New Tooling For Quick Changeovers

QUICK CHANGE VISE JAW SYSTEM
The CARVEsmart™ quick change vise jaw system from Bellatex Industries LLC (Prior Lake, MN) is designed for production and tool room applications, replacing the often cumbersome, conventional method of attaching vise jaws to a vise using face mounted cap screws. This patented system employs three (from the top) channeled clamping elements and a dovetailed jaw design to couple the master jaw and soft or hard jaws. It dramatically reduces set-up time and improves set-up reliability and quality.

Its dovetailed aluminum extruded bar stock makes the soft jaw an inexpensive cut to length tool that can be reused or quickly recut with each part run. This is ideal for shops running repeating and tight tolerance work. Face mounted cap screws are problematic since they are located in a vise’s sweet spot. They extend into the workholding zone forcing work to be held in front of or above the cap screws. The CARVEsmart dovetailed jaw provides a larger machinable workholding zone that permits holding parts deeper and more securely into the jaws of the vise providing less jaw lift and more secure clamping.

Front- or side-loading of the soft jaws is fast and simple using a T-handled hex wrench to loosen three channeled clamping elements accessed from the top of each master jaw. By designing the clamping mechanism on the top, it is not necessary to open the vise to access the cap screws. Differential screws pull the channeled clamps, providing downward pressure to secure a jaw in place. The operator can quickly change the soft jaw from the front or side with the entire changeover taking 40 seconds to 60 seconds each. This means when setting up an eight-station quad with 16 jaws, all of the jaws can be replaced in less than 12 minutes.

When reusing once carved jaws, reinstalled in to the original master jaw, and a vise that has not moved, using a straight edge or side stop, expect repeatability within .001 in. The alternative is using the original precut program and a resident tool to recut the original female forms in new jaws in minutes. That quad can be in service in a half hour versus a half day and each station will be as perfect to the spindle as the first run. Saving the jaw prep program, not a once used jaw is often faster and more accurate than reusing once used jaws.

Another significant benefit to this quick change vise jaw system is the extruded aluminum soft jaw blanks available in a variety of sizes. Small parts can use jaws as short as 1 in of CARVEsmart extruded barstock. This means four 1 in jaws mounted to a 6 in vise now holds two small parts with $5 of jaw material. This new system offers economical dovetailed extruded aluminum for soft jaws in widths of ¾ in x 2 in, 1 in x 2.25 in and 2 in x 3 in, and lengths of 6 in, 31 in and 94 in. We also have ¾ in x 2 in dovetailed 1018 steel bar stock that comes in 6 in and 31 in lengths.

With CARVEsmart only one saw cut is necessary for any length from 1 in to 94 in. This can reduce jaw cost by half or more compared to purchasing a commercially made jaw or making them in-house. Additional savings will be realized because used carved jaws will no longer need to be organized, stored, found, cleaned, reinstalled, indicated in and offset still yielding than perfect results. “This jaw system is fast and secure,” notes Andy Melde, a senior R&D model shop machinist at a Minnesota Medical Device Company. “The extruded jaw material allows me to cut jaws to any length as I need them. I have cut them as short as 1 in and up to 24 in long.”

Ideal for tool-room and single station vises, for reusing pre-carved jaws, hard jaws or working above the top of the vise, the CARVEsmart #10000 6 in tool steel master jaw set is ground flat and parallel within .0002 in. The set includes two master jaws, a T-wrench and four ½-13 low head cap screws. Best suited for carved jaw and production work, the CARVEsmart #20000 6 in 6061 hard-coated aluminum master jaw set is machined flat and parallel within .002 in. It incorporates threaded stainless steel inserts, pressed into the master jaw from the bottom for the clamp screws. Two master jaws, a T-wrench and ½-13 low head cap screws are included in each set.

The patented CARVEsmart quick change vise jaw system was invented by machine shop owner Bill Ehnstrom to save time and reduce costs in his own operation. In 2011, Ehnstrom partnered with veteran machine tool industry expert Doug Fontaine to form Bellatex Industries and commercialize the system, which is now sold through a nationwide network of distributors.

