Premium chuck with 5 μm accuracy

With a new development in the hexagonal chuck series from Hainbuch, the German clamping device manufacturer says it is taking precision to a new level. The new Toplus Premium Chuck introduces a host of additional advantages.

Hainbuch’s portfolio of chucks has always been very precise and, once chucks alignment is complete, runout is near to zero for repeat clamping. If the various chuck heads are then changed, runout is usually between 3 to 7 μm without alignment.

With the new Toplus Premium Chuck, Hainbuch guarantees a runout of ≤5 μm without alignment, regardless of which clamping head is used. Until now, this was only possible with an expensive hydraulic expansion or a diaphragm chuck. These systems have limitations entailed by their design. In many cases, runout of ≤10 μm is perfectly sufficient. However, components or machining processes that demand a runout of ≤5 μm are increasingly commonplace within the industry. By utilising the new Toplus Premium Chuck with the associated premium clamping heads and, by clamping against the workpiece stop, this level of accuracy is always achieved. As a result, manufacturers no longer have to lose time making alignments for small batch sizes.

To reduce set-up times, improve machine utilisation and reduce costs, a robot is often used to load the workpieces in the machine. This strategy can become a problem if the clamping stroke is too small. With the Toplus Premium Chuck combined with a clamping head, the stroke is increased to make loading easier, even if the robot works somewhat imprecisely. In addition, the Toplus Premium Chuck is very robust and not as sensitive as some other clamping devices. Any slight contact with the workpiece during loading has no effect on the chuck and the process remains stable. The chuck is also sealed against contamination and vibration.

For further information
www.hainbuch.com

Synchro tapping chuck unveiled

Now available in the UK from Industrial Tooling Corporation (ITC) is the Mega synchro tapping chuck from Big Kaiser. This new tapping chuck has a special function built-in to compensate for synchronisation errors that may occur during rigid tapping.

The new product line incorporates more than 60 body types and 193 tap holders. This diverse portfolio enables the end user to select the perfect combination between the fixture and the tap holder, providing the ideal cantilever length for any machine and processing scenario.

Big Kaiser’s Mega synchro tapping chuck compensates for synchronisation errors with any type of tap as the system minimises thrust load to both the tap and workpiece, thus improving thread quality and extending tap life. The chuck has a proprietary feature that intercepts the tap-to-spindle distance when using a tapping cycle to reduce cutting forces. This feature is complemented by a body and tap holder that are fixed with a drive key in the rotation direction – as well as the square of the tap – to guarantee stability and process security. Process security is further improved by a coolant system that delivers coolant through the tool as well as around the periphery of the tool simultaneously.

ITC’s Andy Boyles says: “There are many companies now producing a ‘synchro’ type tapping head, but the Big Kaiser Mega has a unique difference. Due to its design, it’s possible to interchange the tap holders to different sizes, and it is available in several different lengths. Furthermore, the system permits through-coolant Synchro tapping in very deep holes with a very stable set up.”

For further information
www.itc-ltd.co.uk

Southern Manufacturing set to return

Southern Manufacturing & Electronics will make a welcome return to Farnborough on 8-10 February 2022. The show’s organisers report a healthy uptake in stand bookings from firms eager to recommence face-to-face business. Many of the show’s regular participants have already confirmed for 2022, bringing with them a wide range of products and services, extending from machine tools and automation, through electronic components and production equipment, to additive manufacturing and subcontract services.

Nearly 9000 visitors attended the pre-pandemic event, making it one of the biggest annual engineering shows in the UK. Together with the exhibition and demonstration areas, the free seminar programme will also return for 2022 in a socially-distanced format. Subjects discussed include energy reduction, new technology, innovation, supply chains and business strategy, and an overview of current industrial law and post-Brexit regulations.

For further information www.industrysouth.co.uk

Improved Heller five-axis HMCs

Heller has introduced a second generation of its HF five-axis, horizontal-spindle machining centres. The HF 3500 and HF 5500 incorporate a multitude of improvements that build on the launch of the series in 2016. For instance, although the working volume of the HF 3500 remains 710 x 750 x 710 mm, the larger model has gained 30 mm in the Z axis, so travels are now 900 x 950 x 930 mm. Both machines are available with either an HSK-A63 or HSK-A100 tool interface and in three versions: POWER, SPEED and the new PRO option. The latter is for long periods of simultaneous five-axis machining.

Designed to raise cutting performance, innovations in the second generation include: an approximate halving of the minimum distance between the spindle nose and the centreline of the 225° swivelling trunnion; the availability of twin motors and ballscrew drives for moving the trunnion/rotary table assembly in the Z axis, with position feedback via linear scales; and the offer of six new spindles produced in an automated facility at Heller’s headquarters in Nürtingen, Germany. As before, a column travelling over the bed executes the X-axis motion, while Y-axis movement is courtesy of the spindle head moving up and down the column.

Other notable improvements in Gen2 machines include increased stiffness of key components, shorter chips-to-chip times and faster tool changes from a chain-type magazine with up to 240 pockets or a rack-type magazine with up to 405 positions. The high-end PRO package additionally offers 10 m/s2 acceleration in X, Y and Z. The guideways employ linear roller bearings, enabling high dynamics and rapids up to 90 m/min, while the rotary axes have direct drives and stable YRT bearings.

For further information
www.heller.biz

Automation simplifies machining cell

At the EMO 2021 machine tool exhibition in Milan last month, prismatic machining equipment manufacturer Hermle demonstrated its latest automation system, the RS1. The system feeds workpieces and machine pallets automatically into and out of either one or a pair of the company’s three- and five-axis machining centres. According to Hermle, the resulting production cells are now sufficiently simple for use by semi-skilled staff. The sole sales and service agent for the UK, Irish and Gulf markets is Kingsbury.

Occupying a compact area of just 12 sq m, the new RS1 robotic unit is capable of minimally attended operation, 24/7. In addition to performing its loading and unloading duties, the six-axis robot automatically exchanges handling devices for pallets and fixtures, as well as grippers for raw billets and finished components. Pallets accommodating large, heavy workpieces weighing up to 60 kg may be transported, or individual workpieces up to 15 kg.

A modifiable rack storage concept accommodates pallets, workpieces, fixtures and the interchangeable end effectors for the robot. Furthermore, it is possible to extend the standard two-rack modules with a third, while users may also incorporate automated guided vehicles and other expansion solutions such as measuring and cleaning modules.

For cells comprising two Hermle machines, a third-party control system with graphical user interface from SOFLEX is employed to plan and organise order processing, control workpiece flow, oversee resource provision and transmit the necessary production information to the machine tools. For single-machine cells, a Hermle Automation Control System (HACS) with integrated touch panel provides intelligent order processing, as well as intuitive operation and control.

For further information
www.kingsburyuk.com