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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.

One turn-key system often overlooked is magnetic chucks. The magnetic milling chuck was first implemented on machinery to reduce set up times between unique parts, it has uniform clamping of the entire part in contact with the chuck, reducing vibration therefore extending tool life and the end result is a better workpiece finish. The magnet is capable of repeatable location through adding a side, end stop or dowel pins and the power of the magnet has made it a choice consideration over conventional or hydraulic clamping.

Designing this magnetic turn-key solution is not an easy task. The first step is to look at the application itself, the entire production process must be understood in order for the system to be built to meet the specific needs of the production. The workpiece is the center of attention, the material type, material hardness, overall dimensions, condition of the raw material, and the dimensions/tolerances of the final product must all be factored into the solution. Choosing the appropriate magnetic pole design for the application is the next step in the process for the pole design dictates how the magnetic flux will balance, the depth of the magnetic field, and the overall magneto-motive force of the magnetic circuit.

DocMagnet, Inc., 6220-100 Angus Drive, Raleigh, NC 27617, 919-788-7999, Fax: 919-788-7861, www.docmagnet.com.

OD HOLDING CLAMPS LOCK & PRECISELY LOCATE WORKPIECES WITH IRREGULAR SHAPES
Fixtureworks^®Workholding Technologies (Fraser, MI) offers Imao OD holding clamps as part of its workholding and fixturing technologies. The OD clamps, available in up to 90 mm diameter sizes in both round and square styles, allow for holding on irregular shapes and those workpieces with a circumference. The four-part aluminum jaws can also be machined to custom fit the part, while the body is made of SAE-1045 alloy steel to provide for a strong and solid base. The clamps allow for part repeatability of ± 0.03 mm and jaw locating repeatability of ± 0.02 mm, while the clamping stroke of each jaw is 0.15 mm, ideal for clamping die cast parts, extruded, solid-drawn and prefinished parts to name a few.

The clamps come with a diamond pin for body locating. The shaft and locking screw are made from alloy steel, hardened with black oxide finish. When the locking screw is tightened the central bottom part of the jaw is pulled down. At the same time the four jaw sections, applying equal pressure, tilt toward the center to clamp the circumference of the part. The jaws, also available separately, can be machined to hold almost any shape and many different materials can be clamped. An adapter is also available so that the clamps can be used on a lathe. Ease of use is straightforward. Insert the diamond pin (included) into the body for locating. Secure the body to the fixture with four socket head cap screws. Engage the keyway on the bottom of the jaw. Secure the jaw. Set the locking ring in the jaw. After machining, loosen the locking pin.

Besides the Imao OD Clamps, Fixtureworks offers Fairlane® Products full line of grippers, rest pads, Swivots® swivel/pivoting positioning components, Quick Release ball-lock pins, rollers and bumpers; Kipp® rest and riser pads, levers, handles, knobs, and hand wheels; Imao® manual clamps, supports and stops, risers, T-nuts, sliding mounts, springs, supports, grid plates and blocks; OK-Vise® single and double wedge clamp designs; Mitee-Bite^®low-profile edge clamps.

Fixtureworks Workholding Technologies, 33792 Doreka, Fraser, MI 48026, 586-294-1188, Fax: 586-294-4843, info@fixtureworks.net, www.fixtureworks.net.

MODULAR MULTI-PART CLAMPING SYSTEM MAXIMIZES MACHINING CENTER PRODUCTIVITY
The modular OML CIVI Rail workholding system from Lexair, Inc. (Lexington, KY) boosts the productivity, accuracy and repeatability of horizontal machining centers, providing multi-part clamping in virtually limitless configurations on tombstones and trunnions. A unique V-jaw design pulls parts down against the parallels and a 60 deg angle on serrations provide more clamping surface for a sure hold on high-value parts. CIVI Rail can be used as a vise on existing machines, mounted vertically or horizontally on a tombstone or with a trunnion, providing flexibility and the ability to produce better parts, more efficiently.

