CoroChuck 970 SynchroFlex Benefits

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Egbert Ryan
5 years ago
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Benefits Better surface quality on the flanks of the

Greater process security Due to the reduced risk of

accurate depth control For a more precise production

due to slim design Eliminates oversize threading

1 Benefits Better surface quality on the flanks of the cut threads Longer tool life due to less friction Greater process security Due to the reduced risk of breaking the tap especially with small dimensions Very accurate depth control For a more precise production process Will never wear out Improved chip evacuation due to slim design Eliminates oversize threading problems 1 Automotive engine - AE_MoreInfoCoroChuck970 - Version 1.0

2 Benefits Holders are coordinated to the geometry of the tap for a complete threading solution Reduced torque allows the tap to cut more freely Benefits are maximised when used with high spiral and high relief taps Reduced thrust forces on tap flanks Better surface quality on the flanks of the cut threads Long tool life will give less tool change and therefore less downtime Ensures a precisely defined minimum compensation Allows the maximum performance of CNC machines to be fully exploited Leads to increased productivity 2 Automotive engine - AE_MoreInfoCoroChuck970 - Version 1.0

3 Machine interfaces Available with and without internal coolant supply Suitable for use on CNC machines with synchronised tapping cycles Coromant Capto HSK A/C DIN 1835 B/E MAS-BT Cylindrical 3 Automotive engine - AE_MoreInfoCoroChuck970 - Version 1.0

4 Programming Simply programme the machine according to the pitch of the tap, the recommended tapping speed for the specific tap and material of your work piece 4 Automotive engine - AE_MoreInfoCoroChuck970 - Version 1.0

Installing the tap Select the proper square drive ER collet for the taps shank and square Insert the groove of the collet into the eccentric ring of the clamping nut.

5 Installing the tap Select the proper square drive ER collet for the taps shank and square Insert the groove of the collet into the eccentric ring of the clamping nut. Push collet in the direction of the arrow until it clicks in. Screw nut with collet into the tool holder A torque wrench is to recommend when tightening the nut Mark on bottom Coolet groove Eccentric ring 5 Automotive engine - AE_MoreInfoCoroChuck970 - Version 1.0

6 Installing the tap Use two wrenches to tighten the collet nut firmly. It is not recommended to tighten by gripping the shank of the attachment Use caution not to over tighten the nut, as this can cause damage to the tap driver Recommended Nut tightening Torque Values for ER tapping Collet Nuts 6 Automotive engine - AE_MoreInfoCoroChuck970 - Version 1.0 All ER11 All ER20 All ER25 18 Nm/13 ft-lbs 40 Nm/29 ft-lbs 130 Nm/95 ft-lbs

7 Technical information Use a special collet with a square inside to fit the tap ER 20 ER 25 ER collet nuts for through-coolant 1. ER collet nuts for through-coolant 2. Wrench 3. Wrench 4. Counter wrench 7 Automotive engine - AE_MoreInfoCoroChuck970 - Version 1.0

8 Technical information SynchroFlex Plastic and rubber parts 8 Automotive engine - AE_MoreInfoCoroChuck970 - Version 1.0

9 Technical information Internal Coolant Balanced by means of Coolant tube Balanced High pressure coolant with approx. Three times higher coolant flow Sleeve with press fit New housing for improved Stability Previous design of SynchroFlex New Design for CoroChuck Automotive engine - AE_MoreInfoCoroChuck970 - Version 1.0

10 Technical information Micro axial compensation Axial compensation is limited to a very safe range Torque is transmitted through the drive rollers and pins Not the flexure 10 Automotive engine - AE_MoreInfoCoroChuck970 - Version 1.0

Technical information Balanced Coolant System High pressure coolant Now with almost 3 times higher flow rate CoroChuck 970 includes a Balanced Coolant System for maximum flow.

