Design and Manufacturing

Transcription

1 custom workholding

2 Design and Manufacturing It s a competitive world out there. To profit in the material-cutting business you have to explore all the possibilities. You have to process the part with less setup time, at a lower cost and a better quality than your competitor. Let Hardinge help you maximize your workholding productivity show you the options. You can t always get by with an off-the-shelf collet or workholding device. As a matter of fact, sometimes custom-made could save you money as well as setup and cycle times. Collets, Expanding Collets, Feed Fingers, Step Chucks, Special Accuracies, Special Shapes and Fixturing are some of the common specials made daily at Hardinge. We specialize in solutions for extruded stock, non-round parts, eccentric, offcenter and stepped parts. Over 50% of Special inquiries can be quoted instantly over the phone without being passed on to an Engineer many times your Special Requirement or a similar request has been previously manufactured here at Hardinge! ID Pickoff Collet Assembly designed for Euroturn 6/32 fits in standard OD Pickoff Attachment Table of Contents Design and Manufacturing...2 Sample Specials...3 What is a Special Collet...4 Styles of Special Collets...5 Application Specific...6 Fixturing for Mills...6 Special Materials...7 Saving You Money...8 Requesting a Quote Hardinge will work closely with you to solve your individual needs while working within your parameters. Our Design and Applications Engineers have over a century of combined experience. Top-of-theline machine tools and dedicated, highly-skilled machinists can help expand your capabilities. Wire and Ram (EDM) electrical discharge machines allow custom collet shapes and stepped-holes. Precision grinding machines, milling machines and CNC lathes are maintained in top form for fast, dependable throughput. Specials are manufactured to rigid specifications, including material, proper heat treat and machined accuracy. For generations, Hardinge specials have been the choice of experienced machinists, manufacturing engineers and productivity-oriented manufacturers. Hardinge will work with you for the fastest possible delivery time to meet your deadline. Quite often a stock item can be altered to meet your requirements. 2

3 Sample Manufactured Specials Collets, Expanding Collets, Step Chucks, Fixturing Devices and more Expanding Collet Optical Lens Collet custom manufactured for your special application. Hydraulic Fixture Glass Rod Collet Expanding Collet Gear Hobbing Collet High Production Rotary Transfer Collet Capsule Collet Double Head Collet Extended Dead-Length Collet 16C Hydraulic Fixturing with ID Grip AG20 Pickoff Collet Swiss Pickoff Sure-Grip Expanding Collet 3

4 What is a Special Collet? A standard collet is one whose order hole (round, round serrated, hex or square) is on the center line of the collet with a TIR within the manufacturer s specifications for that collet style. A Special Collet deviates from a standard collet. It s TIR may be extremely close at.0002". The order hole may have one step to act as a stop, or multi-stepped allowing the part to be end-for-ended after completing the first operation. The order hole may be eccentric (not on the centerline of the collet) or it may be a special shape. Below are many common special collets that Hardinge manufactures. ORDER HOLES Angular Slotted and Zig-Zag Holds hex, square or triangular parts on their corners rather than on the flats. Corners will fall into the slots of a standard collet. Zig-zag are used for stock under 1/4". Bearing Relief A relief groove is placed in the center of the bearing length to increase the gripping force in that area. Customized for the Application Collets or workholding devices can be completely designed from scratch to accommodate assembly work, high-speed production machines and specialty machines. Dead-Length Pinned Step Chucks and Closers Holes are drilled in the step chuck, aligned with the gage point of the workpiece. Pins are located in the closer to go through the holes in the step chuck. The pins are lightly faced to make them perpendicular to the center line of the spindle. In operation the part is located against the pins and the step chuck is closed. The part will not move even when there is a variation in the chucking diameter. SERRATIONS Double-Head Provides extra gripping on the bar stock. May be reversed when one side wears out. Expanding Collets Internal Gripping Many similar specials are available for expanding collets such as serrated, eccentric, stepped, and spring ejectors. Extended Nose Straight or Tapered Extended nose collets are sometimes required when there is a tool or slide interference situation on the machine tool. Extended Nose Collets Pinned This extended nose collet has a pin in each slot to restrict the collapse of the collet under the head angle eliminating collet breakage. Because the collet no longer collapses, there is more substantial grip on the part. Extra, Extra, Extra Extended Step Chucks and Closers Parts that have shanks bigger than the thru capacity can be held in these special step chucks and closer assemblies. The Z-Axis work stroke of the machine tool is reduced. Extruded Variations include thru-collet, step collet, and off-center. 4