The system includes interchangeable bases, moveable jaws and fixed supports. Bases are available in standards lengths from 10 in to 24.8 in (250 mm to 630 mm) and 2.4 in or 3.5 in (60 mm or 90 mm) widths, and include one fixed support. A 1.5 in (38 mm) jaw can be used on the 2.4 in (60 mm) rail for clearance around all sides of the part.

The CIVI Rail vise offers, as an option, the patented self-locking CLAK parallel system, with a dual-pin, ball-detent design, that snaps the parallels into place and keeps them there. The CLAK system allows for quick-change of parallels and jaws, making part changeovers and size changes quick and easy. Rail serrations are spaced 0.10 in (2.5 mm) apart for greater precision, and a scale machined into the side of the rail provides easy relocation of jaws and faster setups. Guarding and seals on the jaws keep chips and fluids out of the ramp system to protect system components. All components are precision hardened and ground.

Lexair is the exclusive importer and master distributor in the U.S. and Canada for OML, the Italian-based manufacturer of modular clamping systems, tombstones and precision vises.

Lexair, Inc., 2025 Mercer Road, Lexington, KY 40511-1018, 859-255-5001, Fax: 859-255-6656, www.lexairinc.com.

STRONG, VERSATILE ENCLOSED POWER CLAMPS
The new 82M-3E Series of enclosed pneumatic power clamps from DE-STA-CO (Auburn Hills, MI) provides automotive and sheet metal processing customers with superior holding power in a versatile, user-friendly and low-maintenance package. This full line of lightweight aluminum power clamps includes four sizes: 40 mm, 50 mm, 63 mm and 80 mm. The 82M-3E Series is well suited for a number of applications, including manual and automated fixture welding, positioning and locating.

All 82M-3E Series power clamps feature infinite arm opening adjustment with the industry’s greatest opening angle range: from 0 to 135 deg. This provides system integrators with maximum flexibility. The angle is easily adjusted in just seconds from behind the clamp. Not only does this patent-pending design feature save time, it also means 82M-3E power clamps require less space, allowing fixtures in which they’re installed to be lighter and more ergonomic than those equipped with other clamps. The 82M-3E’s sensors never need adjustment, even when the opening angle is changed, providing additional time savings.

Each of the 82M-3E Series 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. To provide long life with minimal maintenance, each 82M-3E Series clamp features an enclosed body, sealed needle bearings and a completely enclosed sensor to prevent the intrusion of dust or debris. Repairs are simplified by the sensor cartridge’s two-part design, which makes it possible to replace only the damaged component instead of the entire cartridge.

“Developing a new family of power clamps gave us the opportunity to step back and look at the product from the customer’s perspective,” explains Peter Schauss, the DE-STA-CO global product director for power clamps. “As a result, we’ve come up with a best-in-class series of clamps that is flexible and easy for integrators to set up, and that will perform for the end user customer over millions of cycles with minimal maintenance.” The 82M-3E Series is available worldwide and conforms to NAAMS and Euro mounting standards.

DE-STA-CO, 691 North Squirrel Road, Suite 250, Auburn Hills, MI 48326, 248-836-6750, Fax: 248-836-6743, www.destaco.com.

MODULAR CLAMPING SYSTEM REDUCES SETUP TIME; INCREASES MACHINE UTILIZATION
Single Source Technologies (SST; Auburn Hills, MI), a North American distributor of machinery brands such as Makino Inc. (Mason, OH), is pleased to announce the addition of the FCS Modular Clamping System (Breyl) to its product line. This unique clamping system provides unrestricted access to five surfaces of the workpiece and enables operators to spend less time on setups and more time on machining.

http://youtu.be/Ol_8m5JQXmw
An overview of the SST FCS Modular Clamping System.

“This modular system allows diverse fixturing options for any machining sector and turns hours of setup into minutes,” said Darrell Johnson, a product manager of milling consumables at SST. “Companies have reported increasing production time by 88 percent on average with this system, which translates into higher machine utilization and lower costs. Additionally, faster equipment and pallet changes mean a more standardized work process for improved part quality and consistency.”