11 Technical information Balanced Coolant System High pressure coolant Now with almost 3 times higher flow rate CoroChuck 970 includes a Balanced Coolant System for maximum flow. With the new system our holder does not extend under pressure and there is no effect on the axial compensation For high pressure up to 80 Bar 11 Automotive engine - AE_MoreInfoCoroChuck970 - Version 1.0

12 Technical information When using SynchroFlex, the thrust forces on the tap flanks can be considerably reduced Weldon rigid Competitor SynchroFlex 42CrMo N/mm 2 Emulsion 5% Vertical machining 1.5 x D 12 Automotive engine - AE_MoreInfoCoroChuck970 - Version 1.0

Technical information Tool life 315 threads Tool steel 1.

13 Technical information Tool life 315 threads Tool steel Emulsion 5% / 12 m/min M6-12 mm deep 245 threads 175 threads 13 Automotive engine - AE_MoreInfoCoroChuck970 - Version 1.0 Weldon rigid Competitor SynchroFlex

Test tools specification CoroTap 200 test: - M8 CoroTap 200 held in CoroChuck 970 SynchroFlex - M8 CoroTap 200 held in ER

ER25 collet Description of test: Through holes were drilled in Material CMC 1.2312 35mm thick.

had been met. Material: CMC 1.2312 Machine tool: DMG Mori Seiki Mill Tap 700 Coolant: 40 bar external coolant vs.

14 Test tools specification CoroTap 200 test: - M8 CoroTap 200 held in CoroChuck 970 SynchroFlex - M8 CoroTap 200 held in ER collet chuck (ER25) Looking for: Tool life Tools Tap: Holders: EP03M8 970-B using ER20 collet A2B using ER25 collet Description of test: Through holes were drilled in Material CMC mm thick. 272 holes per billet, The tap was inspected and photographed after each billet to see any wear pattern or failure criteria had been met. Material: CMC Machine tool: DMG Mori Seiki Mill Tap 700 Coolant: 40 bar external coolant vs. Data for EP03M8 v c = 35m/min 2 tool holders were evaluated, and the results between them have been recorded. 14 Automotive engine - AE_MoreInfoCoroChuck970 - Version 1.0

Test result CoroTap 200 test: In the test CoroChuck 970 v ER25 proved that CoroChuck 970 SynchroFlex is the superior choice over ER collet chuck in a BT30 spindle for tapping application.

The CoroChuck 970 with the EP03M8 produced 1500 threads, with just a small wear and would have continued to produced more threads, but we had reached a conclusion at this point. Material: CMC 1.

15 Test result CoroTap 200 test: In the test CoroChuck 970 v ER25 proved that CoroChuck 970 SynchroFlex is the superior choice over ER collet chuck in a BT30 spindle for tapping application. Tool life for the EP03M8 in the ER collet chuck holder was only 500 threads before chipping The test was continued but the tap was breaking after just a few threads more. The CoroChuck 970 with the EP03M8 produced 1500 threads, with just a small wear and would have continued to produced more threads, but we had reached a conclusion at this point. Material: CMC Machine tool: DMG Mori Seiki Mill Tap 700 Coolant: 40 bar external coolant CoroChuck 970 after 1350 holes: CoroChuck ER collet chuck +270% INCREASE IN T OOL LIFE ER collet chuck after 500 holes: 15 Automotive engine - AE_MoreInfoCoroChuck970 - Version 1.0

16 Tapping problems Floating tap holder Spindle power: 3,3 Kw Torque: 126 Nm Depth = 95 mm (3.740 inch) SynchroFlex holder Spindle power: 1,1 Kw Torque: 42 Nm Depth = 85 mm (3.346 inch) 16 Automotive engine - AE_MoreInfoCoroChuck970 - Version 1.0