Bellatex Industries LLC, 5780 Starview Lane, Prior Lake, MN, 55372, 952-440-3419, CARVEsmart.com.

QUICK CHANGE POWER CHUCKING SYSTEM
The DURO-NCSE Flex power chuck from Röhm Products of America (Lawrenceville, GA) provides a quick and simple way to change out jaws and clamping tools. Shops gain ease and flexibility to switch from mandrels to collet chucks to face drivers. Especially beneficial to those shops needing frequent clamping tool changes, this power chuck system allows them to switch from mandrels to collet chucks to face drivers and centers without having to the remove the power chuck from the machine tool.

In short 4 ft bar feeding applications, this power chuck reduces the amount of prep cutting needed as well as material waste. As opposed to cutting 12 ft long bar stock three times in 3 ft lengths and ending up with four pieces of unusable remnant stock, the DURO-NCSE with an added dead-length collet chuck generates more support for longer 4 ft sections. This means shops cut bars only twice and end up with one less piece of remnant.

At the base of this system series is a case hardened steel chuck that features individual unlocking jaws for easily moving, changing and turning them. High accuracy holding and precision gripping ensures dependable performance, especially in extremely high-speed applications. Other variations within the series include the DURONCSE Flex KZZT/KZZT-A collet chuck and DURO-NCSE Flex ABSIS mandrel models. The KZZT/KZZT-A secures parts radially on their OD and accommodates round, hexagon and square bar stock with its full through hole, while the ABSIS clamps workpieces radially from their ID by using an expandable segment sleeve.

Headquartered in Lawrenceville, Röhm Products of America, a division of the Röhm Group (Sontheim/Brenz, Germany), has been a leading provider of high-quality clamping and gripping technology to the North American metalworking industry since 1978, with a broad product portfolio that encompasses drill chucks, live centers, lathe chucks, vices, automation technology, power chuck technology, mandrels, tool clamping systems and customized solutions for turning, milling, drilling and grinding applications in the aerospace, automotive, energy, engineering, micro-technology and rail vehicle manufacturing sectors.

Röhm Products of America, 5155 Sugarloaf Parkway, Lawrenceville, GA 30043, 770-963-8440, www.rohm-products.com.

MAXIMIZE MILLING/TURNING APPLICATIONS
SCHUNK, Inc. (Morrisville, NC) has developed the highly flexible ROTA-S flex manual chuck that is ideal for machining a wide workpiece range on milling/turning machines. This chuck is the proven ROTA-S plus lathe chuck with extended guideways that transform it into a large, light weight chuck (for its capacity), which makes it particularly versatile.

A demonstration of the ROTA-S flex manual chuck.

Compared to conventional lathe chucks used for large clamping diameters, the weight with ROTA-S flex is approximately 60 percent of a conventional chuck with the same capacity. At an identical table load, much heavier workpieces can be machined and, due to the low height, enough space remains for the workpiece and the tools. For machining smaller workpieces, the extended guideways can easily be disassembled, considerably improving workpiece accessibility when compared to a clamping application with conventional large chucks. A special lubrication system ensures permanently high clamping forces for both versions. Dirt seals prevent chips and dust from entering the chuck.

This clamping solution is available in sizes 700, 1000, and 1200 for ROTA-S plus, and the ROTA-S plus 2.0 manual chuck is available in sizes 315, 400, and 500. Depending on the size, the chuck (without top jaws) weighs 170 kg, 360 kg, or 490 kg respectively. The ROTA-S flex can be combined with numerous chuck jaws from the 1,200 types of the world’s largest standard chuck jaw program.

Another quick change solution is the VERO-S quick change pallet system which, when combined with MAGNOS magnetic chucks, creates the highest possible flexibility in production and an enormous reduction of setup costs. The system features simple handling, precise repeat accuracy, tremendous setup cycle time reduction, and flexible application possibilities. Control is done by a separately ordered unit that is available in 480 volt with over 200 lb psi clamping force. Standard sizes include 16 x 16 and 16 x 24. Custom sizes available upon request.

SCHUNK, Inc., 211 Kitty Hawk Drive, Morrisville, NC 27560, www.schunk.com.

