THIS WEEK IN PRODUCTION TECH: Milling Chucks, Carbide Burs, Workholding and More

New products from BIG KAISER, PFERD, RÖHM, Schenk RoTec and Walter.

BIG KAISER to Showcase Milling and Turning Solutions at EASTEC 2017

BIG KAISER will showcase the new HMCJ super-slim milling chuck and a boring bar to eliminate vibration and maintain cutting speeds at EASTEC 2017.

The HMCJ comes with a peripheral coolant supply, designed to support heavy-duty and finish end milling tasks with power and precision using Ø1/2” or Ø12mm cutters. It features a clamping bore with fine slots surrounded by hundreds of needle bearings for concentric and smooth clamping when the nut is tightened.

BIG KAISER stated in a press release, the HMCJ applies the highest gripping force to the cutting tool shank of any comparable milling chuck in its class, and five to six times greater compared to collet chucks.

BIG KAISER will also highlight the Smart Damper boring bar for lathe applications. A heavyweight, strengthened damping mechanism integrated into the tool holder functions as both a dynamic counter and friction damper to absorb vibration and eliminate chatter. It’s also designed with the capability of supplying coolant through the body directly to the cutting edge.

The Smart Damper boring bar features three modular insert holders for right-hand I.D. turning with ISO standard inserts at a minimum diameter of Ø1.58”. Metric bodies are available in Ø32 and 40mm, with inch versions at Ø1.250 and 1.500”. The Smart Damper boring bar can reach boring at depths of approximately 7xD.

For more information, visit EASTEC 2017 Booth 5248, May 16-18 at the Eastern States Exposition in West Springfield, MA and visit the BIG KAISER website.

New TITANIUM cut burs from PFERD

PFERD Inc. recently introduced new TITANIUM cut burs to its carbide bur line-up for machining hard titanium alloys with tensile strength greater than 500 N/mm2.

Unique tooth geometry generates stock removal rates up to 60 percent higher than conventional cross-cut burs, for smoother milling for reduced vibration and noise, improved surface finish and longer tool life.

The tools double-cut burs with facet and chip breakers generate larger, easier to handle chips.

TITANIUM cut burs are suitable for the aerospace and defense industries for electric or pneumatic straight grinders and automated equipment. Applications include milling, chamfering, contouring and weld dressing. Other uses include work with structural components, thin-walled tubing in chemical processing and with components requiring particularly high corrosion resistance.

TITANIUM cut burs have a recommended cutting speed of 850 – 1,500 SFPM. They are available in cutting head diameters of ⅜”, with a 2-½” length and ½” diameter with a 2-¾” length. Both have a shank diameter of ¼ in. Rotational speed is up to 14,000 RPM for the ⅜” model and 12,000 RPM for the ½” diameter size.

For more information, visit the PFERD website.

Workholding Products at PMTS 2017 from RÖHM Products of America

RÖHM Products of America will be showcasing several workholding products at PMTS 2017, including: the modular CAPTIS clamping system; the AGILIS, ABSIS and MZS mandrel part-clamping systems; quick-change jaw chucks; the RZM vise; efficient CoE workpiece face drivers; and power-operated KZF collet chucks along with a variety of collets.

In addition, RÖHM will spotlight its F-senso spindle-pull-in force measuring device.

The modular CAPTIS workpiece clamping system provides a range of holding options through different combinations of modular components. Quick-change capability allows conversion from external to internal clamping in less than a minute and collet changes take less than 15 seconds. Compatible with the industry standard BZI collet interface, the CAPTIS system produces clamping forces without deformation of delicate workpieces while offering high repeatability and minimal run-out.

The AGILIS power-operated cartridge mandrel clamping system provides rigid workpiece ID clamping of very small diameters for grinding, turning, milling, drilling and measuring applications. At PMTS, the AGILIS system will feature the available manual quick-change system that cuts time needed to switch out clamping devices on the AGILIS. With quick-clamping screws, operators can complete manual clamping changes in approximately 30 seconds, all while maintaining positioning accuracy within .005mm. The manual quick-change technology enables the use of central lubrication and airflow measurement devices. RÖHM will demonstrate the mandrel’s air-sensing capabilities at the show.

The compact, solid ABSIS power-operated segment mandrel clamps are suited for high-precision machining. The mandrels independently secure workpieces against a rigid work stop for high repeatability and axial and radial accuracy.