5 Styles of Special Collets Flat Face The flat face is a locating surface for the workpiece. The flat face should never be behind the face of the spindle when the collet is closed on the part or a step will be worn in the spindle angle of the machine tool. Off-Center, Eccentric Off-Center, Eccentric collets can be round, hex, square, rectangular, or extruded. Oversize Step Chucks and Closers An oversize step chuck can be used when the standard step chuck is too small to hold your workpiece. Tooling interferences should be thoroughly checked before ordering. Over-The-Shoulder When you have to clear a shoulder and grip on a smaller diameter, an over-the-shoulder collet may be used. These collets are usually standard as pick-off collets on automatic screw machines. This style collet can also be used on CNC lathes that have a long draw bar stroke. These collets are multi-slotted and double angled. The closing angle is very short and the opening angle is very steep. The collet requires an extremely large spread and is only practical for light machining operations such as face, chamfer, etc. Round Off-The-Spindle Fixturing Several fixtures are made with round chucking surfaces. The chucking diameter of the fixtures are held within.0002" of each other. The bore of the step chuck is made to the same diameter as the chucking diameter of the round fixtures. While one part is running in the machine, another fixture can be loaded to reduce setup time. The critical lengths are controlled because the chucking diameters of the round fixtures are held to within a couple ten thousandths. Holding lengths to.001" are the accepted norm. If closer length tolerances are required, pins can be used in the step chuck and closer assembly. Custom Serrations Serrations add 10% additional gripping power using the same draw bar pressure popular round serrated collet sizes are standard. They can help prevent push-back and radial slipping during heavy forming or drilling. Serrations can be made in circular, buttress, diamond, tap and tapered flat (for draft angles). Special Shape Special shape collets are used for precision cast parts and molded products. Many of these collets are made using the EDM process. Contour milling may also be done using a CNC VMC mill or a precision jig boring / grinding machine. Part size is only limited to the machine tool s capabilities. Stepped, Single & Multi-Stepped This style collet locates the part a specific distance from the face of the collet. It eliminates push back of the stock but does not control lengths due to stock diameter variations. A single-stepped may have a thru-hole to grip on the shank of a part during the first operation or it may be a clearance hole for a drill or boring tool. Multi-stepped are used when end-for-ending the workpiece. Synchronized Collets A synchronized collet is used when a point on the part has to align with the center of the keyway of the collet. Hex and square collets are synchronized to the center of the flat or the corner. Some standard collets for specific machines are already synchronized. Tapered Taper styles include regular Morse, Jacobs and custom tapers, as well as reverse taper. Threaded Threaded collets can be ordered in solid, 3-split and 4-split. STYLES See pages 9-11 to assist you in obtaining a quote for your required workholding device. 5

6 Application Specific Rely on Hardinge for a durable workholding solution for your specialty or high production machine. No job is too complex or unusual! Our team of experts can provide an accurate and reliable solution while minimizing your setup and handling without compromising the integrity of your machine. You ll experience less breakage and wear with Hardinge workholding products and that means more uptime on your machine! Capsule Collet (top) Ballpoint Pen Tip Collet (center) Packer-Matic Polishing Collet (bottom) Specialty & High Production Machines Hold pins and electronic components inserted on boards Hold pill capsules for assembly Hold pipes for bending into tail pipes and bumpers Fasten tops on perfume bottles Crimping with expanding collets Hold engine valves for grinding Expand plastic tubing Hold long delicate glass tubes Second Operations A multi-spindle automatic can be set up for secondary operations using special Dead- Length collets, or expanding collets. A standard CNC 3-Jaw chuck-style lathe can be equipped with a spindle adapter for draw collets or stationary collets. Increase your milling productivity with fixturing for single or multiple part setups. Hardinge can provide OD and ID gripping solutions in hydraulic or pneumatic fixturing. Custom-designed toolholders can pick and place parts for automated machining. Spindle draw bar linkups Hardinge manufactures draw bar linkups for mounting chucks, expanding collets and collet chucks. Request form B-91 to provide the necessary measurements. A Hardinge-designed toolholder picks the part and moves it to and from the special fixture on this vertical machining center for automated machining. LOAD & RUN IT Hardinge makes special Hydromat Collets for us that are unique to the industry. I m simply amazed with the quick turnaround and delivery they re able to provide into Canada. Charlie Ruecker Advance Precision 6

