OPPORTUNITIES IN WORKHOLDING

COMPLETE WORKHOLDING SOLUTION IN ONE SIMPLE UNILOCK STARTER KIT
Stevens Engineering Inc. (Phoenix, AZ) and BIG Kaiser Precision Tooling Inc. (Elk Grove Village, IL) introduce a complete workholding solution in one simple Unilock Starter Kit. The kit allows users to plug the components immediately into their production cell when it supports a Stevens Engineering mounting grid pattern to instantly eliminate setup time while increasing productivity.

Stevens Engineering?s captured screw and captured dowel assemblies allow the kits to be installed in seconds. The kit also contains universal pallets that allow the user to quickly attach and detach their positioning and clamping components or workpieces. Starter Kits support the Stevens Engineering grid pattern with other grid spacing available upon request.

Unilock can be used in virtually any process where change-time needs to be reduced. Unilock can be used to quickly and accurately exchange work pieces in excess of 5,000 lb. However, these kits are designed for use with small parts and fixtures that can easily be shuttled by hand or robot from one process to another.

Stevens Engineering has been a U.S. leader in Modular Fixturing for over 40 years and is singularly devoted to the design and manufacture of workholding accessories for horizontal and vertical machining centers. BIG Kaiser Precision Tooling is a leader in high precision tooling systems and solutions. With brands including Kaiser, BIG Daishowa, Speroni, Unilock, Sphinx, and more, BIG Kaiser?s line is focused on extreme accuracy and repeatability. info@stevenseng.com, www.stevenseng.com, bigkaiser@bigkaiser.com, www.bigkaiser.com

HYDRAULIC POSITION AND RETENTION PIN
Master WorkHolding Inc. (MWH; Morganton, NC) releases the hydraulically actuated position and retention pin (H-PRP) that builds on the ever popular (PRP) patented design which utilizes a metal-to-metal seal to eliminate contamination from entering the mechanism. MWH developed the dual-purpose hydraulic version to first snap the work piece into position and then, once hydraulics are actuated, clamp the part for machining.
? Eccentric body and adjustable head make the H-PRP very flexible and easily adjust to casting variations.
? Can be used for primary, secondary and tertiary clamping.
? A simple rugged design makes them easy to install and service.
? Available in two capacities 500 lb and 1000 lb clamping force @ 5000 psi.
? The low profile size 500 lb (Ø1.25 in x 2 in) 1000 lb (Ø1.63 X 2.25) will allow for maximum part accessibility and machining from multiple sides while reducing the complexity of prismatic work holding.
? Reduces the cost of fixture components up to 50 percent.
? The first hydraulic clamping component without ?pinch points?.
? Designed to utilize standard MWH heads.

20 years of custom fixture design has led MWH to develop specialty workholding components not offered anywhere else and we are excited to now make these available to the public. www.masterworkholding.com

DOVETAIL VISE CLAMPING COMPONENT FOR AEROSPACE APPLICATIONS
Advanced Machine & Engineering Co. (AME; Rockford, IL) introduces the dovetail vise clamping component as an addition to their line of fixturing and workholding products. This dovetail vise is widely used in the aerospace industry for aluminum milling operations, but can also be used for many other applications.
? Precision bushing holes allow for quick and easy location of vise
? ½?-13 SHCS and precision dowel screws are used to secure vise on 2 in grid system
? 15 deg dovetail angle holds pre-machined parts securely during machining operations
? Maximum part width 4 in or 5 in
? Vise available in 5 in, 8 in, 12 in, 16 in, or 24 in lengths
? Up to 12 jaws, depending on vise length
? Metric locating and mounting hole version available on request

Advanced Machine & Engineering is a global manufacturer and distributor serving the Machine Tool OEM, Production Saw Machine, and Fluid Power-Safety markets. www.ame.com

MODULAR FIXTURING FOR WELDING
As an alternative to traditional 2D welding tables, Bluco Corporation (Aurora, IL) offers 3-dimensional modular fixturing bases which provide the foundation for a variety of different fixture setups. Expandable in five directions by attaching modular angles, blocks and beams with stabilizing legs where needed, this base is the ideal solution for both prototype and production environments. www.bluco.com

COMPENSATING CHUCKS ARE IDEAL FOR IRREGULAR SHAPED WORKPIECES
EB Manufacturing Co., Inc. (Middletown, CT) offers a line of Compensating Chucks that are ideal for all types of workholding applications that incorporate eccentric workpieces, particularly in the firearms, automotive, aerospace and medical industries. Both 2-jaw and 3-jaw models are available, in sizes from 6 in to 18 in diameter. A 1/8 in compensation per jaw is provided.

