Faster Tool Changeovers Achieve Higher Throughput and Increase Flexibility
Technological advances regarding chucks, collets, and quick-change systems boost your shop’s levels of productivity and flexibility to respond to smaller batch sizes. The post Faster Tool Changeovers Achieve Higher Throughput and Increase Flexibility appeared first on Fabricating & Metalworking.
Faster can be better. The ability to change tooling systems, sometimes within seconds, not only reduces setup and changeover times, but guarantees more parts will be produced per shift — without compromising accuracy. Not to mention, these advantages also increase the overall utilization of the machines in your shop.
First Fully Automated Workholding Changeover System
Hainbuch America Corp. (Germantown, WI), a leading name in machining technology, offers manufacturers a seamless and error-free alternative to manual changeovers with its AC (Automated Change) Line. The first fully automated system for workholding device changeovers is setting new standards in manufacturing efficiency and precision.
Key features of the AC Line include:
- Precision Automation: The AC Line’s precision-engineered automation ensures consistent and reliable changeovers, eliminating human error and optimizing machining processes.
- Automated Clamping Heads (Collets) and End-stops: In addition to workholding device changeover, the AC Line automates clamping heads (collets) and end-stops, further enhancing operational efficiency and accuracy.
- User-friendly Interface: Designed with ease of use in mind, the AC Line features an intuitive interface that allows operators to program and adapt quickly, enhancing operational efficiency.
- Versatile Adaptability: From varying part geometries to diverse materials and machining techniques, the AC Line adapts seamlessly to meet a wide range of production requirements, ensuring versatility without compromise.
- Industry-leading Support: Hainbuch America’s commitment to customer success extends beyond innovative technology. Our team of experts provides comprehensive support, from personalized solutions to hands-on guidance, ensuring a seamless integration of the AC Line into existing manufacturing workflows.
Collet Pads and Jaws Expand Machining Capabilities
Dillon Manufacturing, Inc.’s (Springfield, OH) collet pads and jaws, with unique Carbinite coating to better grip parts, allow job shops to perform a range of machining operations, including through-hole chucks that hold small bar stock for Swiss-type machining, and tube stock. In addition, the use of Carbinite coating securely grips parts with varied geometries and allows more aggressive machining for reduced cycle times. Increased capabilities, faster processing, shorter cycle times, greater repeatability, and faster changeovers also enhance the efficiency of the jobs completed, boosting profitability. Dillon collet pads and jaws are ideal for precision boring, high-speed machining, tapping, drilling and finishing. They are especially suited for small diameter machining of stems, spools, crimp assemblies, manifolds for high pressure air systems, medical parts, miscellaneous fittings, mechanical and transmission components and specialty valves, and more.
A collet pad top jaw system increases a chuck’s range of workholding capabilities, allowing more varied part geometries to be machined with the same jaw system. Precision ground collet pads provide tight tolerances for workpieces, with full contact across the gripping surface for greater holding power. Full contact of gripping surfaces provides a more stable grip and allows heavier cuts resulting in shorter cycle times. Round, hex, and square collet pad shapes with both smooth and serrated gripping surfaces available, including Carbinite.
Quick Changeovers result in more machining time. Changing over to collet pad jaws is easily accomplished and requires just a jaw change. The time required to change jaws and collets is generally accomplished in a few minutes and is much quicker than changing entire chucks which may take up to several hours to complete the changeover. The ability to quickly change between sizes allows shops to increase their machine cycle times by up to 30%. Machinists using collet pad jaws can maximize their chuck capabilities and investment by taking advantage of both chuck and collet pad work including the ability to run material that is hex or square in shape. All Dillon Manufacturing products are Made in the USA.
FPC Milling/Drill Chucks Increase Machining Speed and Tool Life
EMUGE (West Boylston, MA) high precision/performance FPC Mill/ Drill Chucks provide unprecedented rigidity, vibration dampening, concentricity, machining speed, and tool life versus conventional chuck technologies for milling and drilling applications.
Featuring the world’s only chuck with a 1:16 worm gear, the EMUGE FPC Chuck’s patented design delivers three tons of traction force. The unique design and body provide 100% holding power for maximum rigidity, and the collet-cone assembly absorbs virtually all vibration for maximum dampening.
Unique features and advantages include:
- Extremely high transferable torque provides maximum process reliability. Transferred torque on a tool shank diameter of 20 mm is 400 Nm.
- Increased accuracy with a 3 X D tool length. Concentricity is ≤ 3 µm to guarantee long tool life and quality workpiece surface finishes.
- Chuck is mechanical drive-actuated with a hex wrench; a simple design that enables quick tool changes in seconds.
- Special holder design reduces vibration, dramatically improves workpiece surface finishes and provides exceptionally long tool life.
- For maximum safety, the strongest clamping force is provided to prevent the possibility of pull out.
EMUGE FPC Chucks are available in five shank styles (CAT, HSK-A, SK, BT and PSC) in 68 different SKUs for a range of applications. A full range of high precision collets and accessories are also available for the FPC line. EMUGE FPC Collets are available in three ranges (FPC 14, 20 and 25) in more than 110 different SKUs, from 1/8- to-1-1/4″ and in metric from 2 mm-to-32 mm.