7 Special Materials Quite often it is necessary to hold a soft or brittle workpiece, a part that cannot be marked or scratched, or a thin-walled part. Hardinge can provide a gripping solution for all types of workpiece materials. Special Collets are available to hold glass rods, optical lenses, pill capsules, plastics and wood. Hardinge has experience with all types of materials including brass and aluminum extrusions, castings and die castings. Different collet materials to accommodate non-typical workpiece materials Carburized and hardened steel results in the hardest (62-64 RC), longest wearing collet. Most Hardinge collets are made of this material. Hardinge has been perfecting this process for over a hundred years. Other manufacturers use thru-hardened tool steel, resulting in a softer collet with high wear potential. Thru-hardened tool steel is usually hardened to 55 RC. These collets are typically used where wear is not critical, such as expanding collets. Bronze and brass collets are made to hold polished rod and parts where scratches cannot be tolerated. Bronze and brass inserts or pads can be used in hardened and ground collets when collet spring and spread is critical. Carbide provides the highest wear resistance. Collets can be impregnated with carbide or a carbide insert can be brazed into the collet and then ground to size. Iron is used for some feed finger pads to reduce marking. Delrin and Nylon are used to hold delicate parts. Inserts or pads of either of these materials can be used in hardened and ground collets when collet spring and spread is critical. Rubber inserts provide cushion for glass rods. Expanding Collet with impregnated Carbide surfaces for increased gripping power. Master pads made from Nylatron to eliminate marking the workpiece. 7

8 Saving You Money Economical pick-off Collet Assembly designed for low-cost alternative for Euroturn 6/32 Standard Pickoff Attachment shown left with Hardinge ID Pick-off Collet Assembly (right). Hardinge Machine COMPARE: Collet ID Attachment Assembly & Kit Cost $2,995 $43,650 Setup 15 minutes 8 hours Length Control* *finished part length Manth-Brownell Saves $40,655 Increases Productivity and Improves Accuracy Hardinge designed an ID Pickoff Collet Assembly as an alternative to purchasing the machine tool builder s ID Pickoff Attachment and Kit. This allows the customer to change just the collet rather than the entire attachment, saving hours of setup time. The ID Pick-off Collet Assembly with built-in part ejector is available for Euroturn, Gildemeister and Tornos Deco s standard OD pick-off attachments and is application specific. Wes Skinner, President (right) of Manth-Brownell (Kirkville, NY), Cal Macomber, Director Sales & Marketing, (left) Hardinge Workholding Manufacturing Specifications Concentricity When you purchase a Hardinge Special Collet with a defined concentricity, you can be assured of a qualified inspection. Each collet is inspected in a fixture that rotates in a set of precision bearings. The fixture itself is a mirror image of your spindle. This assures each collet will hold your parts consistently during your machining operations. Concentricity is measured in terms of Total Indicator Runout (TIR) a set distance from the face of the collet. In-House Heat Treat and Spring Temper One of the keys to manufacturing collets, feed fingers and pads that are long lasting and provide the performance you expect is the raw material used and the heat treat process control system to guarantee proper hardness and tempering. Collets and feed fingers are prone to breakage where the hardened area meets the tempered area on the product. Hardinge heat treat processes are planned to eliminate breakage on critical design areas to provide a long lasting product that is not subject to breakage and wear. Hardinge collets are 5 to 7 points of Rockwell C harder than competitive products. Hardinge is our sole supplier for special accuracy collets. They deliver the precision and quality we demand. Lori Pollock TRW Fuji Valve Inc. Hardinge provides the proper combination of hardness and tempering for longer wear. This exaggerated case shows extreme flexibility without breakage! 8

9 Custom Quote Request 1 of 3 To place your order or Request a Quote simply fill out this form and send the requested information below. All of this information is necessary for us to process your order quickly. Checking the box in front of each item will help to ensure everything is complete before sending the information to us. The following two pages will assist you in choosing your collet configuration. Your Name Company Address City, State & Zip Phone Fax Machine Make and Model Number on which workholding will be used: (Example: Hardinge Quest 8/51, 1-1/4" Acme) Collet Required: (Example: 5C, 16C, 1-1/4" Acme, etc.) Spindle Nose: (Example: A2-5, A2-8, etc.) Sample Stock (6" long - extruded stock), casting, first operation part, finished part Legible Prints of the stock, finished part. These must be marked to show the diameters or surfaces to be gripped. Mark the locating surface used for length control. Please mark the surfaces to be machined. AutoCad Files or dxf files of the above, if available. Written Explanation of any special requirements: For example special concentricity or perpendicularity requirements, concerns with chip flushing, requirements for thru-spindle coolant, customer concerns with part being deformed by gripping, large variation of gripping surface or locating dimensions, etc. Explanation: This page may be duplicated 9

