Toolholders MetalTech Report
- March 4, 2012
Tool clamping for high speed
Emuge Corp.’s tool clamping system, the PGR, is designed for carbide and HSS cutting tools, taps, thread mills, and end mills.
It achieves the higher mechanical grip and torque transmission required by high speed cutting (HSC) and high performance cutting (HPC) applications while achieving the precision and surface quality demanded by customers.
The system solves the problem of clamping shortcomings and runout inconsistencies associated with conventional collet-based toolholders. Hydraulic expansion chucks, while stronger than collets, still have grip limitations when used in HPC applications. Compared to shrink fit toolholders that require heat and cooling cycles to set their grip, the PGR System requires no operator heat shielding or waiting time after setting the desired mechanical grip. Unlike shrink-fit holders, the PGR System generates no heat, a safety issue requiring cooling time and caution when handling shrink-fit tooling. PGR avoids the damage heat can cause in machine tools including bonding the tool to the holder that makes removal impossible.
The PGR System consists of a bench-top press with a quick-change adaptor with a special tapered collet and toolholder. The cyclindrical cutting tool shank is inserted into the collet and placed in the toolholder. The holder is designed with a gap between the collet shoulder and the toolholder that creates an interference fit. The bench-top press generates nine tons of force to push the collet through the interference gap, making the toolholder expand slightly and allowing the material’s elasticity to clamp back on the tool. The rigid clamping force prevents any movement of the tool within the collet.
Extended gauge lengths
BIG Kaiser has expanded its BIG-Plus line of toolholders with extended gauge lengths for BIG-Plus shell mill adapters, end mill holders and shrink fit toolholders.
BIG-Plus CAT50 Shell Mill adapters are now available standard in 8 in., 10 in. and 12 in. (203 mm, 254 mm and 305 mm) gauge lengths on 1 in., 1.25 in. and 1.5 in. (25.4 mm, 31.75 mm and 39.1 mm) pilot diameters. The 1 in. (25.4 mm) pilot diameter 10 in. and 12 in. (254 mm and 305 mm) lengths are designed with a tapered body for increased rigidity.
As well, BIG-Plus 50 end mill holders are now available standard with a 6 in. (152.4 mm) gauge in all diameters, and standard with an 8 in. (203 mm) gauge length for 1 in., 1.25 in. and 1.5 in. (25.4 mm, 31.75 mm and 39.1 mm) diameters.
BIG-Plus CAT40 shrink fit holders are now available standard with a 6 in. (152.4 mm) gauge length for 0.5 in., 0.625 in., 0.75 in., and 1 in. (12.7 mm, 15.87 mm, 19.05 mm and 25.4 mm) in diameters. The CAT50 shrink fit holders are now
available in 6 in. (152.4 mm) lengths for 0.75 in., 1 in., and 1.25 in. (15.87 mm, 25.4 mm and 31.75 mm) diameters. These toolholders offer high clamping forces, low runout, and a small nose diameter to reduce clearance issues.
Exsys Tool Inc.’s line of Preci-Flex toolholders are a fast, accurate and cost-effective solution for lathe tooling changeovers, says the company. The modular system is the first tooling system on the market with a single base holder and multiple tooling adapters that utilizes the ER collet pocket.
The compact design assures maximum torque transmission and rigidity, resulting in increased machining accuracy and improved productivity. Additionally, the conical and flat face planar interface allows the use of either an adapter or a standard ER collet, and enables collets, endmill holders, expanding collet chucks and shrinks fit tooling to be mounted on a single base holder.
Two-second shrink fit
Shrinking and unshrinking toolholders is efficient and easy with Lyndex-Nikken’s latest Shrink Fit Machine. In as little as two seconds, the machine can firmly insert a cutting tool into a Shrink Fit Holder, making this unit the fastest shrink machine available, claims the company.
With its patented induction coil, the shrink fit machine can handle cutter bodies made from HSS, heavy metals and carbide. The machine is compatible with all holders with varying geometries, shrinking 2 – 40 mm shank sizes with the same inductor.
Designed to be plug-and-go, the machine is equipped with a three-phase 220V power connector for shop compatibility. The compact table top design and the machine’s shrinking range (14.57 in., shrinks .080 to 1.5 in.) make this shrink fit unit a versatile yet powerful tool for shrink fit needs.
Unique toolholding approach
Rego-Fix’s new slim-nose powRgrip 6 series and new secuRgrip tool-locking option and expanded line of HSK 40 E holders enhance the capabilities of the company’s existing poweRgrip toolholding system. As a unique approach to toolholding, the powRgrip system offers better TIR, improved tool dampening, easy presetting, longer tool life and unparalleled clamping forces, claims the company.
Additionally, the toolholding system is ideal for high speed machining applications, and offers an extensive taper selection, including CAT, BT, HSK and TC versions. All powRgrip toolholders are balanced by design, improving part quality and surface finish, and lowering manufacturing costs.
Unlike other clamping systems where heat or hydraulics are used to expand the material, the powRgrip system uses the mechanical properties of the holder
material to generate tremendous gripping force with run-out below 0.0001 in.
Designed for easy operation and use, it takes less than 10 seconds to press in a tool or remove it from the holder. Because no heat is used, tools can be used
immediately after a tool change.
The company’s XL (Extended Length) Holder System features new (patent pending) Micro-Friction-Dampening (MFD) technology to absorb and dampen unwanted vibrations faster than standard long length holders. The toolholders are offered with CAT, BT, TC and HSK tapers in 2 in. increments up to a maximum length of 15.7 in. (400 mm). Versions of the products will be available in the ER 16, ER 32, PG10, PG15 and PG25 series of Rego-Fix toolholders.
Quick change clamping
With the quick change clamping units from Sandvik Coromant you can maximize the amount of actual machining time on your machine.
The clamping units utilize Sandvik Coromant’s quick change tooling system, Coromant Capto,which has been proven to dramatically reduce downtime with setup and tool changing efficiency.
These new products are equipped to channel high pressure coolant from the latest CoroTurn HP cutting heads to reduce temperature and improve chip control.
With Coromant Capto quick change driven toolholders, all application areas can be covered with one clamping unit. The reduced need for dedicated units saves turret space and changeover time.
The Tribos -Mini from Schunk directly clamps the smallest of tool shanks consistently along the entire axis. Machining medical, dental and micro level parts are the most challenging applications faced today. The toolholder eliminates troublesome collets, collet nuts and inconsistent tool clamping.
With run-out accuracy of less than 3 microns and a balance grade of G2.5 at 25,000 rpm, high rpms and fast feedrates are achievable. Unique in the proven Tribos design is the direct clamping through the elasticity of the toolholder material. The patented technology utilizes a polygon form in the clamping bore to generate the clamping.