VC Collet Chuck Provides Superior Accuracy and Rigidity
Lyndex-Nikken (Mundelein, IL), a manufacturer and provider of high-performance machine tool accessories, offers the VC collet chuck that provides high performance for aggressive machining.
For manufacturers that are looking to minimize common challenges such as vibration, chatter, heat generation, workpiece stability, and tool wear — the VC collet chuck provides excellent runout accuracy, cutting rigidity, high precision finish, and high speed rotation. The VC collet chuck is ideal for aggressive milling, high speed machining, thread milling, and ultra-precision reaming applications.
A key design advantage of the VC collet chuck is a TiN bearing nut that reduces friction and improves runout accuracy of 3 microns at four times the diameter of the cutting tool. The TiN bearing nut improves surface finish and ultimately increases cutting tool life.
Additionally, the 8° internal taper collet and ground ion nitrided thread further improves the accuracy of the tool. With the extended collet and collet compression force being perpendicular to the centerline of the collet bore, this maximizes the runout accuracy and is another source of gripping strength. Other features include a thick wall design of the VC body providing cutting rigidity and improved dampening. Further, the symmetrical external nut design, without notches, allows for ultra-high speed rotation of up to G2.5 at 40,000 rpm.
Because a collet system is used, tool changeover is faster and less expensive than a tool holding system that requires a machine in order to insert or extract the cutting tool. The VC collet allows for a wider range of sizes from 0.079”-to-0.5”, while with other toolholder solutions that require external equipment you need a holder for each size of cutting tool. The collet system enables fast and easy tool changes, reducing downtime and increasing productivity in CNC machining.
The VC collet chuck is also available in Taper Plus, which combines taper accuracy with flange rigidity. Additionally, the VC has coolant through capabilities offered in a coolant-through disc, jet coolant splash, or slotted disc for different applications.
New Holding System Streamlines Small Part Machining
Sandvik Coromant (Mebane, NC), an industry-leading manufacturer of metal-cutting tools and solutions, has introduced the QS
Micro — a new quick-change holding system developed specifically for sliding head machines. It promises exceptional precision, security and repeatability, and maximized machine utilization.
The QS Micro holding system is specifically designed for small part machining and sliding head machines. It covers the majority of industry segments such as general engineering, automotive, aerospace and medical. With an extensive range of cutting heads and shank adaptors, the system offers a multitude of configurations and quick tool changes.
The assortment includes rectangular shaft adaptors in sizes 10-×-10 mm up to 20-×-20 mm, and equivalent inch sizes. It also features cutting heads for general turning, parting and grooving, and threading in the Sandvik Coromant families CoroTurn® 107, CoroCut® 2, CoroCut XS and CoroThread® 266. The CoroTurn 107 and CoroCut XS families provide cutting heads designed for Y-axis machining, offering advantages such as higher stability and better chip evacuation.
“One of the main benefits of the QS Micro holding system is that it is possible to quickly change cutting heads with high precision, which reduces the machine’s downtime,” said Hampus Jemt, global product manager for small part machining and threading at Sandvik Coromant. “Another benefit is the modularity, which enables the fitting of different types of cutting heads in different adaptors, reducing the need for a large tool inventory.”
Other benefits include a rigid holding mechanism that minimizes vibrations, enabling unprecedented precision in sliding head machines without compromising process security. High indexing precision (+/- 3µm) also ensures supreme component quality, exceptional accuracy and repeatability across various operations.
Furthermore, efficient chip control is crucial in small part machining. All QS Micro shank adaptors provide through-coolant functionality, allowing easy coolant connection to the cutting heads, and the precision coolant is delivered directly to the insert. “Effective chip evacuation is critical,” Jemt added. “Chip smearing can significantly impact the intricacy of the machined parts. Fortunately, our through-coolant functionality results in exceptional chip control, extended tool life and increased productivity.”
Combining quick and easy tool changes with a high degree of modularity, QS Micro is ideal for small part machining operations where precision and security are of utmost importance.
Reduce Setup Time and Quickly Center Tapered Parts
Speedgrip Chuck Co.’s (Elkhart, IN) Quick Change 3-Jaw Chuck with its large through-hole capacity comes with two sets of master jaws to allow offline pre-assembly of top tooling for the next job, which reduces traditional setup time by 95%. The presetting fixture provides ±.0005” repeatability between jaw changes and accommodates all chuck sizes that range from 6”-to 24”. For the Quick Change 3-Jaw Chuck, Speedgrip offers its mono block jaws. Made from a nitride material that allows hardening after forming without significant distortion, the mono block jaws’ one-piece design without jaw bolt obstructions allows shops to work closer to the chuck face. The blocks are also compatible with all standard jaw chucks.
Speedgrip Chuck Co.’s innovative, American-made standard and customized workholding solutions provide manufacturers the means to improve efficiency and productivity by reducing cycle times while featuring affordability and durability.
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