Tooling and Workholding Advances Foster Adaptability in a Variety of Uses
Tooling and workholding play a crucial role in machining operations, facilitating superior cutting processes that result in time savings and use in a wide range of applications.
Posted: April 3, 2024
Time-saving and Flexible: Collet Adapter is a Smart Investment
The GDS µGrind collet adaptor from ANCA Inc. (Wixom, MI) is designed with the highest level of consistent accuracy and improved productivity in mind. The performance of any process relies on the performance of its individual components. This is particularly relevant in the grinding of precision tools. The increasing need for extreme accuracy and tolerances, as well as competitive and labor pressures, result in the demand for accessories that are more precise, easy to use and maintenance free.
A selection of good quality, easy to use workholding that provides minimal and consistent runout is one of the prerequisites for successful grinding, resulting in quality tools and happy customers – once again reinforcing that the quality of the whole process relies on the quality of all its components.
ANCA has partnered with GDS, a renowned German manufacturer of high-quality precision accessories for grinding and machining processes. One of their flagship products is the µGrind workholding, which is now available from ANCA’s distribution network. The µGrind has been customized to suit the requirements of ANCA grinding machines and can be set up in a matter of minutes.
Benefits of the µGrind workholding:
- Time saving: Thanks to minimal and consistent 2um runout, which provides consistency over large batches and collet changes.
- Easy and fast setup: It only takes minutes to get the µGrind ready for grinding and readjustment between collet changes is not needed. Concentricity and wobble adjustments are easy to perform.
- Flexible: A suite of compatible collets with form factors to suit almost all applications is available. µGrind comes in two form factors (standard and long nose) to suit almost all applications.
µGrind performance has been tested in real-life applications and the results are very consistent. A test was performed over a large batch of 6 mm tools where runout was measured before and after grinding at 2.5 x Ø and 10 x Ø. Even with thousands of clamping and diameter changes, the runout remained virtually unchanged.
Expansion of Fullcut Mill Tools Results in Wider Applications
BIG DAISHOWA (Hoffman Estates, IL) has expanded its lineup of Fullcut Mill FCM tools to include larger diameters and additional lengths. The BIG-PLUS BBT series now offers a 63 mm diameter cutter. The 25 mm and 32 mm diameter series have extended their length to 105 mm (4”).
The larger diameter cutter and new lengths both boost the Fullcut Mill FCM BBT line’s already-considerable versatility, allowing machinists to tailor their tool selections for many different applications. The BIG-PLUS BBT shank products are compatible with both BIG-PLUS and existing BT spindle machines. This allows for seamless integration, no matter the machining setup.
In addition, the integrated structure and low-cutting resistance result in high-efficiency machining, ideal for grooving and shoulder milling. These products also offer a maximum depth of cut nearly four times more efficient than that of conventional arbor-type cutters.
Sustainability with Green Carbide
With the goal of making innovation sustainable, CERATIZIT USA Inc.’s (Schaumburg, IL) CT-GS20Y grade is a premium carbide with reduced CO2 footprint that combines high performance with focused, sustainable production.
The CT-GS20Y grade consists of more than 99% high-quality secondary raw materials. Additionally, low-CO2 production is achieved through low-emission production processes and energy sources as well as consistently short transport routes throughout the entire process chain.
With 2.6 kg of CO2 per kg of carbide, the grade has an exceptionally low footprint. The corresponding survey and calculation of the product carbon footprint is based on the verified corporate carbon footprint for the Reutte, Austria production site.
Due to the low CO2 footprint of the carbide, manufacturers can significantly reduce the CO2 footprints of their tools, and CERATIZIT will provide the basis for shops to calculate the carbon footprint of their products. Plus, with the use of secondary raw materials for the CT-GS20Y grade, the company can guarantee price stability and counteract supply risks.
The performance and high consistency in production of a premium grade allows you to use it in the most demanding applications.
According to the CERATIZIT Group, the company as a whole strongly emphasizes sustainability and the responsible treatment of the planet. This means transforming their industrial behavior by responding to social, environmental and economic challenges while continuing to meet and exceed the expectations and requirements of its customers and stakeholders.
Jaws Distribute Gripping Pressure to Minimize Distortion
With maximum contact area for a solid gripping surface, Dillon Manufacturing Inc.’s (Springfield, OH) full grip jaws provide more friction for drive with reduced part distortion. The company has the industry’s most comprehensive lineup of full grip jaws in both standard and custom configurations to suit varied workholding applications. Manufactured from 6061 aluminum, 1018 steel, cast iron, and brass, Dillon Full Grip Jaws will not mark or mar the workpiece surface. Standard sizes available to 32” diameter. Custom designs are available with special heights, diameters, materials, and configuration to securely grip any workpiece, including a matching serration location, which is exactly perpendicular to the slots. In addition, these special full grip jaws can reduce and simplify setup times, enhancing project profitability. Dillon Full Grip Chuck Jaws are made in the USA with industry-leading lead-times. They are ideal for high-speed machining, as well as precision boring, tapping, drilling, and finishing across virtually all industrial markets.