EB's Compensating Chucks are equipped with a floating jaw mechanism and can hold any eccentric parts. As one of these chucks grips the part, it compensates for the irregularity between the ID and the OD. When the part is turned, the chuck centers it and turns the OD concentric to the ID. EB Manufacturing also repairs and rebuilds chucks, lathe hydraulic cylinders, pneumatic actuators, collet chucks and mandrels. info@ebmanufacturing.com, www.ebmanufacturing.com

3D FIXTURE CREATION
R&R Modular Fixturing (Grand Haven, MI) introduces FixtureBuilder 3D CAD Software for documenting fixture setups & doing offline part programming. You can build a fixture set-up quickly and easily from its catalogs of R&R components and base plates. Simply drag and snap into position. The software automatically builds a list of components and their placement for future reference. If desired, you can import your part?s CAD file into the set-up to show the part and the fixture. For those with offline programming capabilities, the whole fixture and part can be exported to create a part program. FixtureBuilder makes creating fixtures a snap! www.cmmfixture.com

PALLET SYSTEM IS IDEAL FOR 5-AXIS MACHINING
Schunk Inc. (Morrisville, NC) provides new possibilities in automated production with the Schunk Unilock NSA SF quick change pallet system for small pallets. The NSA-SF is compact (10 in x 10 in), robust and highly accurate. Fixturing can be changed out in a matter of seconds with 0.0002 in repeatability. Precise centering is achieved by four short tapers on the corners, which also compensate for torques and tilting moments. The unique taper design makes for ease of loading the pallet. The NSA series is fully sealed against contamination. Forced airflow removes chips and contamination from the short tapers during the pallet change, therefore ensuring an absolutely flat work surface. The NSA-SF is ideal for 5-axis machining centers.

75kN (16,860+ lb) of force is generated by the single Unilock clamping module. The Schunk Unilock NSA SF is failsafe, using four spring driven form-fit, self-locking clamping slides into a robust centering sleeve that can be monitored. To unlock the clamping modules, a standard air supply (pressure of 6 bars) is sufficient. Other features of the NSA-SF include four independent air ports for plumbing of pneumatic fixtures on top of the pallet. www.schunk.com

ZERO POINT CLAMPING SYSTEM
Jergens, Inc. (Cleveland, OH), one of the world?s largest manufacturers of standard tooling components, vises, and other workholding equipment, adds Zero Point Clamping System to its already broad line of Quick Change fixturing solutions. The Zero Point System (ZPS) combines ease of alignment, high-accuracy positioning, and high clamping forces with the ease of hydraulic or pneumatic actuation. Jergens will offer individual modules, complete systems and plates, as well as design and technical assistance.

Jergens? Zero Point System reduces complicated machine setup procedures into a single step. Unlocking and removing the clamping device is made simpler; the system eliminates the need to search for the bore, minimizing the risk of damage to high-precision zero-point bores and nipples. The Jergens ZPS is compact in size but still provides excellent holding and pull-in forces. The balls are 784 percent larger than those used in competitive locking systems. The balls roll freely in the form-fitting ball channel, which allows the balls to easily reposition themselves, allowing heavy fixtures to self-align easily. All components are made of stainless steel.

The Jergens ZPS reduces setup times while increasing setup accuracy and repeatability. The new system adds to their existing Ball Lock Fixturing System, Vises, Hydraulic Clamping Products, and Jergens? own broad line of tooling and fixturing components and allows Jergens to offer a complete line of workholding solutions for all fixturing needs.

Founded in 1942, Jergens has grown into four separate operating divisions providing superior engineered solutions and products: ?The standard components with the highest standards.? The Jergens Difference might be better engineering or better service but the result is always the same?a better solution for our customers. Jergens is an ISO 9001:2000 certified company. info@jergensinc.com, www.jergensinc.com

ROTARY TABLE ANSWERS LARGE DIAMETER BAR WORK AND OIL PATCH APPLICATIONS
Lyndex-Nikken's (Mundelein, IL) Ultra Large Bore (diameter 205 mm) Rotary Table is the answer to large diameter bar work and oil patch applications. One of the newest additions to its rotary table product line, the CNCB450 features a large through hole and a powerful clamping system.

The Ultra Large 8 in diameter thru hole and the rigidity of this Nikken rotary table offers new innovative solutions to the Oil Patch industries' large pipe applications. Supplied by Lyndex-Nikken, Nikken rotary tables are designed with a unique and patented carbide worm system. The carbide worm system incorporates a carbide worm screw and an ion nitrided worm wheel, rather than a conventional bronze or bronze alloy actuation mechanism. The result is a reduction in friction and wear by up to eight times.

The worm screw consists of a less brittle V-grade form of carbide, while the worm gear is ion nitrided to a depth of 0.1 mm and an external surface hardness of 68 Rc. These properties, as well as a steel way hardened to 58-60 Rc, all work to enhance system rigidity and longevity, and make Lyndex-Nikken rotary tables ideal for high-speed, high-accuracy rotation. www.lyndexnikken.com

MAGNETIC CHUCKS FOR CUTTING ROUNDS AND RINGS IN TURNING OPERATIONS
Designed specifically for the precision required in today?s turning and grinding operations, SAV North America (South Windsor, CT) has introduced a new line of magnetic chucks that delivers superior holding ability for highly accurate cutting of parts. SAV?S Radial Pole High Power Electro-Permanent Magnetic Chucks hold parts securely while allowing full access in a single set-up reducing labor costs and increasing throughput of finished work.

