard vises in production can continue to use them with the new FS stamping unit. Pre-stamped workpiece blanks with a continuous contour can be held by form-fit in the previous holding serration of the five-axis vise without a problem—even at higher holding forces. What applies to the five-axis vise in terms of compatibility also applies to the stamping unit. For customers that decide in favor of the new FS vises but are already working with a stamping unit in their machine shop, a conversion set is available. This enables the use of new types of stamping jaws on existing stamping units.
“As an interface between machine table and workholding device, the Quick Point plates and rail system is characterized by an enormous range of variations and provides a solution for nearly any machine tool when it comes to setup time savings and minimization of unproductive time. Our workholding vise family can hold parts from round, rectangular or square in shape, for single or multiple clamping. It can be used universally in vertical and horizontal machining centers, on three- and five-axis tables and 4th axis rotary or trunnion systems,” says Dobosenski.
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