17 Technical information The higher the thrust forces, the more wear on the tap. Tests show SynchroFlex exerts the lowest thrust forces Torque measurements are also reduced, indicating that the tap is cutting more freely Torque test : 10 Holes, M6 R45-AL, 2 Flute Tap (3xD), AL7075 at 2000 RPM Holder type Average mean torque (Nm) Average downcut torque (Nm) Average reverse torque (Nm) Ateel collet holder (rigid) Competitor Competitor SunchroFlex Automotive engine - AE_MoreInfoCoroChuck970 - Version 1.0

18 MQL, Minimum Quantity Lubrication An environmentally friendly alternative to recirculating coolant Insures a direct passage of air and lubricant to the tap Precise lubrication delivery for improved tap life Reduced coolant and maintenance costs Adjusting screws for taps with internal or external center For one channel or multi-channel systems Note! Can be ordered as special. Contact PM For more information. ADJUSTING SCREW 18 Automotive engine - AE_MoreInfoCoroChuck970 - Version 1.0

19 Customer case Customer from Oklahoma, USA Application: Workpiece material: Tap size: Tap style: Tap material: Hole depth: Speed: Coolant: Tap driver: Machine: Problem: Rigid tapping CF8M Spiral 3 fluted, modified bottoming, GH-3 HSS rpm Master chemical E206 Tap collet (rigid tapping) Mazak VTC 16-B Short tap life Solution: Installed CoroChuck 970 Result: Tap life increased from 72 to 216 holes per tap. Tap costs reduced from $77 to $25 per day and production increased from not changing taps so often. CC970 paid for itself in 7 days in tap cost savings alone +200% INCREASE IN TAP L IFE 19 Automotive engine - AE_MoreInfoCoroChuck970 - Version 1.0

20 Customer case Customer from Krummenau, Switzerland Application: Workpiece material: Tap size: Tap style: Tap material: Hole depth: Speed: Coolant: Tap driver: Machine: Problem: Solution: Installed CoroChuck 970 Result: Rigid tapping 42CrMo4 V Heat treated to 650 N7mm 2 M8x1 metric fine thread Through hole DIN 376 HSS-PM powder metal vaporized, ESO 10 mm 500 rpm Aral oil emulsion 6% Conventional collet chuck (rigid tap driver) LINEA horizontal machining centre with 11 pallets and Fanuc 16M control. Parts loaded on pallets by ABB robot Excessive tap wear and breakage after only 1000 holes resulting in downtime during unmanned shifts Tap life increased from 1000 to between 2400 and 2900 holes per tap. Greater security that all holes are tapped during an unmanned shift +200% INCREASE IN TAP L IFE 20 Automotive engine - AE_MoreInfoCoroChuck970 - Version 1.0

21 Customer case Customer from Washington, USA Application: Workpiece material: Tap sizes: Tap styles: Tap material: Hole depth: Speed: Coolant: Tap driver: Machine: Problem: Solution: Result: Rigid tapping Titanium 6AL4V, Hardness psi Tensile 8-32 and /4-28 Spiral, cutting Spiral, TiN, Coolant Thru HSS HSS, TiN Coated /695 rpm 685 rpm Manually applied specialty cutting fluid Conventional collet chuck (rigid tap driver) Mori Seiki SC500 B, vertical machining centre Short, inconsistent tap life and tap breakage. Manually applied specialty cutting fluid expensive and slowed production Installed CoroChuck 970 Tap life increased up to 200%. Eliminated inconvenience of specialty cutting fluid +200% INCREASE IN TAP L IFE 21 Automotive engine - AE_MoreInfoCoroChuck970 - Version 1.0

22 Tapping depth control What kind of tapping depth control should I expect? Depth control is consistently very accurate, just as with a normal solid holder. Because the amount of compensation needed is very small, we designed our flexures to have very high Force vs. Deflection Rates. Before the development of synchronized tapping, machines used cycles for tapping that were not synchronized. This required tap holders with soft springs and a large amount of axial compensation. 22 Automotive engine - AE_MoreInfoCoroChuck970 - Version 1.0

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