QUICK CHANGE SYSTEM SAVES MAN-HOURS AND MONEY
Featuring more flexibility and faster set up time, the new range of driven tools with the MTSK Quick Change System offered by MD Tooling, LLC (Howell, MI) will save both man-hours and money. These modular tool holders can be used on any CNC machine fitted with MD Tooling MTSK driven tool holders. Company president Wes McLucas says, “You can be confident when you select these quick change tools since they are based on the proven and tested HSK-T standard. The system has a quick change clamping nut so the modular tool adapters can be easily ejected to eliminate the need to apply force to break the taper free.”

When ordering this new system, included is the new anti-rotation wrench that increases safety during tool clamping and only requires one hand to hold. Accurate tool positioning, repeatability and rigidity are all integral parts of this modular system, as well as an overall size reduction of the tools. A full range of MTSK quick change tool holders is offered, including ER Collet Chucks, ERA Collet Chucks, Shell Milling Adapters for MTSK-63, MTSK-50, MTSK-40 and MTSK-32.

Founded in 2003, MD Tooling has a full technical support department with over 35 years of CNC experience along with the largest range of precision live tooling for Turning Centers and Lathes available for most major machine tool manufactures. Products include an extensive line of standard live tooling as well as innovative specialty tool holders such as 0-90 and 0-180 adjustable angle tool holders, gear hobbers, slotting tools and even worm gear generators.

MD Tooling, LLC, 10139 Bergin Road, Howell, MI 48843, 877-918-6657, www.mdtooling.com.

SPEED UP TOOL CHANGES
Tube bending machine tool manufacturer Schwarze-Robitec GmbH (Cologne, Germany) has developed the new Quick Tool Unlock rapid clamping system for tube bending machines according to the “keep it simple” engineering motto. This system allows quick change of bending former without tools to reduce set up time noticeably.

The rapid clamping system is comprised of a split tension rod with clamping lever, as well as a swivel device. While in customary models the continuous tension rod to the swivel cross arm must be unscrewed at the top of the bending former for a tool change, the procedure becomes much simpler with the Quick Tool Unlock. Here, only the clamping lever is actuated to disengage the connection to the swivel cross arm. The swivel device can then be opened so that the bending former is exposed to the top.

In interaction with the automatic tool clamping, the bending former can be removed without any difficulty. There is no longer any need for the previously necessary unscrewing of the bending former. The work-saving technology is absolutely self-explanatory and quick. Another plus of Quick Tool Unlock is that all connections from static to rotating parts are carried out via rolling bearings which contribute to the durability of the machine.

Schwarze-Robitec, founded in 1903, is a leading international manufacturer of tube bending machines that manufactured the world’s first CNC-controlled tube bending machine back in 1977. To date more than 2,400 machines have been sold, some of which have been used in unrestricted production for more than 35 years. These include tube bending machines and bending tools, tube perforating machines, measuring stations and special machinery construction for manufacturers in the automotive, energy, shipbuilding, aerospace and other industries.

Since 2011 the company has been run by the managing directors Bert Zorn and Hartmut Stöhr and currently has 130 employees at its headquarters in Cologne. The company is represented worldwide via long-term partner enterprises.

Schwarze-Robitec GmbH, Olpener Straße 460 – 474, 51109 Cologne, Germany, +49(0)221-89008-0, Fax: +49(0)221-89008-9920, sales@schwarze-robitec.com, www.schwarze-robitec.com.

COMBINATION ER COLLET CHUCK / QUICK CHANGE SYSTEM IN ONE TOOLHOLDER
In the past, acquiring non-perishable tooling after a major machine purchase required a large expenditure — one that was often uncomfortable for shops with limited budgets. In a hyper-competitive marketplace that is still dealing with a sluggish economy, this cash outlay can be worse than uncomfortable; it can be crippling. That’s why, for shops focused on conserving costs and improving productivity, the innovative QuickFlex^® system from WTO Inc. (Charlotte, NC) can be a game-changer.

An overview and demonstration of the Quickflex system.

