Tooling & Workholding Showcase Two

ADVANCED TOOLHOLDERS FOR DEMANDING APPLICATIONS
Schunk Inc. (Morrisville, NC) offers the PRISMO3 tool grinding toolholder directly clamps every shank diameter between 3 mm and 20 mm without the use of collet chucks or sleeves. The tool shank is automatically centered in the toolholder during the clamping process. The set-up time is reduced by up to 70 percent in comparison with conventional multi-range grinding toolholders. Regardless of the tool diameter, the X-axis doesn’t change, which means the chuck jaws remain in the identical axial position. This makes it possible to machine the widest range of drilling, reaming, and milling tools around the clock in unmanned operation without reprogramming the L1 measurement.

The design layout, the base sleeve, and the robust construction give the toolholder its high rigidity. Its sturdy jaw guidances prevent the grinding discs from swinging up and almost completely eliminate tube imbalance. The toolholder is rinsed with clean oil during grinding operation, which prevents dirt accumulation, and helps to maintain the high precision. Compact dimensions of 125 mm x 125 mm leave ample space for the tools, grinding process, and loading.

The TRIBOS-Mini HSK-E 20 polygonal toolholder is the first standardized precision toolholder for micro machining with the HSK-E 20 spindle interface from Schunk. In comparison to conventional steep taper interfaces, the HSK-E 20 interface ensures excellent change and positioning accuracy, as well as high process reliability. The narrow tolerances of the tapered seat ensure maximum precision at high rotation speeds. With a repeat accuracy of ≤ 0.003 mm at 2.5 x D and a balancing grade of G 2.5 at 25,000 rpm, the TRIBOS-Mini HSK-E 20 meets the highest standards. It is suitable for all tool shanks in h6 quality, transmits torque up to 4.5 Nm (at ø 6mm) and is rated up to 85,000 rpm.

Both the precision on the workpiece, and the service life of the tools benefit from the excellent concentricity properties. Reliable tool changes can be done in seconds with the help of a hydraulic clamping device. The HSK-E 20 is available for ø 1.0 mm, 1.5 mm, 2.0 mm, 3.0 mm, 4.0 mm, 6.0 mm and 1/8 in. The L1 dimension is 35 mm. In addition, smaller shank diameters down to 0.3 mm, and other special designs are possible.

Schunk also offers SVP-Mini and SVP-RM manually actuated clamping devices that run on factory-defined set pressure, saving time and energy, reducing set-up costs, and eliminating operating errors. They can be fastened vertically or horizontally at a workstation, or used directly on the TRIBOS polygonal toolholders at the machine spindle. SVP-Mini and SVP-RM are the ideal supplement for operators who use TRIBOS for micro and high-speed cutting. They are more economical than the TRIBOS clamping devices, and will always generate the clamping pressure necessary for tool change. Due to the firmly integrated expansion sleeve, no reduction inserts are necessary and tool change is simplified.

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With a run-out and repeat accuracy of less than 0.003 mm at an overhang of 2.5 x D and a balancing grade of G 2.5 at 25,000 rpm, the TRIBOS polygonal clamping technology will fulfill any requirement. Instead of a round mounting hole, the precision toolholders have polygon-shaped holes for the tool. A defined pressure is actuated from the outside, the mounting hole deforms to a cylindrical shape and the tool can be easily inserted into the toolholder. Then the pressure is reduced, the internal diameter moves back to its initial polygonal shape because of the elasticity of the material, and due to the internal stress of the steel, the tool is clamped by force-fit.

Schunk is broadening its program for high performance hydraulic expansion toolholders with the TENDO AVIATION toolholder that specifically focuses on demanding applications that usually occur in the aerospace industry. It combines the strength of hydraulic expansion technology with that of Weldon toolholders, with high run-out accuracy, a balancing grade of G 2.5 at 25,000 min-1, perfect vibration damping, and a fast tool change using an Allen key. An integrated anti pull-out mechanism ensures an orientation of the tool and form-fit clamping when using the Weldon shank. The mechanism prevents tool pull out, and positional tolerances can be held. These features allow the full potential of both tool and machine to be used.

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TENDO AVIATION allows maximum torque transmission at a consistently high precision and process reliability. Compared with conventional Weldon and Heat Shrink toolholders, where the run-out accuracy decreases over time, it offers tremendous advantages. The run-out accuracy and vibration damping of the TENDO hydraulic toolholders prevents the cutting edge from wear, extends the tool life, and ensures smooth surfaces. The uniform load profile ensures a longer service life of spindle and spindle bearing as well. This affordable toolholder is available for the interfaces HSK-A63, HSKA 100, CAT 40 and CAT 50.

