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SHOP SOLUTIONS


pulled out of a standard shrink-fi t chuck and broke when trying to machine a slot deeper than 1×D. The test study was conducted when a group of representatives from the aerospace industry, the Technical University of Dortmund, and Technical University of Hamburg-Harburg, visited Heller. The Safe-Lock system features special drive keys in the chuck and slots in the tool shank that prevent milling cutters from turning or being pulled out of the chuck during machining. Heller Machine Tools is known as a source of machining innovations when working with materials that are diffi cult to process like titanium alloys. Heller is known for its high-quality four- and fi ve-axis CNC machining centers, CNC mill/turn centers, CNC machines for crankshaft and camshaft machining as well as fl exible manufacturing systems. According to Werner Kirsten, a Heller technolo- gist responsible for the area of diffi cult-to-machine


Haimer Heavy Duty Shrink Chuck (middle) and Power Shrink Chuck (on the right) next to a shrink-fi t chuck with a standard geometry. Both chucks on the right can be equipped with the pullout protection system Safe-Lock. This combination provides highest runout accuracy, process reliability, and eliminates the problem of tool pullout.


materials, “Our service includes optimizing the machining processes together with our customers and suppliers. We often achieve this aim with an optimized roughing operation which ultimately results in a reduced fi nishing process. By maintaining the same technology values, but shortening the fi nishing depth of cut by 50%, the overall machining time is reduced to half. However, this requires process reliability and controllable systems during roughing,” said Kirsten. In this regard, Kirsten said all machining components in


the process chain have to be considered in order to improve productivity. “The machine tool is the most obvious com- ponent of the machining process, however, the tool, the toolholding system, the coolant supply and other elements are also essential for a successful operation. In the end, the weakest link of the process chain limits its success.” In Kirsten’s opinion, most machine shops don’t pay atten- tion to the toolholder even though it is especially signifi cant for high-performance cutting. “Many of the trials which we carried out during the last few years have proven this point. We realized that the toolholder has an incredible infl uence on the machining process. In the case of reinforced shrink-fi t chucks, for example, the vibration node is closer to the bear- ing point due to the larger mass. The result is a smoother machining process with less vibration and a better surface fi nish quality while using the same tool, machine, process parameters, and fi xturing technology,” Kirsten said.


34 AdvancedManufacturing.org | June 2017


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