Officially introduced in 2012 and now available for the North American market, this innovative quick change system for driven toolholders saves a substantial amount of money in out-of-pocket tooling costs. It also dramatically reduces tool change time and provides greater flexibility. “Providing an ER collet chuck and quick change system in one toolholder allows you to buy many fewer tools than you would have to otherwise,” says Anthony DeHart, the director of sales and business development at WTO. “Best of all, this flexible system doesn’t compromise rigidity, performance, or accuracy, which is great news for high-precision contract manufacturers.”

“The base unit comes in a straight (radial) or right angle (axial) configuration, which, when combined with the wide range of adapters available, covers virtually any machining process requirement, all in a single system,” explains DeHart. “This approach enables the shop to incrementally invest in a full range of options with minimal initial capital requirements. It also accommodates the multiple setups and frequent changeovers that are required for the short manufacturing runs in today’s production environment.”

There are seven specific benefits of the QuickFlex^® system:

• It is comprehensive. The system covers a full range of different tool clamping adapter types and sizes.
• The system is extremely cost effective. With a minimal initial investment, shops can get unprecedented mileage out of toolholders. They can start by simply clamping the cutting tools directly into the toolholder using a standard ER collet. No need to buy a complete quick change system right off the bat.
• Setup time is reduced. For all manufacturers, time is money. The longer it takes to change from one tool to another, the longer production is paused. Setup delays can seriously cut into productivity and limit profits. In contrast, QuickFlex^® cutting tools can be preset while the machine is operating, meaning that the setup time for tool change at the machine can be significantly reduced.
• The system combines precision with high rigidity and safe handling.
• It incorporates user-friendly handling. Changing tools is quick and easy with the new one-hand wrench, which is patent registered. Just use the one-hand wrench to hold the system spindle and tighten the large collet nut with the spanner wrench. The system adapters, which use the inbuilt thread nut, are tightened the same way.
• It’s surprisingly flexible. While the system toolholder can be used without a quick change system, it’s also easy to add a quick change function. Buy quick change adapters after the initial purchase and reduce tool change time even more dramatically. The complete quick starter kit, which is user friendly and reasonably priced, includes three different adapters and a one-hand wrench set.
• This system improves tool change handling. In the past, changing tools has been difficult, time consuming, and in some cases risky. Not so with this system, which boasts quick, easy, and safe tool change handling with the new one-hand wrench.

The basic elements of the QuickFlex^® system are the two independent taper connections (see Figure 3). The short taper (Figure 2, Detail 8), located closely behind the thread of the collet chuck, is for radial centering and axial support of the adapter. This taper guarantees that the system will be highly precise, independent of possible abrasion at the cone of the ER collet chuck. The location of the taper behind the thread (Figure 2, Detail 7) keeps it protected against chips and dirt, which permanently guarantees the high precision of the system.

The short taper also works as a definedcontact face,whereas the rear part of the ER collet chuck cone guarantees Figture 2, Detail 11CFigure 2, Detail 7 full performance can be transmitted from the turning center to the cutting tools. The polygonal torque transmission (Figure 2, Detail 10) is placed just behind the radial support.

WTO is a privately held, second generation family-owned enterprise that is headquartered in Ohlsbach, Germany and has specialized in the design and manufacturing of high-precision toolholders for CNC machine tools since 1977. A recognized pioneer and leader in the industry, the company specializes in the production of static and driven toolholders for multi-tasking machines, turning centers, multiple spindle machines, and Swiss type machines. To maintain high quality standards, all tooling lines are manufactured exclusively in Germany.

Offices in Charlotte provide customer service and support for the North American markets with an in-house service center that performs both preventative maintenance and does complete rebuilds to exacting factory standards.

WTO Inc., 14301-4 South Lakes Drive, Charlotte, NC 28273, 704-714-7765, Fax: +1 704-714-7767, www.wto-usa.com.

TOOL-POSITIONING SYSTEM REDUCES SETUP TIMES
The Eppinger Trifix® Tool Positioning System recently introduced by Exsys Tool Inc. (San Antonio, FL) facilitates quick and accurate exchanges of both static and driven tooling for DMG/Gildemeister multi-tasking machines. Based on the VDI interface, the system can reduce tool setup times by up to 80 percent compared to prior methods while delivering positioning accuracy within 10 μm between tool stations and single-position repeatability of less than 5 μm at a tool length of 3.9 in (100 mm).