The manual MZS cartridge mandrel has a center hole for internal clamping in grinding, turning, milling and measuring applications. The lightweight mandrel’s clamping sleeves are affixed with easy-to-change central tension screws.

RÖHM’s quick-change jaw chucks feature special bayonet-style connections. Shops need only change an attachment system to switch clamping devices from one part-machining operation to the next.

With high positioned clamping jaws and its horizontal spindle situated at the top of the vise and closer to the jaws, the RZM vise provides greater workholding rigidity and strength and contributes to higher accuracy 5-axis machining. The vise’s jaws are shorter and complement its overall compact height of only 7.7” to keep interference to a minimum, while RÖHM’s special double jaw-guidance system ensures precise positioning.

The high-accuracy modular CoE face driver enables workpieces to be turned along their whole length without re-chucking. A mechanical compensation system guarantees strong and consistent clamping forces on uniform as well as uneven workpiece faces.

RÖHM engineered its KZF power-operated collet chuck with a fast-action bayonet catch that significantly speeds collet changes. The chuck works with either conventional steel collets or segment collets and is ideal for bar machining.

Fitted with adapters for HSK or steep taper shanks, RÖHM’s F-senso device mounts into a machine tool’s spindle and provides an exact measurement of its toolholding pull-in force for shops to detect changes in force before they affect machining quality. Force readings cover a range of 0 – 15kN (3,370lb).

For more information on these products, visit RÖHM Products of America in booth 1231 at PMTS 2017, April 25-27 in the Greater Columbus Convention Center, Columbus, OH and visit their website.

Automated Tool Balancing for Serial Production from Schenck RoTec

The new Distectool vertical balancing machine from Schenck RoTec is designed for fully-automated balancing of small and large precision tools and tool adapters for the serial production of precision tools.

All operating elements on the Distectool as well as the measuring device with its touchscreen monitor are located on the main operating interface of the machine. Short spindle distance supports easy deposition of the tool or adapter to be tested and the obligatory protection device closes automatically over the work area. As soon as the workpiece is inserted, the entire balancing process runs fully automatic.

Energy-efficient drives were used in the Distectool’s design and typical ineffective hydraulic and cooling systems were neglected to create a smaller footprint for easier integration into existing production lines.

In addition, it is designed as a crane hook machine for easier relocation and adaptability to changing space requirements.

The Distectool uses a measuring device of the Type CAB 870 from the Schenck RoTec portfolio for simple, direct touchscreen input of tool data and a logical-intuitive operating concept. Clear displays and operating aids guide Distectool users through the balancing process to the result. An intuitive measuring device offers proven algorithms for the complex unbalance correction, different methods for the display of results, recording, documentation and the option of evaluating statistical characteristics all in one unit.

Users are also able to define the degree of automation, with options ranging from the use of a handling system for loading and unloading to the integration of adaptive, collaborative robot systems.

For more information, visit the Schenk RoTec website.

MS3 Cutting Geometry from Walter

Walter recently introduced a new cutting geometry, the MS3, teamed with a new high tech grade, WSM01.

The new WSM01 grade, manufactured using the HiPIMS (high-power impulse magnetron sputtering) method, provides extremely smooth surfaces that are characterized by excellent layer thickness, outstanding layer bonding and high-level wear resistance.

The combination of the HiPIMS PVD coating and the new MS3 geometry is suited for machining ISO S materials with difficult cutting properties such as high temperature alloys, titanium, cobalt-based and nickel-based alloys.

Secondary applications for this new grade/geometry combination are steel, stainless steel and non-ferrous material groups (ISO P, M and N).

Negative inserts with MS3 geometry are available with both sintered and fully ground circumference. Their smooth surface and sharp cutting edges minimize buildup and improve surface finish to more easily and reliably manufacture burr-free components.

The new insert is suitable for machining unstable or thin-walled components and setups with long overhangs, since its highly positive geometry provides low cutting pressure and prevents vibration.

The MS3 insert – much like Walter’s RM5 – is equipped with coolant jet guiding geometry to ensure optimum cooling directly on the cutting edge. It is well-suited to turning applications and to medium machining applications in the aerospace industry, medical components manufacturing, general mechanical engineering and the automotive industry.

For more information, visit the Walter website.