These new Radial Pole High Power Electro-Permanent Magnetic Chucks are engineered with a heavy-duty holding force of 245 lb per sq in. Unlike competitive models, the high strength and surface area of SAV?s magnetic chucks allow for hard turning without sacrificing speed and feed capabilities of machine tools. Part size is not restricted and those with limited surface areas can be held securely thus reducing the possibilities of work slippage, inferior cuts and wasted materials.

SAV?s Radial Pole High Power Electro-Permanent Magnetic Chucks are built using standard designs. Each chuck is built to a user?s specific turning application and machine model regardless of size. The solid body construction of these magnetic chucks allows for superior balance and stability of the work piece allowing for flexible mounting options. Top tooling elevates the work piece to be turned or cut making access easy and changeovers quick and efficient. Its separate top plate is fully sealed to prevent any short circuiting due to coolant leakage from machines during the cutting process ensuring a consistent and strong magnetic hold. Custom Mechatronic part centering options for operator error-free placement of work pieces are available.

Utilizing advanced electro-permanent magnet technology, SAV?s Radial Pole High Power Magnetic Chucks have greater clamping force than other magnets. Special design features allow for secure holding of parts until a programmable release cycle is activated fully demagnetizing the chuck and releasing work pieces quickly and cleanly. These new chucks operate on standard North American voltages. SAV is a designer, manufacturer and supplier of workholding solutions. www.sav-workholding-na.com

ECONOMIC POWER CHUCK
Schunk introduces a new line of economic power chucks, the ROTA NCKplus. In addition to features like a large through hole, an improved lubrication system, and high clamping repeatability, the ROTA NCKplus offers the compatibility with a wide range of existing machining centers. The ROTA NCKplus offers a robust one-piece chuck body for increased rigidity. The long precision piston guide and support guarantee less wear, a high level of continuous clamping accuracy, and long life. Combined with the industry?s best warranty of two years, this power chuck represents an interesting alternative to already existing lathe chucks.

The jaw interface is available in two versions: fine serration 1.5 mm x 60 deg or with 1/16 x 90 deg serration offering the user a high flexibility with regards to the use of existing top jaws. The ROTA NCKplus is available for all CNC lathes in the sizes 165 (6 in), 210 (8 in), 250 (10 in), and 315 (12 in), with clamping forces from 57 kN (12.814 lbf) to 144 kN (32.392 lbf). It is suitable for maximum speeds of 6,000 rpm and combines jaw strokes ranging from 2.75 mm (0.108 in) ? 5.30 mm (0.208 in) per jaw. www.schunk.com

ALUMINA FIXTURES FOR HIGH TEMPERATURE BRAZING
Morgan Technical Ceramics? Wesgo/Duramic business (Stourport, UK) offers custom made Alumina Fixtures used to isolate and insulate metal components during high temperature brazing processes. MTC?Wesgo/Duramic fixtures have proven to be excellent options when brazing medical and laser industry components, high electrical field devices and magnetic resonance imaging (MRI) equipment. Design and configuration of these Alumina Fixtures are highly flexible. Both simple and intricate features, including small diameter holes, can be machined to tight tolerances to meet customer requirements. Cleanliness is ensured through a specially designed air firing process. Also, during the brazing process, thermal expansion of the fixture is matched to that of the Alumina insulator used for ceramic-to-metal seals.

These Alumina Fixtures hold distinct cost and cleanliness advantages over other materials used during the brazing process. Alumina is an economical alternative to molybdenum or tungsten. MTC?Wesgo/Duramic Alumina has an excellent dimensional stability at higher temperatures (greater than 800 deg C) and a long service life, lasting years rather than months. Also, braze material does not stick to Alumina as it does to other non-ceramic materials. Alumina also offers a clean solution compared to graphite, which can contaminate surrounding surfaces. Unlike graphite, which converts to carbon monoxide/carbon dioxide over time, MTC?Wesgo/Duramic Alumina shows no material degradation in a wet reducing atmosphere. If the MTC?Wesgo/Duramic Alumina is contaminated with foreign materials, it is easier to see because of its inherent white color. Finally, there is no outgassing or material transfer to parts it is in contact with during vacuum brazing applications.

Morgan Technical Ceramics manufactures a comprehensive range of ceramic components, braze alloys, ceramic/metal assemblies and engineered coatings from manufacturing locations in North America, Europe, Asia and Australia. mtcuksales@morganplc.com, www.morgantechnicalceramics.com