Author Archive: mjones

Productivity and Efficiency Enhancements Set ZeroClamp Apart from the Rest

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Workshop benefits for milling include direct clamping of the component onto a base unit. Holes as sockets for the clamping studs are specified at the design stage. Components can be changed quickly and accurately across all machines for second ops and finishing.
In the case of turning operations the productivity increases are achieved with pre-balanced base units. Maximum safety at high forces comes from the additional retaining elements. EDM workholding functions reliably even under water or in dielectric. The base units are equipped with special drain holes so that the water can escape when the pots are opened.

Leader Partners with S F T

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For the clamping of challenging workpieces, SFT Spannsysteme GmbH, located in southern Bavaria is synonymous for smart and innovative high-precision clamping technology. The company offers a wide range of intelligent and highly innovative multi-purpose clamping solutions for machining operations, including the 5-Axis Multiple Clamping device, as well as the Zentro and Smart vice ranges.

The new SFT two-in-one 5-axis or multiple clamping device has several innovative features. A highly flexible, modular jaw system with positive-locking jaw connection at 40 kN. A 4-tonne clamping force can be achieved with just 85 Nm of torque.

The SFT Zentro centric vice is said to be ideal for high-precision manufacturing with internal and external clamping capability. Repeatable accuracy is just 5 micron from the very high rigidity, modular jaw system design that offers 30 different jaw designs as standard. An enclosed spindle removes concerns of swarf ingress.

Convertible from centrical to double-centrical operation, or for clamping against fixed jaw and/or double-clamping against fixed jaw, the SFT Smart vice is ideal for clamping small parts with outstanding versatility. Offering up to 15 kN clamping force with jaw widths of 22, 32 and 42 mm.

 

 

Leader Chuck & Tecnologie F R B- Working Together to Get the Job Done

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Manufacturing high quality face drivers for over 50 years, only one thing has never changed: the FRB patented balancing and holding system. Being completely mechanical and technologically advanced it still ensures absolute reliability, constant repeatability of the results and unparalleled holding capacity.

Over the same time period, the FRB live centres have been considered one of the best options for all mechanical processes using machine tools. Starting with the timeless FRB patented 65, 80 and 85 live centre series with axial load distribution, the company’s ongoing research and development has produced the latest 2000, 2006 and 2008 series. Today, a wide variety of revolving centres equipped with Morse tapers ranging in size are available, with standard or special features to fit any requirement.

From Zero to Work-Clamping Hero; the ZeroClamp Pneumatic Centring Clamping Fixture 160

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Alongside its automation systems for machine tools, available from workholding, productivity improvement and manufacturing efficiency specialist Leader Chuck International, ZERO CLAMP also offers a new, matching clamping device for handling component blanks and raw billet material.

The pneumatic centring clamping fixture 160 offers powerful, infinitely variable clamping with forces of up to 45 kN at a maximum of 9 bar of compressed air. The compressed air supply is connected to the underside of the clamp. The centring clamping fixture is controlled using the four-channel clamping pots of the company’s advanced zero-point clamping system. Alternatively, the air ports on the side can also be used for this task.

What makes the centring clamping fixture unique is the system’s low pretension of 60 kg, which ‘lightly’ holds loaded material preventing the loss of clamped components when working with shuttle tables, for example, moving in and out of the machining envelope.

In addition to this, the generous clamping jaw stroke of 8.5 mm can be infinitely ‘fine-tuned’ with adjustment slots in the top of each jaw allowing a range of +/- 5 mm each side via the eight Allen head bolts that securely fix the top jaws to the vice. This increases the service life of the jaws as they can be accurately adjusted to compensate for any wear as well as for any deviation in the size of the raw material, such as castings being undersized.

The extensive range of jaw attachments, including grip jaws, carbide-coated jaws, profiled jaws or prism jaws to suit the workpiece, allows the centring clamping fixture to achieve clamping widths of 10 to 130 mm, making it suitable for a huge variety of applications.

