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In Focus - Archive February 2012
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By using tool extensions, complete machining on modern 5-axis machines is child’s play.
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When selecting the suitable extension it is worthwhile of taking care that the consulting service is system-neutral.
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02.02.2012 -
Due to the success of modern 5-axis machines, tool mountings with slim interfering contours have experienced a real boom. With sufficient torque, and high run-out accuracy they allow a deep, collision-free tool path into the workpiece, and thus ensure precision machining, even in areas which are difficult to access. These slim tool extensions are economic, flexible, and can be assembled between tool and toolholder on request. They can be combined with various machine tapers.
Compared to toolholders with a customized taper shape and gage length, the tool extensions are more versatile in use. They are available for various clamping systems, such as heat shrinking, polygonal clamping, or hydraulic expansion technology. The combination of less interfering contours and transferable torques is also an advantage of heat shrinking extensions. However, for heat shrinking toolholders, often an expensive special unit is necessary to change the extensions. Users, who have no heat shrinking unit available, usually choose another type of clamping technology, which works without an expensive peripheral unit. However, if heat shrinking toolholders are already available, and the customer already owns a shrinking unit, heat shrinking extensions can be used economically. The use of hydraulic expansion extensions is recommended only if vibration-damping characteristics or frequent tool change are required. Hydraulic expansion extensions minimize vibrations, and even ensure a high runout accuracy after numerous clamping operations.
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Polygonal extensions can be flexibly combined with various base toolholders
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The slim CELSIO SVL heat shrinking extension transfers high torques.
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Extremely slim
Tool extensions based on polygonal clamping technology are extremely slim. With an L1-dimension of up to 250 mm, a runout and repeat accuracy of less than 0.003 mm, the one-pieced, maintenance-free extensions are also suitable for high-precision applications. The extensions can also be combined with many other toolholders. Practical examples show that expansion toolholders and polygonal extensions can be used for high tensile aluminum roughing/milling operations. Experienced operators are using the polygonal extensions for achieving extreme extension lengths: They clamp several extensions in each other, and still achieve high runout accuracy at the cutting edge, too.
Polygonal extensions for tools with a shank diameter of up to 5 mm can be clamped in handy and low-priced manual clamping devices. The operator inserts the extension into the clamping device, turns the clamping screw with an Allen key to the dead stop, and exchanges the tool. Within 20 seconds the operation is completed, and the number of operating errors is reduced to a minimum. For extensions with a larger diameter universal clamping devices are available, in which polygonal toolholders of any size can be clamped precisely and safely.
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The TENDO SVL hydraulic extension
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Universal application
Tool extensions, which are based on hydraulic expansion technology are the most flexible ones in use. At a length of up to 200 mm, they don’t need any peripheral unit, and transform any precision toolholder independent from the spindle interface into a highly flexible specialist for narrow spaces. The precise runout accuracy, the excellent vibration damping and the possibility of equipping it with an internal coolant supply, provides excellent machining results and long lifetimes of the tools. As it is usual for hydraulic expansion toolholders, a simple Allen key is enough for a fast tool change within seconds. Since the clamping screw is radially actuated, the exchange is very comfortable, and if necessary, it could be done directly in the machine. By using intermediate sleeves, the clamping diameter of the hydraulic expansion extension can be even reduced to 3 mm. Their high torque ensures a save clamping of the tool during drilling, reaming, and finish milling operations. However during rough milling it can make sense to use extensions of the polygonal or heat shrinking technology.
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A combination of TENDO
hydraulic expansion toolholders and TRIBOS extensions.
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Combination for tool grinding
The extensions are especially important for tool grinding. Since even thousandths of millimeters decide the quality of the manufactured cutting edge, it is worthwhile to combine toolholders and extensions in a sophisticated way. The combination of hydraulic expansion toolholders and polygonal extensions has proven to be a great solution. Operators thereby achieve excellent runout and repeat accuracies between 0.003 to 0.006 mm at normal tool lengths, measured at the sharp cutting edge. While hydraulic toolholders are dampening the occurring vibrations, the extension optimally sets the tool blank in an upright position. Moreover, this combination ensures a minimum interfering contour which leads to an unhindered interference between the grinding wheel and toolholder, and therefore achieves particularly precise workpiece geometries.
When selecting the optimal extension, the user should consider, if all the required parameters can be met. This is the only way how a minimized interfering contour will not impede the radial stiffness, torque, process reliability or precision. By offering a vast toolholder program, SCHUNK the competence leader for clamping technology and gripping systems is also covering the requirements of extensions for all other relevant clamping systems. Therefore the innovative family-owned company is offering best prerequisites for a system-neutral consulting service, and a custom-tailored solution for any application.
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12.2012
New application possibilities for square pole technology
The electro-permanent square pole technology is a part of the magnetic clamping technology, and represents an ideal clamping solution for machining centers. It offers numerous advantages: Workpieces are easily accessible, and can be machined in one set-up from five different sides. It is no longer necessary to spend time on the fine adjustment of clamping elements. Multiple clamping operations of workpieces during the machining process are no longer necessary as well. In addition to milling applications, square pole technology also covers flat grinding applications. Moreover, special display modules increase process reliability and create optimum preconditions for automated loading.
 more...