These wrap-around type top jaws distribute more of the gripping pressure across the workpiece, reducing part distortion. Standard and custom full-grip jaws are available in serrated, tongue and groove serrated, Acme serrated, and square serrated designs.
New Tool Program Ideal for Job Shop Applications
EMUGE-FRANKEN USA (West Boylston, MA), a leading manufacturer of high-performance taps, thread mills, drills, end mills and other rotary tools, has introduced its MultiTOOL program that includes versatile, affordable high-quality taps, thread mills and drills that are ideal for a wide range of materials in high-mix, low-volume job shop applications.
“We are pleased to offer our customers a comprehensive threadmaking solution with our new MultiTOOL program,” said Marlon Blandon, product manager, drills, thread milling. “As the innovator of the industry-leading MultiTAP™, EMUGE-FRANKEN has expanded its successful multi-purpose tool concept to also include new thread mills and drills.”
The EMUGE MultiTOOL program includes the following products:
- MultiTAP tapping solution ranges from cut taps to form taps in different coatings, in addition to taps with extended lengths. Versatile MultiTAP features an innovative geometric design and a special base material and surface treatment, which allows it to cut a wide range of materials such as carbon steel, steel alloys, stainless steel, aluminum, cast iron, copper, brass and bronze. The taps are uniquely designed to produce threads within both 2B and 3B classes of fit, eliminating the guesswork required when calculating H-limits. MultiTAP significantly improves thread quality and boosts output, while reducing production costs.
- New MultiTHREAD™ MILL is an ideal general-purpose, cost-effective thread milling solution for job shops where part applications and materials frequently change. They are designed to cut a wide range of standard materials very efficiently. MultiTHREAD features a proprietary TIN T21 coating developed by EMUGE and is offered in a complete size and thread style range in either Full Form or Single Plane types. Only one tool is required for both through and blind holes, as well as for right or left-hand threads. The thread mills enable shops to boost their production and save on costs, due to reducing the number of tools needed.
- New MultiDRILL™ features affordable, high-quality solid carbide 3XD and 5XD drills for manufacturers that have limited quantity production runs or operate in a job shop environment with many materials. MultiDRILL is made of a unique sub-micro grain carbide grade that is harder than conventional carbide grades for drilling, yet it retains the ability to withstand shock and chipping. The new drills feature advanced TIALN-T63 coating utilizing nano-layer technology with surface hardness exceeding standard TIALN-based coatings, for reduced friction at high temperatures. The double margin designed drills are self-centering and feature concave cutting edges for higher chip shearing ability, providing longer tool life and productivity.
https://info.emuge.com/multitool
Pneumatic Workholding Supports for Flexibility in Workpiece Alignment
Fixtureworks® (Fraser, MI) a leading North American manufacturer and supplier of clamps, fixturing accessories, machine tool components and rollers and bumpers, now offers two varieties of pneumatic workholding supports — the BJ370 and the AMNS. These easy-to-use workholding supports are compact in design and allow for remote control activation and simultaneous control of multiple units. The BJ370 version can mount on either the top or bottom of the surface plate, while the AMNS can be side surface or bottom mounted.
In both versions, the spring-loaded piston is compressed under the workpiece. After the workpiece is clamped, air is applied to lock into position. Release the air to unlock the piston. The piston is tapped to accommodate a work support tip. The bodies are made from anodized 5052A aluminum.
In the BJ370 version, the piston is made from SK95 steel, quenched and tempered, with a black oxide finish. The locking shaft is made from 1045 steel with an electroless nickel plated finish. In the AMNS version, the piston and locking shaft are made from 1045 steel with an electroless nickel plated finish. The cylinder is made from A5056 aluminum with an anodized finish.
The BJ370 is available in lengths of 50 mm and 60 mm, in widths of 25 mm and 30 mm and in heights of 30 mm and 36 mm, with support capacity up to 150 lbs. The AMNS work support is available in 36 mm and 46 mm lengths, 8 mm and 10 mm widths, 33 mm and 43 mm heights, and has a support capacity up to 16 lbs. even with its compact size.
New Abrasives Offer Unprecedented Grinding Performance
Saint-Gobain Abrasives (Worcester, MA), one of the world’s largest abrasives manufacturers, offers the Norton RazorStar™ fiber discs, quick-change discs and belts featuring innovative engineered shaped ceramic grain, a breakthrough technology with unbeatable performance even in the toughest grinding applications. A unique combination of razor-sharp grains with a supersized grinding aid helps to significantly reduce heat generation for cooler cuts and longer life on a range of materials such as carbon steel, aluminum, stainless steel, nickel alloys and other hard-to-grind metals.