When searching for ways to increase productivity it is important to evaluate even the smallest steps of a production process. Minor adjustments, such as the incorporation of an improved VDI interface, can greatly reduce setup time — and this tool positioning system is a great example as it provides a faster, more accurate tool holder exchange.

Tooling can be mounted with four additional hold down screws to maximize rigidity in heavy chipload operations such as milling, and employing this tool positioning system does not prevent a facility from using other tooling it already has. The Eppinger name has been synonymous with innovation, precision and reliability for decades, and the Trifix system continues the tradition by reducing setup time and providing increased positioning accuracy.

Founded in 1987, Exsys Tool provides high-precision rotary and static-fixed tool holder solutions for CNC turning centers. The company is the exclusive importer of German-made Eppinger tooling, including the revolutionary Preci-Flex® adapter system for lathe tooling changeovers. With headquarters near Tampa, FL, and support offices in California, Canada and Mexico, the company effectively offers over 22,000 different types of tool holders, gold standard tooling repair and applications expertise to manufacturers throughout North America.

Exsys Tool, Inc., 11654 Corporate Lake Boulevard, San Antonio, FL 33576, 352-588-4345, Fax: 352-588-4821, info@exsys-tool.com, www.exsys-tool.com.

ONE-CLICK MULTI-CONNECTION MANIFOLD SIMPLIFIES DIE CHANGE
Industrial Innovations, Inc. (Wyoming, MI) offers the Quick Spray Release Multi-Connection manifold that enables a “one-click” disconnect and connect of multiple hoses to assist with Quick Die Change. This simplified method eliminates costly set-up time and confusing lube line hookup to ensure lubricant spray is applied where intended every time.

In traditional die change, operators disconnect and then connect all hoses individually, hampering quick die change efforts. There is also a greater chance for error as the operator may potentially mismatch hoses and nozzles to deliver the wrong amount of lubricant to the wrong place at the wrong time. With this one-click spray nozzle multi-connection design, each die has hoses connected to a single standard manifold. During die changeover, the operator simply unclicks the quick-disconnect manifold and removes the die. The new die is then put in place and the new manifold plugged in. The operator then loads the part program and spray profile for accurate volume, placement and timing of the lubricant.

Industrial Innovations is a leading manufacturer of industrial lubrication equipment for operation in metalworking industries, including die casting, metalforming, machining and stamping. The company is known for its comprehensive approach to lubrication solution development, supported by the effective engineering principles, reliable components and the quality construction of its equipment.

Industrial Innovations, Inc., 2650 Thornwood, Wyoming, MI  49519, 616-249-1525, Fax: 616-249-0983, troy@industrialinnovations.com, www.industrialinnovations.com.

A REVOLUTION IN RIGID TAPPING
MicroFLOAT Quick-Change Tap Holders from Teckniks Inc. (Indianapolis, IN) feature tension/compression float technology that is optimized specifically for rigid tapping, greatly improving overall tap performance. The revolutionary design increases tap life, decreases scrap rates, and improves thread quality. During the tap cycle, the load on the tap peaks as the spindle reverses direction, a common cause of tap breakage. The MicroFLOAT Tap System greatly reduces this load, stabilizing the tap throughout its cycle, resulting in unparalleled performance and increasing tap life up to 295 percent.

http://youtu.be/Du5StWG5BbM
An overview and demonstration of the MicroFLOAT Quick-Change Tap Holder system.

These tap holders are available for CAT40, CAT50, BT30, BT40 and HSK63A spindles. Using extensions can create gauge lengths up to 9 in and eliminate the need to buy special holders. Coolant-thru is standard on all of these tap holders. Techniks is a manufacturer of tool holders, collets, set-up equipment, and accessories for CNC machining centers, headquartered in Indianapolis.

Techniks Inc., 9930 East 56^th Street, Indianapolis, IN 46236, 317-803-8000, info@techniksusa.com, www.techniksusa.com.