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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.

INSTANTLY ALIGN AND LOCK VISES AND FIXTURES ON MACHINING CENTERS FOR ULTRA ACCURATE SETUPS
Quickly align and setup any part on any machine with the DockLock® zero-point workholding system from Kurt Manufacturing Company (Minneapolis, MN). The DockLock system provides the fastest, most accurate and repeatable method for making setup changes on all types of horizontal and vertical machining centers.

A demonstration of a Kurt DockLock system used with a Fanuc robot.

For example, a typical workholding setup change requiring 20 minutes using standard methods is done in less than two minutes with the DockLock. Operation is simple. The DockLock allows the user to locate or remove the workholding from a machine, or move it offline or to another machine and/or back again in just seconds with zero-point accuracy every time.

Available in pneumatic and hydraulic models, DockLock systems may be ordered in standard, automatic and heavy duty models for most applications. The hydraulic DockLock Safe 20 model consists of a patented hydraulic actuated locking cylinder that instantly aligns and locks a vise or fixture with a clamp down force of 2,800 lb per locking cylinder (12,456 newtons) and with a retention force of 9,000 lb per locking cylinder (40,033 newtons). For other models, the Safe 30 has a clamp down force of 20,000 newtons, retention force of 60,000 newtons, and the Safe 50 has a clamp down force of 30,000 newtons, retention force of 90,000 newtons.

Once positioned, the workholding remains immobile using the DockLock. A uniquely designed collet connection dampens vibration tendencies in the workholding setup, which is an important design feature. “The DockLock system is a proven workholding system used throughout Europe,” reports Mike Chester, a technical service representative for Kurt. “U.S. machine operators have grown to like it because of its simplicity and ease of use. The top down design makes the fixture handling process effortless. With few components, the system is easy to keep free of chips and coolant. Also, the system’s rugged design requires minimal maintenance and ensures long life through repeated use.”

Kurt also offers the D688 vise with an 8.8 in jaw opening and repeatability to within 0.001 in. It produces up to 7,968 lb clamping force with just 80 ft-lb input torque. Designed for the high performance requirements of the latest machining centers, the D688 meets the needs of today’s highly skilled and demanding machinists.

Designed with high precision roller bearings and alloy steel screw mechanism (competitor models use less efficient ball bearings), D688 vises distribute clamping force evenly and precisely across the full jaw surface. The Anglock® design in the movable jaw (patented by Kurt) further reduces jaw lift. Providing overall vise rigidity while absorbing machining vibration, Kurt D688 vises have porosity-free, 80,000 psi ductile iron bodies.

Additional features include removable, hardened jaw plates, ergonomically designed vise handle, and GrooveLock® workstops that store easily in the vise body.

Kurt Manufacturing Company, Industrial Products Division, 9445 East River Road NW, Minneapolis, Minnesota 55433, 877-226-7823, Fax: 877-226-7828, workholding@kurt.com, www.kurtworkholding.com.

VICE BOOSTS RIGIDITY AND PROCESS ACCURACY FOR 5-AXIS MACHINING
The newly redesigned RZM Centric Vice from Röhm Products of America (Lawrenceville, GA) provides exceptional workholding rigidity and contributes significantly to higher accuracy 5-axis machining. The vice’s new design features clamping jaws positioned relatively high and a horizontal spindle situated at the top of the vice and closer to the jaws for unmatched stability. The jaws are shorter and complement the vice’s overall compact height of only 7.7 in to keep interference to a minimum, while Röhm’s special double jaw-guidance system ensures precision positioning.

A demonstration of the Röhm RZM Centric Vice.

In operation, the first jaw moves along an outside guideway as the second jaw travels on an inside one. This quasi-telescopic arrangement allows for a greater guidance length without placing any significant limits on machining operations. When fully opened, the RZM presents little, if any, interference, and its telescoping design allows the jaws to close to the zero point. For small or fragile parts, Röhm’s SKB claw jaws are an idea attachment for the RZM. These jaws securely clamp unfinished parts at depths as shallow as 0.078 in. Hardened claws on the jaws create an interlocking hold for extremely strong clamping, but with minimal required force and only a slight loss of material.

ZG and ZS manual lathe chucks from Röhm feature enhanced designs that include control edges for adjustability, safety adapters to regulate force and spray water rims that protect machine tool spindles. The control edges on the chuck bodies allow for fast and simple on-machine scroll adjustments. The new safety adapters on the chucks let users easily set and control clamping force via a torque wrench – a capability especially beneficial when machining deformation-sensitive workpieces. Located at the upper edges of the chucks, the spray water rims redirect cutting fluids away from machine spindles to help prevent contamination and increase their working lives.

Röhm redesigned its RKE NC-Compact Vice clamping system to include several technical improvements to further optimize its function in CNC machining centers with high working accuracy. Featuring a solid steel body with its contact surfaces and guides hardened and ground on all sides, the RKE NC-Compact Vice now offers better chip discharge with fewer interfering contours. Furthermore, protective caps and dirt protectors prevent chips from penetrating the inside of the vice body. A central grease nipple sits next to the adjustable drive spindle for easy accessibility and simple lubrication of the spindle threads and all guides.

An overview and demonstration of the Röhm RKE NC-Compact Vice clamping system.

Röhm Products of America 5155 Sugarloaf Parkway, Suite K, Lawrenceville, GA 30043, 770-963-8440, www.rohm-products.com.

TURN-KEY WORKHOLDING
Everyone wants to bring down the cost of manufacturing while increasing production. One common solution to this issue is turn-key workholding or fixtures from DocMagnet, Inc. (Raleigh, NC). A turn-key system improves production, the quality of the part, and tool life. It is a solution that has an initial expenditure with a long term payoff, cutting down on set up time adding location repeatability and reducing machine time.