Becker GmbH in Wuppertal, Germany now relies on CentroteX quick change-over systems from Hainbuch to simplify set-up processes and guarantee repeatability of ≤0.003 mm.  

Optimal planning of Becker’s manufacturing processes is achieved by production technology manager Dirk Schmidt, using the SMED method [single minute exchange of die]. This makes it possible to set up a machine or a production line within a production cycle so that it can be reused with only minimal delay.

“The most important aspects of the method are accuracy, low-distortion clamping and set-up minimisation,” says Schmidt in describing the clamping device requirements. “Hainbuch is one of the few companies that helps the customer to develop solutions. I usually have an idea of what I need and discuss it with Hainbuch. We work together to optimise processes and achieve the best possible result.”

In a planned production line, Becker will machine several different vacuum pump housings. The first clamping set-up will use the Hainbuch CentroteX S quick change-over system with different mandrels for ID clamping to ensure maximum centring accuracy with minimum deformation. The workpiece is removed from the first clamping set-up and equipped with four zero-position clamping bolts, which will be used in all subsequent clamping set ups and potentially also in assembly. Downstream machining steps will then take place on a machining centre with a rotary table. A Hainbuch quick change-over system mounted on the table generates an additional axis.

In this set-up, Becker uses a pallet from another manufacturer on a Hainbuch clamping adapter. In this way, the company benefits from minimal set-up times and high repeatability of the Hainbuch quick change-over system if the factory’s set ups require clamping devices that are not included in the Hainbuch product range.

For further information www.hainbuch.com

Big Kaiser is launching its Hydraulic Chuck Lathe Type B for Swiss-type turning machines, with UK availability via Industrial Tooling Corporation (ITC). The Type B is optimised for select Star Micronics machines and has a repeatability of less than 1 μm. This new addition features a rectangular design and multiple tool rows to accommodate the compact size of these machines.

The design minimises interference in compact work envelopes and enhances machining capabilities in space-constrained set-ups. The Hydraulic Chuck Lathe Type B expands Big Kaiser’s line-up and adds to the standard, F type and R type with its tailored adaptability for specific machine requirements. The standard model offers front tool clamping, while the F type allows rear operation in tight spaces. The R type, with its square shape, suits set-ups needing multiple tool rows without interference.

Compatible with leading automatic Swiss-type turning machine brands, including Citizen, Star, Tsugami and Tornos, the chucks facilitate safe and swift cutting tool changes with a simple Allen key. The versatility of the B type (SL22B) and R type (SL22R) chucks allows for application in a broad array of Star machines, providing customers with the flexibility to choose the optimal chuck for their specific applications. The B type is particularly suitable for machines with a single-level tool post, while the R type caters to dual-level posts.

Giampaolo Roccatello, chief sales and marketing officer for Big Kaiser Europe, reflects on the company’s 30-year history of hydraulic chuck production: “Since unveiling our first hydraulic chuck in 1994, we’ve consistently contributed to advancements in precision hydraulic chuck technology. Each chuck undergoes two thorough manual inspections before leaving our factory, ensuring it meets the highest quality standards.”

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

A new, rail-guided changing table for the safe, rapid movement of today’s increasingly heavy press tools, moulds and dies is now available from Roemheld in three versions for loads of up to 15, 25 or 40 tonne. The electrically-driven RWS system comes as a single or tandem cart and can feature two different push-pull arrangements to enable tool exchange on most types of equipment, including vertical forming and injection moulding machines. The changing tables help car manufacturers transport increasingly heavy tools for producing large castings comprising many individual parts, such as when mega-casting a vehicle frame or body.

The cart is guided on floor-level round rails with a rolling resistance so low that one person can manually move loads of up to 5 tonne easily. The rails facilitate precise guidance and prevent dirt ingress and tripping hazards. A safety mechanism ensures that it is only possible to move loads when the RWS table is firmly attached to either a machine or the storage location.

Consoles that bridge the distance between the machine bed and the die-changing cart make tool handling rapid and effortless. The amount of time needed for actual changeover is minimal as the table features integrated lifting bars in addition to the pull-push system. It means that the press or moulding machine is able to continue production right up to the moment of tool exchange.

Plants can connect several presses by a single table; positioning accuracy is within ±0.3 mm. Semi or fully automatic die change is possible due to the cart’s integral control system.

For further information www.roemheld.co.uk

With a revised stamping unit (featuring a new type of serration) and a complete, additional series of five-axis vices, Lang Technik say the company continues to develop its ‘original’. According to Lang, the company’s stamping technology has been setting the bar for top-notch quality in five-axis machining through its form-fit clamping philosophy for years. Now, Makro•Grip FS is taking this to a whole new level with even more impressive milling performance. 

The abbreviation FS stands for fully serrated/full serration and describes the new, continuous holding serration on the clamping jaws of the new-generation vice.  The new form-fit between the continuous holding serration and the matching contour in the pre-stamped workpiece blank increases holding force by up to 60%, depending on the material and stamping depth. For machining, this means even more reliability and safety in workpiece clamping, which in turn allows higher cutting performance and faster milling processes.

Lang’s stamping units with adapted stamping serrations impress with numerous new features, making operation even easier and more effective. For example, the process of setting the stamping pressure can be significantly accelerated thanks to the new stamping depth gauge. The setting is now data-based by reading off the dial gauge instead of visually checking the workpiece.

A new centring unit also makes it child’s play to insert the workpiece blank exactly in the centre, reports Lang.

Lang’s five-axis vices of the FS series are available in all previously known sizes and models, and also in a new mini version: the Makro•Grip micro. The FS series will initially run alongside the established Makro•Grip series, but is expected to replace it in the medium term due to its performance advantages.

For further information www.lang-technik.de

It is now possible to retrofit the Röhm iJaw, which features sensor technology and wireless data transmission to measure clamping force in real time during machining, to all turning machines. There is no need to integrate the technology into the machine’s control system.

“With iJaw, we are effectively revolutionising the machining process,” says Gerhard Glanz, CEO of Röhm GmbH. “This is because real-time measurement of the clamping force during the machining process provides the user with a whole range of benefits. The advantages start with higher machine availability because of a reduction in set-up times and faster machining processes. The result is lower part costs on the one hand and increased component quality on the other. Overall, sensor-controlled workpiece machining is, of course, much safer than conventional manual clamping by feel.”

Gone are the days when operators would have to set the clamping force higher than necessary in order to ‘play it safe’.

“Especially with thin-walled components or sensitive surfaces, this is known to be counter-productive because having too high a clamping force quickly leads to deformation or even crushing of the workpiece,” says Glanz. “With exact knowledge of the applied clamping forces, you can significantly reduce rejects.”

This is how the iJaw works: an integrated sensor detects the forces introduced into the jaw, with data processed accordingly. The iJaw measures not only the actual applied forces of the internal and external clamping but also its own temperature. The system constantly displays the charging status of the battery. Röhm’s iJaw measures in real-time during machining.

For further information www.roehm.biz