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11.2012
High-performance automation from the modular system
Those who plan high-performance assembly plants for electronics, medical technology, automotive, or consumer goods industry, know of the challenges, if individual modules and assembly groups need to be linked to an entire system. Missing mechanical joining elements, incompatible controller concepts, or insufficient planning tools influence the planning and implementation processes as well as during the process itself. The variety of combinable system programs can be an efficient alternative - provided they are well thought out in terms of performance, volume, compatibility, and configuration.
more...
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10.2012
Applying strengths in a targeted way
Stationary clamping systems have enormous hidden efficiency and quality potentials for production. Those who want to utilize them, should question, where the strengths of the individual clamping technologies are. If they are selected and combined in a targeted manner, their investment costs can be amortized very quickly.
more...
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09.2012
The underestimated collaborators
In view of sophisticated lathe chucks, clamping blocks with compact performance, and highly engineered devices, the technological possibilities of chuck jaws may seem at the first glance rather limited. In reality, however, these direct interfaces to the workpiece open up enormous potentials: Beside conventionally hard and soft top jaws, a broad range of established chuck jaws ensure that even tricky clamping tasks can be economically solved. An overview shows what is potentially possible.
more...
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08.2012
Efficient concepts for automated machine loading
In the past, automated loading and unloading was restricted to large series, today though, small batches and individual pieces are now standard. The ultimate aim is to reduce set-up involved downtimes and to have as few workers possible manning production around the clock. What is needed, is the sophisticated interaction of innovative clamping equipment and automated components which lead to utmost precision and ensures reliable processes all at the same time.
more...
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07.2012
Consistent maintenance increases precision, process reliability,
and safety of the clamping vises in the long run
Vises used for workpiece clamping in today’s production environments are exposed to extreme conditions. This significantly influences the precision of the workpiece, process stability, and safety for both operator and machine. In order to ensure optimum clamping force, users normally follow the manufacturer’s information on lubrication intervals. Moreover, many more companies are choosing preventive maintenance programs, where the clamping vise is thoroughly tested in defined cycles. This ensures longtime accuracy, minimum wear, and high process reliability.
more...
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06.2012
High performance without chatter
The times when brachial roughing was normal are over. Those who want to produce a lot of chips in a short space of time now take advantage of high-quality cutting and intelligent toolholding systems that transmit high torques and, at the same time, reliably absorb any occurring vibrations. Modern toolholders protect the cutting edges, the machine spindle, and the workpiece surface and allow you to work with high metal removal rates even when using challenging materials.
more...
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05.2012
Pneumatic or mechatronic gripping?
In many industries, the increasingly wide range of product variants, the ever-shorter cycle of innovation, and the increasing comparability among products are leading to an enormous pressure on costs. Experts believe that production automation will be one of the keys to business success in the coming years. These issues also apply to gripping systems: the precision, flexibility, speed and reliability of a gripping system has a significant impact on the profit margin which they can achieve. Although pneumatic gripping systems were long considered the state of the art, mechatronic solutions have since made significant strides. As a result, users and system planners are increasingly faced with the question of which drive concept is more advantageous to handling and assembly processes: pneumatics or mechatronics?
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04.2012
Vacuum clamping technology: an ideal addition to the standard clamping devices
In comparison to clamping brackets, clamping blocks, jaw chucks, quick-change pallet systems, or magnetic clamping technology, vacuum clamping technology is mostly unknown in the metal cutting industry. Nevertheless, vacuum clamping technology can perform a valuable service here, especially when machining thin parts that are susceptible to deformation, or workpieces made of aluminum and other non-ferromagnetic materials. Particularly when they are in the form of versatile matrix plates, they are a useful and easy to handle addition to clamping devices already in use.
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03.2012
Gripping Systems of the future
Mechatronic handling systems offer distinct advantages: They are very flexible, offer numerous intelligent functions, and despite higher acquisition prices, they quickly pay off. Therefore, it is no surprise that the handling issue is becoming increasingly important in the pneumatics dominating world. This particularly applies, since more and more mechatronic components can be easily operated by average users.
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02.2012
Tool extensions with minimal interfering contours
Due to the success of modern 5-axis machines, tool mountings with slim interfering contours have experienced a real boom. With sufficient torque, and high run-out accuracy they allow a deep, collision-free tool path into the workpiece, and thus ensure precision machining, even in areas which are difficult to access. These slim tool extensions are economic, flexible, and can be assembled between tool and toolholder on request. They can be combined with various machine tapers.
more...
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01.2012
Up-to-date support for all gripping tasks
Gripping systems in handling and assembly are often in operation around the clock, seven days a week. Many components have to withstand external influences such as chips, dust, aggressive media or heat. In addition, tight margins and deadlines due to just-in-time production often result in enormous scheduling and planning pressure, usually starting well before the initial commissioning. In view of these challenges, many purchasing decisions are increasingly made based not only on the quality and performance of the modules, but also on the range of services offered. Services increase planning reliability, facilitate commissioning and ensure maximum cost effectiveness during operation.
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In Focus - 2013
In Focus - Archive 2012
In Focus - Archive 2011
In Focus - Archive 2010
In Focus - Archive 2009
In Focus - Archive 2008
In Focus - Archive 2007
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