Home / Engineered Workholding Solutions

Engineered Workholding Solutions

A review of some of the latest advanced workholding solutions that meet tighter specs, tighter tolerances for location accuracy, and ease of loading as they help to speed up processes and improve throughput.

Posted: April 28, 2014

The move to multitasking and automation equals tighter tolerances for location accuracy and ease of loading that require compact, space-saving fixtures that can also integrate into the pallet system of the machine tool.

The VERO-S plus 138 module from SCHUNK clamps small workpieces with the SPM Plus 138 top plate as well as pallets, clamping stations, existing fixtures, and tombstones with one or more clamping pins. The radial aligned clamping slides of the quick-change pallet system pulls in the clamping pin and locks it. This action retracts the diaphragm top plate to hold the work piece with up to 50 kN of force with a repeat accuracy of at least 5 microns (0.0002 in).

The PRONTO quick jaw change system from SCHUNK is suitable for OD clamping of pre-machined and finished parts. By using the interchangeable insert, the clamping range can be extended by up to 16 mm, without having to re-set the supporting jaw, an increase of 300 percent in comparison to conventional lathe chucks.

Thame Workholding has a range of around 30 standard top jaws which suit the InoFlex® chucks thus enabling customers to select the most appropriate jaws for their application, further increasing the flexibility of the system. (first view)

The InoFlex® system from Thame Workholding lends itself to irregular shaped parts as well as round, square and rectangular shapes, saving a considerable amount of setting time, especially where single parts or low volumes are being produced. (first view)

The InoZet system from Thame Workholding changes a three-jaw chuck into a compensating six-jaw chuck. Its InoTop system aligns the part from the outside but clamps it internally, making it ideal for thin walled components, and its InoGrip system achieves 10 times higher holding force with minimum clamping pressure, through its patented stamping technique.

For short runs of parts, the Samchully quick jaw change chucks from Thame Workholding enable shops to change jaws in less than one minute, compared with 10 minutes for some chucks. The wedge bar technology used by Samchully gives higher accuracy than wedge hook systems achieving TIR of .02 mm or less for chucks up to 300 mm, significantly less loss of grip under rotation and much lower spikes in grip pressure, which can damage the part.

Vac-Mat, Metapor, Flip-Pod, rotary vacuum fixtures and other vacuum workholding from Thame Workholding can be customized for use on thin, irregular and non-magnetic parts, especially if they have a large surface area.

With repeatable positioning accuracy to ± 0.0002 in on a typical part setup, the DockLock system from Kurt ensures high quality finishes, no scrap parts and substantial setup time reduction.

The D688 vise from Kurt is designed for use on the latest machine tools including machining centers and knee-type mills. The D688 is ideal for all types of machining operations including precision boring, tapping, drilling and finishing with high accuracy on most part configurations. The D688 vise is the only vise of its type made in the USA.

The double jaw-guidance system from Röhm moves jaws smoothly along their axes to accommodate a wide range of part sizes without having to remount the jaws.

ZS manual chucks from Röhm are available in diameters from 2.9 in to 49.2 in, as well as with a full range of clamping jaw options for all machining requirements. Users can also choose between the Basic (steel body drop forged) and Economy (vibration-damping special cast iron body) chuck versions.

ZG manual chucks from Röhm are available in diameters from 2.9 in to 49.2 in, as well as with a full range of clamping jaw options for all machining requirements. Users can also choose between the Basic (steel body drop forged) and Economy (vibration-damping special cast iron body) chuck versions.

Available in four different jaw widths – 3.6 in, 4.9 in, 6.3 in and 7.9 in – the RKE NC-Compact Vice from Röhm provides for horizontal, lateral or vertical mounting options. Thread connections allow use of all Röhm flat-clamping jaws within the 4.9 in and 6.3 in width sizes.

