FEATURE ON WORKHOLDING

Multi-Part Clamping Transforms CNC Machining

With hundreds of zero-points across the table or pallet of a vertical or horizontal machining centre, Sinco MultiZero work holding offers modularity and precision when securing multiple components for machining. The systems are sold into the UK and Irish markets under an exclusive agency agreement with 1st Machine Tool Accessories, which also provides a consultancy service to manufacturers wishing to maximise the advantages of the Slovenian-made work-holding equipment.

Central to Sinco’s approach to increasing CNC machining efficiency and profitability are the virtually limitless work-holding arrangements made possible by its MultiZero base plate. It features an array of precisely spaced, conical, zero-point locations at 50 or 100 mm centres. The high-density grid maximises machine capacity usage by simplifying multi-part clamping all over the machine table, utilising matching centring elements on the underside of other MultiZero modules that fit accurately into the conical holes.

The additional modules include clamping pallets that attach directly to the base plate and can hold workpieces directly. Five different pallet types are available for manual or automatic clamping of parts on a machining centre, while a die-sink or wire EDM machine, measuring machine, or assembly station may be similarly equipped. Pallets can be supplied fitted with an RFID chip to allow integration into an Industry 4.0 factory environment, enabling automation, digitalisation, automatic data capture and scheduling of production.

Other accessories such as modular vices, stoppers and risers can be mounted on top of the clamping pallet in countless ways to suit different workpiece sizes and shapes.

More information www.1mta.com

Clamped, centred and aligned with flange mandrel

With the KFDF flat-element flange mandrel, Ringspann says it offers a compact precision clamping tool for optimising many turning, drilling, grinding, milling and balancing processes in gearbox construction, gear production and tool manufacturing. It scores with precise concentricity, a short clamping length and a standard clamping diameter of up to 375 mm, which can be extended to up to 560 mm by using alternative clamping elements. Its flat clamping body centres the workpiece and aligns it level.

The turning and drilling of steel coupling elements, the grinding of carbide rolling rollers, the milling of aluminium gearbox covers and the gear grinding of hollow shafts made of stainless steel are just a few applications examples of the KFDF flat element flange mandrel from Ringspann. They illustrate the versatility of this compact clamping fixture, whose domain is mechanical machining processes that place increased demands on precision. Apart from its concentricity of ≤0.01 mm, it ensures precise centring and a flat alignment of the clamped workpiece.

“The uneven deformation of workpieces – a common problem when using three-jaw chucks for example – can be ruled out with our KFDF thanks to complete 360° clamping,” says Christoph Schulz, product manager for clamping fixtures at Ringspann.

The KFDF is one of the group of purely mechanical precision clamping mandrels in the Ringspann portfolio and can be individually configured in the company’s one-stop web shop in all standard variants for executable clamping diameters from 120 to 375 mm. In addition, the manufacturer offers standardised flat elements that can be used to extend the clamping diameter up to 560 mm. Additional adaptations to different spindle connections, special workpieces or customer specifics are possible via adapted holders, assembly rings, intermediate flanges or spring accumulators.

More information www.ringspann.com

Digital engineering in the industrial metaverse

The industrial metaverse streamlines and accelerates industrial processes. By utilising digital twins and the use of artificial intelligence, automation tasks can be digitally planned, simulated and optimised prior to physical implementation. Work-holding and tool-holding specialist Schunk is therefore enhancing its portfolio with digital engineering to unlock new potential and boost customer productivity.

Virtual simulation not only accelerates the development of new products and systems but also reduces commissioning times, production interruptions and costly post-corrections. Schunk is now also utilising this technology to develop new digital components and drive progress in all areas of automation.

Schunk employs a five-stage approach in developing accurate digital twins. Each stage progressively refines components and assemblies from clamping, gripping and automation technology to mirror their physical counterparts. These digital twins encompass not only electrical properties and interfaces but also physical behaviours such as force, friction and wear.

The company has successfully digitally modelled the complete physical behaviours of several products, including new mechatronic parallel and centric grippers. A significant advancement is Schunk’s AI-supported 2D Grasping Kit, which automates repetitive sorting and handling tasks. The kit comprises a camera with lens, an industrial PC, AI software and an application-specific gripper, facilitating reliable handling of randomly arranged parts even under varying conditions.

“By simulating automation tasks, we offer customers a highly refined and productive solution, quickly optimised for their manufacturing requirements,” says Timo Gessmann, CTO of Schunk. “Thanks to AI, we can greatly simplify engineering. With digital tools and simulations, it is possible to validate all variants digitally in no time.” More information www.schunk.com

Rohm invests heavily in its future performance

Work-holding equipment specialist Röhm has invested over €800,000 in a new Index G320 turn-mill centre. The company says the investment underlines high levels of confidence in its innovation and long-term competitiveness.

The investment project was launched exactly one year ago and the machine is currently in the commissioning phase following installation. Commissioning will make the production of components for cylinders, which were previously turned and then drilled in two individual clamping operations, significantly faster and more efficient. The Index G320 replaces older machines that have reached the end of their life cycle.

The machine is characterized by its special technical features: it has two workpiece spindles, three tool carriers (two star turrets and a milling spindle) and 12 axes that work synchronously with each other. A unique feature is the ability to move the turrets out from under the chucks, creating space for the other turret.

With a weight of 21 tonnes, the machine offers space for up to 80 tools (24 on the turrets and 56 for the milling spindle). It is equipped with chucks, steady rests and Röhm’s iJaw technology. iJaw facilitates the measurement of clamping force in real time during the process to ensure maximum process reliability. Errors are detectable at an early stage, which increases productivity and sustainably improves workpiece quality.

In the coming weeks, the machine will undergo final commissioning and a final acceptance test. Once the tests are complete, operators will undergo training to ensure a smooth start to production.

With this investment, Röhm is demonstrating that innovation and safeguarding the future are top priorities, even in challenging times.

More information www.roehm.biz

The process of refurbishing Nikken rotary tables

At the heart of Nikken’s refurbishment service is a dedicated team of specialist engineers, committed to restoring the company’s rotary tables to the highest standards of quality and performance.

Leveraging Nikken’s extensive stock of over 1 million spare parts, experienced technicians perform complete mechanical rebuilds that start with a full strip-down and end with a product that closely mirrors its original condition, both in function and appearance.

Every refurbishment begins with a comprehensive functionality assessment. This initial check gives engineers a clear understanding of the table’s condition and helps guide the scope of the refurbishment process. Next, the table is completely disassembled and each component undergoes an intensive deep clean. At this stage, parts are meticulously inspected, with any that exhibit wear or damage flagged for replacement. All castings, covers and external surfaces are sent for thorough degreasing and professional powder coating to restore their finish.

As part of Nikken’s standard refurbishment protocol, the company replaces all bearings, seals, O-rings, gaskets, oil sight glasses, oils and greases. Critical components such as the worm screw, worm gear and braking elements are also replaced when necessary to ensure peak operational performance.

Once reassembled, the refurbished table undergoes a rigorous series of functionality and alignment checks using Nikken’s in-house co-ordinate measuring machine (CMM). This final stage ensures each unit meets stringent tolerances and performs as closely as possible to its original factory specifications.

To give customers peace of mind, all of Nikken’s refurbished rotary tables now come with the same 12-month standard warranty as all of its new rotary tables.

More information www.nikken-world.co.uk