10 Custom Quote Request 2 of 3 Fill in the Type of Collet or Special (example 16C) Find the illustration of the feature needed in one of the boxes Put a Bold X in the box to indicate that feature Write the required dimensions next to their numbers in the chart to the right Note: Only fill in the dimensions for the numbers on one illustration Today s Date Date Order Required Customer Number Purchase Order Number Method of Shipping Bill To: Name Title/Dept. Company Address City, State, Zip Phone Fax Ship To: (If different from Bill To) Name Title/Dept. Company Address City, State, Zip Phone Fax Hexagon Eccentric to Corner Hexagon Eccentric to Flats Rectangular Rectangular Eccentric - Short Side Eccentric - Long Side Square Eccentric to Flats Octagon Eccentric to Flat Square Eccentric to Corner Octagon Eccentric to Corner Type of Collet or Special: (5C, 16C, 1-1/4" Acme, etc.) Numbers below correspond to dimensions in boxes 1 Order Hole Size: 2 Order Hole, 2nd: 3 Number of Slots: 4 Radius: 5 Bearing Length: 6 Bearing Length Front: 7 Back Drill Dia.: 8 Relief Dia.: 9 Relief Length: 10 Depth of Step, 1st: 11 Depth of Step, 2nd.: 12 Auxiliary Hole Size: 13 Length of Extension: 14 Dia. at Face: 15 Degrees Taper/Chamfer: 16 Front Dimension of Taper: 17 Rear Dimension of Taper: 18 Taper-Industrial Std: 19 Off Center Distance: 20 Order Hole - Width: 21 Order Hole - Length: 22 Thread Length: 23 Threads Per Inch: 24 Right/Left Hand Thrd.: 25 Class Thread (1), (2), (3): 26 Chamfer Depth: 27 Inscribed Circle: 28 Circumscribed Circle: 29 Clearance Bore: 30 Actuator Stroke: Send Drawings, Sample Parts and this form to: Round Eccentric Triangular Special Extruded Shape Drawing & Sample Stock Required An extrusion drawing must indicate the centerline of the shape in relationship to the centerline of the collet. Sample stock required.* If not available, manufacturing authorization is required prior to entry of order. If approved, item(s) will be manufactured with customer assuming full responsibility. The confirming order. Hardinge Inc. Collet Sales Dept. One Hardinge Drive Elmira, New York Phone: Fax: info@hardinge.com Canada: Other countries: International Fax: This page may be duplicated *One 6" length of stock required when ordering 1 to 3 collets; two 6" lengths for 4 to 7 collets; three 6" lengths for 8 to 11 collets; four 6" lengths for 12 to 15 collets ordered. Return Material Authorization (RMA#) required for Hardinge to receive your Sample Part

11 1. Check mark the box with the feature you require. 2. Record the dimensions on the corresponding lines 1-30 on the previous page. Custom Quote Request 3 of 3 Over-the Shoulder Flat Face Bearing Relief Chamfer - Depth Chamfer - Diameter Radius Special Bearing Length Eccentric Step - Aux. Off Center Eccentric Step - Aux. On Center Single-Stepped Double-Stepped Threaded Order Hole Extended Nose - Straight Extended Nose - Tapered Angular Slotted Taper - Regular Taper - Reverse Zig-Zag Slots This page may be duplicated 11

12 Hardinge Product brochures 7.5MHI 0803 Printed in USA Sure-Grip Expanding Collet Systems: Brochure #2270 Sure-Grip 3-Jaw Power Chucks: Brochure #2357 Collets for Automatics: Brochure #2287 A2-5 16C Pneumatic Collet Block: Brochure #2365 HQC Quick-Change Collet Systems: Brochure #2339 Spindle Tooling for Manual & CNC Lathes: Brochure #2348 Precision Tool Holding Systems for Mills: Brochure #2350 Toolholder Collets, Toolholder Bushings & Round Shank Holders: Brochure #2351 HCAC Collet Adaptation Chucks: Brochure #2352 Swiss-Type Collets, Guide Bushings and Bar Loader Collets: Brochure #2283 Worldwide Manufacturer of Machine Tools and Workholding/Industrial Products Machine Tool Products Overview: Brochure #1325 Sure-Grip Chuck Jaws for All Brands of Chucks: Brochure #2358 Hardinge Inc. One Hardinge Drive P.O. Box 1507 Elmira, New York USA To order in USA: To order in Canada: All other calls: Fax: Internet: (order online) Brochure #2349 Part No. HA August 2003 All specifications subject to change without notice. All marks indicated by or are trademarks of Hardinge Inc. All other marks are trademarks of their respective company. Litho in USA Hardinge Inc. 2003