Magnetic attraction
>TOOLING & WORKHOLDING Try this for size
Roemheld’s ‘Try before you Buy’ initiative is enabling end users in a wide range of sectors, including aerospace, F1, medical and automotive, to test the benefits of its 5- axis vice technology. It offers companies the opportunity to investigate directly the advantages to be gained from using Roemheld vices before committing to an investment.
A recent addition to the 1st Machine Tool Accessories (1st MTA) product portfolio is the high quality Alpha workholding solutions range of magnetic milling chucks and material handling devices.
Ruggedly constructed for consistent accuracy and extended working life, Alpha Bi- Polar (ABP) Milling Magnets are a versatile method of delivering secure clamping, reduced vibration and extended tool life to heavy machining applications. They are available in four lengths from 500-2,000mm long, with standard height and width dimensions of 144mm and 200mm respectively to provide efficient clamping of a diverse range of workpieces. Individual pole extenders can be used to raise parts from the magnetic chuck surface for through-hole work, whilst self-shimming pole extenders are available for holding parts with features such as stepped diameters. ABP’s use of permanent electro technology means that the system does not require a continuous electricity supply to maintain its strong magnetic field. In addition, Alpha controllers are equipped with circuit breakers and, if required, can be linked directly to the machine tool’s PLC.
Using a similar permanent electro-magnetic system to the ABP range, 1st MTA’s Alpha Mill Round (AMR) Milling Magnets are claimed to be the most versatile machining magnet currently available.
The Alpha Mill system ensures that the workpiece is uniformly supported over a larger area, minimising vibration and enabling the use of faster feed rates without impairing tool life or machining quality. With each individual pole generating up to 1,400lbf of clamping force, AMR is ideal for machining processes such as milling, drilling and tapping. Furthermore, simple calculations allow users to verify the clamping safety factor for any given machining application. Allowing five face machining in a single set-up, the system enables set-up times to be reduced by up to 50% when compared to conventional fixturing. AMR’s strong magnetic field also penetrates only
The majority of applications using Roemheld’s 5-axis vice and jaw technology are already safely gripping on 3mm and this has resulted in many operators and production engineers having to re-think how to machine components for optimum productivity. In some instances, being able to grip on 3mm has resulted in a saving of up to 30% on raw material per component.
End users are also finding that the range offers greater control over distortion of components due to repeatable clamping forces. In addition, the Roemheld vices enable the optimum positioning of components on 5-axis tables to enable standard length spindle tooling to be used.
Programmers also have the ability to simulate the machining process due to the availability of Step files and/or CAD files for every vice and jaw within the Roemheld 5-axis range. This not only makes pre-machining processes more accurate, but also reduces costs as potential collision paths can be programmed out prior to machining taking place. Bill Neal, managing director of Roemheld, affirms: “We understand that end users have choices and they must be comfortable and confident with
Reaching out
With market demand for thermal shrink toolholding technology on the increase, Taegutec has now extended its T-Shrink range of thermal tool chucks to include a new HSK A50 holder.
0.4 inches deep, eliminating the problem of unwanted magnetic chip adhesion by keeping the workpiece surface free from residual magnetism. Alpha Mill Round units are fully sealed against coolant ingress and are available in four inch length and width increments.
At the heart of each Alpha Mill system is the Alpha Control, which employs microchip technology to deliver features including machine tool and safety interlocks, a CNC Interface and precise current sensing for assured clamping performance.
Complementing 1st MTA’s new range of magnetic chucks, the Alpha A-Pod Magnetic Workholding system is particularly suitable for frequently changed machining set-ups, or where the use of dedicated fixturing is not practical.
Comprising a series of 93mm diameter modular units, which can be easily mounted by a through bolt into a T-slot or sub- plate, the system requires virtually no maintenance and offers an ideal replacement for systems such as hydraulic fixtures. A-Pods share many of the attributes of Alpha’s chuck
systems, including permanent electromagnetic technology and the generation of up to 1400lbf of grip, to ensure high strength location of ferrous components for machining, grinding, polishing, measuring, welding and assembly operations.
Completing 1st Machine Tool Accessories’ new magnetic range is the Alpha Workholding Solutions Eagle Lifts. Featuring Alpha’s permanent magnet technology, Eagle Lifts are available in five sizes, with flat stock safe working load capacities ranging from 125- 2,200kg. Each model incorporates deep ‘V’ grooves between its pole shoes, for the secure lifting of round stock. Portable, compact and lightweight, Eagle Lift products are designed and tested to exceed the relevant ASME B30 guidelines. The range also incorporates Alpha’s Test Talon safety feature, which allows users to safety test load carrying capabilities for each application prior to use.
The toolholders offer high accuracy levels and a narrow design to enable the tools to machine difficult to reach surfaces.
The new toolholding system has a runout accuracy of 0.003mm that allows the holders to perform to high levels of accuracy, improving machining performance, tool life and surface finish during high speed machining beyond 25,000rpm.
The HSK A50 is an addition to the already established HSK
63 series and can
accommodate tool shank diameters of 6mm, 8mm, 10mm, 12mm, 14mm and 16mm with external diameters of 21mm, 24mm and 27mm. The narrow external diameter permits the end user to efficiently machine deep cavities and complex forms with no possibility of the toolholder colliding with the workpiece. Despite the small external diameter, the T-Shrink demonstrates rigidity to deliver good tool life and surface finish. The T-Shrink system has a length from the shoulder to the cutter that ranges from 80mm to 95mm and as with all holders in the T-Shrink series, the HSK A50 requires an inductive
the investment they are seeking to make when purchasing 5-axis machines and workholding. “Therefore, by offering the option of ‘try before you buy’, we are allowing that confidence to grow as operators and programmers have the time to ensure that any investment made by their companies has been well researched and investigated prior to parting with any money.”
>ROEMHELD
www.roemheld.co.uk
heating device – also available from Taegutec – to successfully clamp the cutting tools.
>TAEGUTEC
www.taegutec.com
>1ST MTA
www.1mta.com
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www.pesmag.co.uk Production Engineering Solutions • August 2010 19
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