Enabling exceptionally high cut rates and material removal, the engineered shaped grain in the Norton RazorStar belts and discs features a consistent shape from grain-to-grain along with razor-sharp cutting points. For long, unparalleled abrasives life, the unique patented geometry and tough micro-structure enable the grain to stay sharp, as new cutting points are exposed when the grain fractures. The products also feature a high concentration of grains that are oriented in an upright position, so the abrasives are ready to cut and aggressively perform at their sharpest point.
“RazorStar fiber discs have raised the bar and are setting the standard in grinding productivity and quality,” said Jeremy Spencer, product manager, Norton | Saint-Gobain Abrasives. “We are seeing an up to 50% cutting performance improvement compared with other ceramic discs on the market today, and we are very excited to offer our customers new abrasive discs that will take their grinding performance to a new level of efficiency when removing welds, grinding, beveling and doing heavy deburring.”
“RazorStar belts, which are designed for medium to high pressure metal removal in challenging robotic or off-hand applications, are producing the same number of parts with fewer belts and less machining and changeover time, while consuming less energy,” said John Benkoczy, Sr. product manager, Norton | Saint-Gobain Abrasives.
RazorStar fiber discs, quick-change discs and belts are offered in 36-grit:
- RazorStar fiber discs are available in sizes ranging from 4-1/2”-to-9” in 7/8 hole, speed-change and AVOS discs. Key markets include MRO, metal fabrication, welding, oil and gas, energy and ship building.
- RazorStar quick-change discs, which are available in 2” and 3” sizes, feature a strong backing that stands up to extreme pressure when removing stock, deburring, beveling and blending, and are especially well suited for aerospace, MRO, metal fabrication, welding and energy industry applications.
- RazorStar belts are made-to-order and are ideal for impact grinding, robotic or off-hand applications in markets such as foundry, aerospace, automotive, metal fabrication, oil and gas and general engineering.
https://nortonsga.us/RazorStar
Three Exclusive new Technologies Maximize the Life of Ceramic Abrasives
In its quest to become a global leader for productivity and safety solutions in the metalworking industry, WALTER Surface Technologies (Windsor, CT) has launched three exclusive new technologies to further maximize life of its high-performance ceramic abrasives.
“Ceramic grains provide longer life, higher removal rates and improve comfort for operators,” said Marc Brunet Gagné, senior product manager, abrasive power tools. “But it takes more than just the grain to build a high-performance abrasive wheel. WALTER has gone beyond the grain with new exclusive technologies to ensure that the ceramic grain is optimized and performs at its best.”
WALTER’s exclusive SMART RESIN™ Technology, found in bonded abrasives such as the ZIP™ XX and the XCAVATOR XX™, works to expose fresh ceramic grains at the optimal moment to achieve the most productive balance between sharpness and life in a metalworker’s given application.
WALTER’s exclusive V-STRONG™ Backing Technology, found in its ceramic sanding discs such as the XTRACUT™ and the COOLCUT XX™, improves durability and toughness of the wheel thanks to stronger resistance of the cloth. “With 14% more vulcanized fiber in the cloth than competitors, WALTER ceramic sanding discs last longer, resulting in less wheel changeover.”
“Most flap discs are baked during the manufacturing process to bond the flaps to the backing,” continued Brunet Gagné. “Unfortunately, this process can dry out the backing cloth of the flaps, reducing its performance.” Now, thanks to WALTER’s exclusive MAX LIFE™ cold curing glue, the freshest abrasives possible are available on products such as the ENDURO-FLEX™ TURBO, to avoid micro-cracking and drying out, which improves consistency, and can extend disc life by up to 25%.
Shaft Collars and Mounts Adjust Quickly Without Tools
Shaft collars and mounts that can be adjusted without tools, plus handles and thumb screws to convert standard shaft collars to quick-adjust types, have been introduced by Stafford Manufacturing Corp. (Wilmington, MA). Stafford quick-adjust products feature the Flip-Lok™ with a split hub and an integral adjustable clamp, Staff-Lok™ lever-actuated shaft collar, and the Python™ Flange Mounting Collar with a six-hole bolt pattern and keyway. Suitable for a wide range of linear and low RPM rotary applications, these quick-adjust products can be easily repositioned by hand without tools.
Available in inch and metric bore sizes from 1/2” to 2-1/2”, depending upon product, Stafford quick-adjust products are made from aluminum anodized black and can be supplied as specials in colors or made from steel and stainless steel with modifications to OEM requirements. For applications using rope, the SlipKnot™ is molded from ABS plastic and allows for precise location as a grip, locator or stop.
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