By combining the benefits of a magnetic workholding device with a custom built solution designed around production parts, DocMagnet creates a magnetic turn-key fixture. This system incorporates the benefits of magnetic workholding while reducing set up or change over time between fixtures. (first view)

The exciting part about a DocMagnet fixture is that the magnetic chuck can be used for multiple parts by using an engineered top plate designed for the chuck (magnetic base of the fixture). These magnetic turn-key fixtures in a production environment can improve load/unload times, cycle times, part quality, and tool life and by doing so, drastically reduces the cost of production with a possible ROI of less than six months.

Imao OD Clamps from Fixtureworks are ideal for holding on the circumference of irregular workpieces.

The OML CIVI Rail vise with moveable jaws from Lexair provides “anywhere” positioning on tombstones and fixture plates, with 60 deg serrations that increase clamping area for improved accuracy and repeatability on precision parts.

The new 82M-3E Series of enclosed pneumatic power clamps from DE-STA-CO provides automotive and sheet metal processing customers with superior holding power in a versatile, user-friendly and low-maintenance package.

Each of the four sizes of DE-STA-CO’s new 82M-3E power clamps is available with a patent-pending hand lever on the right or left side for applications requiring manual loading. The levers feature the distinctive DE-STA-CO red handle and are adjustable for improved ergonomics.

The FCS Modular Clamping System from SST uses virtual design during the CAD/CAM stage of part production to project a grid on the workpiece that calculates the best way to attach the part for machining and chip evacuation. After checking for possible interferences with other holes, it automatically arranges the fixing seats based on the dimensions of the workpiece and combination of pallets and clamping available.

Additions to the CD from AME include two new fixturing products, dedicated manual fixturing and Jakob Antriebstechnik clamps with new CAD models, plus an ISO conversion calculator and measurement unit converter.

Specifically designed to support shaft type work pieces on grinding machines, the SRG line from SMW Autoblok is ideal for crankshaft and camshaft applications. Three sizes are available, providing a clamping diameter range of 20 mm to 85 mm.

The larger capacity RM2-1555 ferris wheel part positioners from Motoman can support an overhead structure for mounting robots in the ArcWorld V-6000 series work cells with reduced footprint.

The RM2-2355 ferris wheel part positioners from Motoman can support an overhead structure for mounting robots in the ArcWorld V-6000 series work cells with reduced footprint.

Low-cost Stallion 9\20 and 9\23 trunnion tables from TrunnionTable.com reduce part handling, speed throughput and improve accuracy at a fraction of the cost of new machines. Standard sizes accommodate popular vise models, made-to-order sizes available.

A GN 852.1 Latch-Type Toggle Clamp with Locking Mechanism from J.W. Winco.

The Loc-Jaw™ system from Mitee-Bite is a simple solution for 4- and 5-axis machining without having to perform a pre-op prior to running your parts. (first view)

The Loc-Jaw™ system from Mitee-Bite is a simple solution for 4- and 5-axis machining without having to perform a pre-op prior to running your parts. (second view)

Dillon soft blank top jaws can be removed and later reused for the same operation, or machined to grip an altogether new part, until the blanks are consumed, making them ideal for machine shops which routinely handle parts with different shapes and geometries.

Dillon also offers their High Performance Jaw Nuts and Keys that are made from 4140 heat treated steel, they provide greater tensile strength, more impact and abrasion resistance and longer service life than traditional case hardened 1018 varieties.

In metal cutting, the move to multitasking machining and automation equals tighter specs or tolerances for location accuracy and ease of loading that require compact, space-saving fixtures that can also integrate into the pallet system of the machine tool. In metal fabrication and welding, automation is driving the use of pneumatic clamping technology, as opposed to manual clamps, to speed up processes and improve throughput. Here is a review of some of the latest advanced workholding solutions that can meet these demands as they help to speed up processes and improve throughput.

DIAPHRAGM CLAMPING SYSTEM FOR SMALL PARTS
A quick-change pallet system from SCHUNK Inc. (Morrisville, NC) takes quick-change workholding to a new level. The VERO-S SPM-138 diaphragm clamping system allows the user to machine the contour of their workpiece into the SPM unit. When the VERO-S module is engaged with the Turbo function the SPM-138 unit clamps evenly around the outside of the part.