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

CUT INTERNAL FACE GROOVES WITH MAJOR DIAMETERS
THINBIT® Kaiser Tool Company, Inc. (Fort Wayne, IN), expands their Deepgroove® line of support blade style tooling with tools that are designed to cut internal face grooves with major diameters starting at 1.574 in and depths of cut to 1 in.  The Deepgrove system utilizes modular cutting heads and clamps and can easily be reconfigured for different major diameter ranges and insert sizes. Inserts are available in 2 mm, 3 mm, 4 mm, 5 mm and 6 mm, with a variety of coating and corner radius options. Shanks are available as left or right hand orientation in 20 mm, 25 mm, ¾ in and 1 in diameters. Deepgrove round shanks will also accept OD/parting & external face grooving heads.

THINBIT Kaiser Tool Company, Inc., 3620 Centennial Drive, PO Box 80430, Fort Wayne, IN 46808, 888-844-6248, Fax: 888-844-6329, thinbit@kaisertool.com, www.thinbit.com.

SINGLE-STEP MACHINING OF DIFFICULT-TO-CUT FEATURES
The Eppinger Shaping Attachment by Exsys Tool, Inc. (San Antonio, FL) enables single-step machining of a wide variety of difficult-to-cut features including grooves, chamfers, Torx screw heads, splines and gear teeth. In addition, permanent grease lubrication of the attachment’s bearing surfaces helps reduce wear and tear on the machine tools that employ the device.

The Shaping Attachment is engineered for productive and efficient operation. In use, it drives the cutter into the workpiece in the Z-axis at cutting speeds up to 1,000 spm. At the end of each stroke an integrated lift-off mechanism returns the cutter to the starting position without drag, protecting the surface finish of the component and the cutting edge of the tool. With a working stroke of 1.3 in (32 mm) and maximum feed of 0.006 in (0.15 mm) per stroke, the attachment can produce maximum groove widths of 0.31 in to 0.34 in (8 mm to 10 mm). The Shaping Attachment’s capability to machine difficult features in a single setup increases production throughput, while its permanent lubrication, lift-off mechanism, and rigidity minimize machine tool wear and downtime that can result from performing tough gearmaking-type operations.

Exsys Tool, Inc., 11654 Corporate Lake Boulevard, San Antonio, FL, 33576, 352-588-4345, Fax: 352-588-4821, www.exsys-tool.com.

BASE MOUNT TOOLING FOR FLEXIBLE MACHINING
Heimatec, Inc. (Prospect Heights, IL) a world leader in live tools, angle heads and multi-spindle drill heads, offers BMT (Base Mount Tooling) standard products from inventory at its Chicago-area headquarters for the North American market. In addition to standard X- and Z-axis tools, styles such as adjustable tools, speed increasers and internal coolant tools with capabilities to 140 bar (2,000 psi) are now available in an assortment of standard BMT tooling types, including BMT 45, 55, 65 and 75.

All BMT tooling is supplied with the unique U-Tec® flexible machining system, which provides extremely high power transmission via polygonal drive. Integrated collet nut, with easy changeout, can convert the output to arbor (for face mills), Weldon or ER collet extensions. The U-Tec® system further allows the cutting tool to be in closer proximity to the bearing, which results in much higher rigidity. The cutting tools last longer and yield an improved finish, as a result of this design feature.

All BMT tooling is manufactured at the company’s home facility in Germany and is now carried in inventory in the Chicago-area facility, which serves the North American machine tool market. Heimatec products are sold through authorized sales representatives and machine tool distributors in North America.

Heimatec Inc., 16 East Piper Lane, Suite 121, Prospect Heights, IL 60070, 847-749-0633, Fax: 847-749-2445, info@heimatecinc.com, www.heimatecinc.com.

INK JET SHEET MARKING
Wilson Tool International (White Bear Lake, MN) offers SmartMark®, the first ink jet sheet-marking solution that fits into a turret punch press. SmartMark is an ink jet printer that can be loaded directly into the C station of most thick turret machines. Using a combination of the exclusive SmartMark Writer software and CNC programming, fabricators are able to easily program the printer to mark parts with alphanumeric text, lines, timestamps or even barcodes.

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Errors that happen during production and assembly can be costly. SmartMark gives fabricators the ability to mark everything from part numbers and descriptions to assembly and part handling instructions – helping to error-proof production. When used as a poka yoke solution, SmartMark can be used to improve the speed and accuracy of the fabrication process, saving valuable time and money. Each SmartMark sheet-marking kit includes the following components: SmartMark printer, proprietary SmartMark Writer software, wireless router, one ink cartridge, two batteries and a battery charger. Replacement ink cartridges and batteries are available from Wilson Tool.

Wilson Tool also offers the HPX guide assembly for thick turret tooling that combines tool-free punch adjustments with replaceable punch technology in one easy-to-use package. The company earlier redefined punch press tooling with EXP punch technology, the first tooling in the industry to offer a standard holder with universal punches. Offering the fastest changeovers and most durable punches in the industry, EXP punches increase productivity and lower tool replacement costs.