Managing Director of Leader Chuck, Mark Jones, says: “For many engineering workshops the highly effective solutions available from ZERO CLAMP make it a one-stop shop for everything – from zero-point clamping systems and modular clamping rail systems to perhaps the most flexible, modular automation on the market. Everything a manufacturing business needs, from a single source.”

Extended & Enhanced Magnetic Workholding Solutions

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Available exclusively from Tamworth-based workholding specialist, Leader Chuck International, the Walmag range of permanent magnet, electromagnet and electro-permanent systems for machining applications such as grinding, turning, drilling and milling, as well as wire and die sink EDM machining has been expanded and enhanced.
“Since we have been offering the high-performance range of magnetised chucks from Walmag, we have seen a growing interest from a number of industry sectors, especially off-highway ‘yellow goods’ manufacturers and material-handling systems specialists,” explains Managing Director, Mark Jones.

Interest that will, no doubt, be increased further with the new Walmag Mastermill; an electromagnetic permanent magnet offering a flexible solution for a variety of workholding applications. Designed with a recess so the chuck can be clamped down onto the table of the machine tool, the chuck can also be drilled through at designated points to allow it to be bolted directly to the worktable or to a pallet changing system with M12 bolts. Pole extensions can be placed on the surface, which is important if there is a long batch, or for five-sided machining operations using simultaneous 5-axis or 3+2 positional milling techniques. The top face is produced from a homogenous piece of steel so there is no chance of swarf or coolant ingress into the electronics of the chuck.

The company’s Neomill Compact is a permanent magnetic chuck for milling operations. Ranging from 250 x 150 x 50 mm up to 600 x 300 x 60 mm (L x W x H), it features the strongest permanent magnetic field in the range with a holding force of 160 N/cm2. Although very rigid, remaining flat and stable under heavy machining loads, the Neomill Compact is designed to be light to handle and lower in construction to minimise the impact on the machine’s Z-axis travel. Again, the top face is a single piece of steel that is water-proof, and it can be pocketed by machining. Up to 10 mm of top face can be machined so raw material recesses can be created and any accidental damage can be removed to revive the plate, with a visible indicator to advice when the limit is being reached.

For turning applications, the Neostar provides a magnetic solution and is available from 130mm to 800mm diameter. A robust, electro-permanent magnetic chuck that is circular in design, milled from a single piece the top plate it has no lamellas and is fitted with radial poles using a double high energy Neodymium magnetic system. A 5mm machinable top plate allows location recesses or spigots to be created or damage to be machined off. With a holding force of up to 140 N/cm2 it is said to be ideal for turning and grinding, within the same set up users can carry out ID, OD and top face work. And, as with all Walmag solutions, it achieves fast clamping with no deformation of the workpiece.

Produced with an aluminium body the Alustar range is lighter and features a bespoke worm gear activation system. This allows the chuck to vary the clamping force, so users can set up and true the workpiece using 10 to 20 per cent of the holding force before applying full clamping power when the part is set correctly. These chucks are available in diameters from 200 to 600mm.

ELMag and ELMag-X are designed for surface grinding small to medium and medium to large components, respectively. These high-performance electromagnetic chucks feature embedded coils with an ultra-hard epoxy resin insulator to provide an even distribution of the magnetic field across the complete surface of the chuck. This performance does not deteriorate over time and the chuck will always function correctly over their life span.

Mark Jones says: “Unlike pressure-based holding methods magnetic holding introduces zero stress into the part so there is little chance of any deformation. Walmag products are developed for the long-term and they just keep performing, backed by a two-year warranty.

“These magnetic systems are extremely cost-effective compared not only to the competitors, but with other methods of workholding. Previously part of the Walker Magnetics Group, Walmag has an established reputation for developing and manufacturing high performance workholding solutions using various magnetic technologies. With a depth of application knowledge built up over many years the Walmag staff can provide extensive information and offer manufacturing industry focused advice on aspects of workholding using magnetic force.”

Based in the Czech Republic, Walmag can trace its involvement with magnetics back to 1960. Over 60 highly skilled staff work at the company’s 30,000 ft2 facility in Kromeriz, near Brno, producing standard and bespoke magnetic clamping chucks for a global manufacturing industry.