VERO-S SPM Plus 138 can clamp workpiece sizes: Ø 36 mm – Ø 125mm, although the work pieces do not have to be round. The SPM unit generates clamping forces up to 50 kN. This paves the way to more precision, efficiency, process reliability, and set up reduction in metal cutting and CMM inspection.

A demonstration of the VERO-S SPM Plus 138 diaphragm clamping system.

The VERO-S is completely compatible and interchangeable with SCHUNK’s previous pallet system and the clamping pins work universally across the new line. Workpieces can be transferred from machine to machine or to a CMM accurately and seamlessly. Hardened stainless steel is used for all the functional components of the VERO-S, such as base body, clamping pin, and clamping slide. This increases the modules’ life and reliability, and reduces maintenance.

The maintenance-free module is completely sealed and protected against the penetration of chips, dust, and coolant. Integrated into the standard module is an air purge connection, which can also be used for part recognition. The position of the clamping slide can also be monitored via an air purge monitoring system. Each module is compatible for automated loading out of the box. Since the module is equipped with bottom and lateral air connections, it is completely flexible in its’ mounting.

With a change-over time of five seconds per jaw, the PRONTO quick jaw change system offers turbo-charged set-up times for all standard lathe chucks with fine serrations of 1/16 in x 90 deg and 1.5 mm x 60 deg. The quick-change retrofit set consists of support jaws and clamping inserts.

http://youtu.be/jhc9BGs10G4
A demonstration of the PRONTO quick jaw change system from SCHUNK.

For jaw changes with exact repeat accuracy, the locking is released with an Allen key, the jaw is removed and replaced by another, eliminating incorrect positioning. In locked condition, a six-sided form-fit clamping ensures maximum process stability, and provides high force and torque transmission. As required by the application, three supporting jaw variations are available for small, medium, and large, clamping ranges. Four hard claw inserts for various diameters and clamping ranges as well soft interchangeable inserts for finished parts processing are provided. Once they have been turned, the inserts can be used repeatedly on a system. The clamping depth can be varied using a workpiece stop. It is available in size 250 with more sizes to come.

SCHUNK Inc., 211 Kitty Hawk Drive, Morrisville, NC 27560, 919-572-2818, Fax: 919-572-2818, info@us.schunk.com, www.schunk.com.

SELF-CENTERING 4-JAW CHUCKS CUT SET UP TIMES
Thame Workholding (Aylesbury, England) offers HWR Spanntechnik compensating 4-jaw chucks. These InoFlex^® chucks have a patented mechanism which automatically centers the part to be clamped within 7 microns using a single lead screw. Available for both milling and turning applications, the range of InoFlex^® chucks goes from 160 mm to 630 mm for the type VD turning chuck and 310 mm to 630 mm for the type VF milling version.

To center the part on the InoFlex chuck, tightening the single lead screw moves the jaws in or out as appropriate through the patented slide and lever mechanism to bring the center of the part into the center of the chuck. With conventional 4-jaw chucks, four lead screws have to be individually adjusted and the part has to be clocked to make sure it is accurately centered. Alternatively, special fixtures must be designed and manufactured and the chuck drilled and tapped to hold the fixture before machining can commence.

The four jaws in the InoFlex^® system also apply lower and evenly spread clamping forces to the part reducing the chance of deformation on delicate workpieces, which might otherwise be damaged by excessive clamping forces – easily done on a conventional 4-jaw chuck.

Maurice Day, the director of Thame Workholding says, “We have been working with HWR Spanntechnik for 20 over years and this is a very exiting innovation and, as far as we are aware, there is nothing like it available on the market at the moment. The time saved by using InoFlex^® will easily justify the investment, however, the simplification of the manufacturing process and the elimination of possible sources of human error will make these chucks essential pieces of equipment.”

Thame Workholding/Thame Engineering Co. Ltd., Field End, Thame Road, Long Crendon, Aylesbury, Bucks. HP18 9EJ England, +44 (0)1844 208050, Fax: +44 (0)1844 201699, mauriceday@thameworkholding.com, www.thameworkholding.com.