HPX guide assemblies combine the industry-leading innovation found in EXP punch technology with patented HP2 punch adjustment capabilities, including tool-free punch length adjustment. The result is the fastest and easiest-to-use thick turret tooling available today. HPX guide assemblies support ABS or non-ABS lubrication, work in all thick turret machines and can be used for round or shaped punches, eliminating the need for multiple assemblies. HPX guide assemblies are available exclusively from Wilson Tool.

Wilson Tool International, 12912 Farnham Avenue, White Bear Lake, MN 55110, 651-286-6000, sales@wilsontool.com, www.wilsontool.com.

ADVANCED PIPE BEVELING TOOLS
Esco Tool (Holliston, MA) offers a full line of pipe beveling tools that can bevel, face, and bore highly alloyed materials for the in-plant or in situ fabrication of shale pumping stations. MILLHOG® Pipe Beveling Tools are ID clamping and feature a rigid blade lock system with TiN coated T-15 tool steel cutter blades that have proprietary chip breakers which transfer heat away from the pipe surface to prevent work hardening. Capable of performing any angle of prep and squaring the pipe ends simultaneously, they are ideal for end prepping all hard pipe alloys including Super Duplex stainless steel and P-91.

Available for pipe from 1.5 in up to 36 OD, MILLHOG Pipe Beveling Tools pull a thick chip without cutting oils. All tools are pneumatic, incorporate self-centering draw rod assemblies that rigidly mount to the pipe ID, and provide torque-free operation.

One portable pipe machining and welding end prep tool that includes a dual spring safety hanger for easily maneuvering and precisely aligning it into a large pipe ID is the Terminator MILLHOG Pipe Beveling Tool. It is designed for large pipe from 8-5/8 in ID to 36 in OD and can bevel, face, and bore simultaneously to produce end preps of any angle, including “j” preps. Easy to maneuver, it comes equipped with a dual spring safety hanger to help align the tool which rigidly clamps to the ID, has a tracker to compensate for variations in wall thickness, and a precision feed control to advance into the pipe.

Providing smooth, torque-free operation, the Terminator MILLHOG Pipe Beveling Tool is equipped with user-selectable formed TiN coated tool bits and is ideal for any large dia. pipe fabrication that requires welding. Available with a 5 hp pneumatic motor or optional hydraulic motor, applications include oil and gas pipelines and process steam lines. The Terminator MILLHOG Pipe Beveling Tool is priced from $45,995 and is available for rent in the continental U.S.

Esco also offers a right angle pipe and boiler tube machining tool that has been upgraded with a new air motor which provides more torque at the cutter head and is easy to disassemble and clean. The Ground MILLHOG is a right angle drive ID clamping tube beveling tool that requires only 1-1/2 in clearance, easily fits into water wall boiler tube panels, and includes all attached wrenches. Featuring a 1 hp pneumatic motor that is easy to disassemble and clean in the field, and a robust gear train with a proprietary gear reduction design, this tool operates at 125 rpm and produces 41 ft-lb torque at the cutter head.

Suitable for tubes from ½ in ID to 2-1/4 in OD, the Ground MILLHOG is designed to machine tubes that are highly alloyed, or have high chrome content, using TiN coated cutter blades and no cutting fluids. Equipped with a push-pull clamp and release that disengages easily, ratchet feed, and a safety lever throttle, this tool can be used in any orientation. The Ground MILLHOG is priced from $4,995 and is available for rent. Pricing and literature are available upon request.

Esco also offers a complete line of boiler tube expanders that automatically control tube expansion to assure precise wall reduction when fabricating and maintaining tube sheet. MILLHOG Rolling Motors and Tube Expanders are air-powered and feature a torque control setting which stalls the tool when it reaches the desired tube expansion to prevent over-under expansion. Enabling users to create a uniform and tight mechanical seal, these tube sheet expanders are easy to adjust and allow precise torque control from 25 ft-lb to 325 ft-lb.

Available with 90 rpm, 190 rpm, and 280 rpm motors, the right angle style MILLHOG Rolling Motors and Tube Expanders are offered as kits for tubes from 3/8 in to 4-1/2 in OD and tube sheets to 5-3/8 in. Supplied complete and ready to use with standard shop air, they are ideally suited for creating mechanical seals in boilers, heat exchangers, and condensers. MILLHOG Rolling Motors and Tube Expanders Kits are offered for sale from $4,695 up or for rent, with 24-hour shipment available.

Esco Tool | Esco Technologies, Inc., 75 October Hill Road, Holliston, MA 01746, 800-343-6926, Fax: 508-429-2811, matt@escotool.com, www.escotool.com.