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MAPAL – Miniaturised Clamping Chucks

Thanks to additive manufacturing, MAPAL now offers hydraulic chucks in miniature format with HSK E25 connection, for example for the direct clamping of tools with a diameter of 3 mm. These meet all the demands on chucks for the miniature sector with respect to radial run-out accuracy, balancing value, cooling lubricant supply and handling.

In order to guarantee perfect radial run-out accuracy, innovative clamping chamber systems are integrated into the new chucks that fit tightly against the shank of the tool. They are fitted with dirt grooves as protection against micro-soiling. The demanded balancing value is ensured thanks to the internal balancing geometries and supporting structures that also aid the optimisation of weight and strength. The miniature chucks allow homogeneous acceleration and deceleration of the whole tool system of chuck and tool for less loading of the spindle.

The innovative manufacturing method has also enabled the chucks for the miniature sector to be equipped with decentralised coolant outlets. These outlets are designed using parameters such as coolant pressure, setting dimension and spindle speed so that they deliver the cooling lubricant precisely to the cutting edge. In the best case, a metered total-loss lubrication system is achieved that eliminates the need for subsequent cleaning of the parts.

The new miniature chucks from MAPAL allow quick and simple clamping of the tool. Neither training courses nor high setup costs or expensive peripherals are required for implementation of the chucks.

The new small hydraulic chucks also offer new possibilities for the clamping of workpieces. For example, for the clamping of artificial hip joint balls. Specially formed clamping chambers inside the chuck and a special outside geometry ensure that the balls are very precisely and at the same time gently clamped. Particularly in medical technology, topics such as reproducible precision are taking on enormous importance – and this is ensured during machining thanks to the new chucks.

Please contact us for more information.

 

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MAPAL – Machining of Unstable Structural Parts

 

Thin-walled parts are used in a wide variety of applications. These components are often manufactured close to the net shape, but nevertheless require a great many machining operations. The particular challenge for these machining processes is that due to their design, these parts are very unstable and susceptible to vibration. That creates special demands upon the design of the process and the tools.

These parts are preferably machined in a single clamping system. In order to meet this demand and to make as many of the surfaces to be machined as accessible to the tools as possible, certain allowances have to be made in the clamping system. As a consequence, the workpiece is not optimally supported and tends to vibrate. Thin webs, voids and interruptions to be machined and widely fluctuating stock removals from the cast blank also call for special tool solutions. For large parts with many machining steps, this would require a huge number of tools. The merging of these steps using combination tools in order to reduce the non-productive times and the number of tool slots is an ideal solution.

Thanks to its vast understanding of the processes for the machining of unstable structural parts, MAPAL is able to offer cost-effective and reliable processes. Three aspects are of particular importance here. Firstly the adjustment of the cutting rate is a factor for reducing or avoiding rising vibration. Both vibration of the tool – which would result in short tool lives and poor machining results – and vibration of the workpiece have to be prevented. The latter would result in a recoiling of the part against the cutting edge and could cause damage to the tool. The second important adjustment in the tool design is the evaluation of the tool body. Vibrations can be reduced here by an appropriate design and choice of material. Furthermore, an intelligent arrangement of the cutting edges in form and position helps to keep the cutting forces low. And finally the machining process itself offers possibilities for reliable machining of parts susceptible to vibration. Reorganization and the choice of alternative sub-processes create a change in the distribution of forces that can increase the process reliability. For example, the use of a circular milling operation instead of a solid drilling operation can help to stabilize the process.

Please contact us for more information on machining of Structural Components.

– This article is an excerpt from Mapal Innovations – Process Solutions 

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Horn + W&F Solutions

Horn and W&F Werkzeugtechnik have come together to offer customers a complete solution covering everything from the spindle to the tool cutting edge. The focus is on equipping Swiss-type lathes with a quick-change system. “By entering into this cooperation, we are filling the gap that exists in our offering between the cutting edge and the machine. It will allow us to respond rapidly to customer enquiries and optimise their machining processes”, says Managing Director Lothar Horn, Paul Horn GmbH. Under the deal, HORN will be responsible for selling W&F tool solutions from Großbettlingen all across the world via its subsidiaries and sales partners in more than 70 countries.

The cooperation also brings many advantages in the OEM area by making it possible to offer customers “everything from a single source”. Thanks to the experience of both partners, new solutions and optimisation approaches can be developed in next to no time. To begin with, the cooperation will focus on quick tool change systems for Swiss-type lathes and internally cooled whirling units. A special Horn catalogue for Swiss-type turning is due to be launched in the autumn of 2018.

The first jointly developed technology to have come out of the cooperation is JET-Whirling. The internally cooled whirling tool is a real USP of the whirling method. Having the coolant supplied directly to the cutting edge during whirling results in higher surface quality, improves the flushing action for removing chips and extends the life of the tool inserts. The tool system – comprising the W&F whirling unit and Horn whirling head – was officially unveiled at AMB 2018 in Stuttgart.

Please contact us for more information on solutions from Horn + W&F!

 

 

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HORN High Speed Whirling

 

HIGH-SPEED-WHIRLING
New technology for shorter machining times

High productivity through turning and whirling operations performed simultaneously

• Long tool life and excellent surface quality as a result of pre-turning the thread diameter
• Machine and Process Technology partners Index / Traub

Please contact us for more information on this new product.