FEATURE ON WORKHOLDING

Quick-change system for static turning tools

A system for exchanging static turning tools quickly and easily in the turret of a fixed-head turning centre has been introduced by German manufacturer EWS Weigele, whose products are sold in Britain exclusively by GEWEFA UK. The new Varia.VXT quick-change system joins the Varia.VX range introduced a few years ago for the rapid exchange of driven tools in lathes. Existing users of the latter tool holders can utilise a special VXT interchangeable insert to allow the cost-effective incorporation of fast static tool changes into the same turn-mill centres and multi-tasking lathes.

Designed specifically for repeatability, precision and stability during turning operations, the VXT mechanism is particularly compact, enabling machining to take place very close to the turret and subsequently allowing extra flexibility when programming cutting cycles. The holder also exhibits high rigidity, which is important when cutting with the component rotating to prevent deflection of the tool tip and discourage chatter.

At the heart of the tool-holding innovation is a double-cone flex system with widely spaced support points. Elasticity designed into the second cone in the rear part of the adapter, combined with additional clamping screws in the shank area, gives the system its damping properties, minimising vibration and maximising tool life. The dual face and taper fit of the tool holder in the EWS interface, which is mounted in the turret, ensures not only high torque transmission but also precise orientation of the tool tip.

Repeatability of tool positioning is ±2 µm and transmissible torque is up to 160 Nm with the VXT3 interface, or 200 Nm with the larger VXT4, although these figures are likely to be revised upwards following ongoing tests. Maximum through-tool coolant pressure is 80 bar.

More information www.gewefa.co.uk

Work-holding specialist trials new cutting fluid

Industrial lubricants manufacturer Rocol has launched a new metalworking cutting fluid to help customers improve efficiency and cut costs. Tests show that TRI-Logic ATi eliminates all previous rework and scrap incurred due to corrosion and staining on complex components when cutting sensitive aluminium grades, even after 100 hours of continuous machining.

The removal of staining can save machine shops expensive man hours from having to rework parts or maybe even generate scrap or miss delivery deadlines. Furthermore, the optimised chemistry of Tri-Logic ATi now means that end users can cut aluminium, titanium and stainless steel from a single sump. The new cutting fluid achieves this without using traditional boron, chlorine and secondary amine chemistries, and is completely free from petroleum oils.

Field trials at work-holding manufacturer Brown and Holmes have delivered outstanding results, with positive feedback versus traditional metalworking fluids. 

Jamie Barton, product sales manager at Brown and Holmes, says: “We’ve been working with Rocol as a supplier for nine years and we continue to be impressed by their service and products. They beat our previous supplier on costs, service and sustainability, with the team available on demand for any issues.

“We’ve been trialling the ATi product in our new filtration system and the early results are superb,” he continues. “There’s been brilliant tramp oil separation, while the process has been a lot more efficient and the cleanliness of the coolant filtrating through the machine is also really positive. We’re machining a multitude of materials, including aluminium, titanium alloys, steel and stainless steel, and the product has performed well on all of them.”

More information www.rocol.com

Nikken helps unlock efficiency and precision

Last month, Nikken had the pleasure of welcoming representatives from Techpoint and DOF Tools to its European innovation centre in Rotherham for an exclusive hands-on experience with the company’s latest solutions for machine shops. Joined by Nikken’s export sales manager Iwao Miyahara, the visit provided an excellent opportunity to strengthen working relationships while showcasing the precision, reliability and performance of Nikken technology.

Throughout the day, guests witnessed live machining demonstrations, highlighting key areas of generating higher performance in processes like milling and drilling. Nikken says the demonstrations showcased how its solutions enhance productivity, improve tool life and deliver precision across a range of machining applications. Discussions with the Techpoint and DOF Tools teams provided valuable insight, reinforcing the importance of collaboration in driving engineering excellence.

To document the visit, Nikken put its new camera equipment to the test, recording the demonstrations in detail. From rapid tool changes to precision cutting, every moment was captured to showcase Nikken’s capabilities. The footage has now been edited into a video, giving a closer look at these technologies and techniques.

While the video provides a glimpse into what Nikken offers, nothing compares with seeing it first-hand. The company is therefore inviting manufacturers visit the Nikken Innovation Centre Europe (NICe), where they can experience these solutions in action, explore new machining strategies and work alongside the company’s expert team to enhance their production processes.

More information www.nikken-world.co.uk

New hydraulic chucks for precision applications

Kyocera Unimerco is introducing two new hydraulic chucks: the Hydro Chuck Uni and Hydro Chuck HD. The chucks are for precision drilling, milling, threading and other machining operations.

Hydraulic chucks use a hydraulic mechanism to clamp tools. Pressurised oil ensures the tool is held firmly in place while simultaneously minimising disruptive vibration, enabling stable and precise operation.

According to Kyocera Unimerco, the new Hydro Chuck Uni offers an excellent price-performance ratio, providing high precision across a wide range of machining tasks. It is a versatile chuck that ensures high machining quality and long tool life, reports the company.

Capable of withstanding high torque, the Hydro Chuck HD (Heavy Duty) is specifically engineered for high-performance cutting applications. Compared with standard solutions, the Hydro Chuck HD offers up to three times longer tool life, improving efficiency and productivity in demanding environments.

Both chucks are suitable for tools with various shank types and diameters ranging from 6 to 32 mm, without the need for special sleeves or adapters. They also enable tool changes in just a few seconds using a standard Allen key, eliminating the need for special tools like torque wrenches. During operation, the hydraulic mechanism provides vibration damping for a runout accuracy of less than 0.003 mm. A special screw allows for easy axial length adjustment.

The two chucks offer a balance grade of G2.5 at 25,000 rpm/Umax < 1 gmm, while the tool shanks meet h6 quality standards.

More information www.kyocera-unimerco.com

ITC simplifies advanced micro-machining

Now available in the UK from Industrial Tooling Corporation (ITC) is the new Big Kaiser HSK-EZ15 Mega micro chuck. This latest Mega micro chuck collet version is specifically for applications involving smaller workpieces, such as watch components and other micro-parts.

Big Kaiser designed the HSK-EZ15 Mega micro chuck according to the HSK-EZ15 norm, a new interface used by the latest machine tools that replaces the previous ATC-E15 norm. The company says its HSK-EZ15 is compact and precise, enabling the miniaturisation of machine spindles. It also meets the micro-technology market’s precision, performance and reliability demands.

The new collet is available in three variations with 10, 12, and 14 mm outer diameters. Each is suited to high-speed machining with shaft diameters from 0.45 to 6.05 mm, maintaining a run-out accuracy of under 3 µm at 4xD. These collet holders can operate at speeds up to 80,000 rpm.

Big Kaiser’s Mega micro chuck provides high positional accuracy and repeatability. It features a slim body and nut, while its rigidity supports high-speed machining and reduced interference. The HSK-EZ15 has a notch-free nut for high-speed applications that prevents vibration and, in turn, offers superior balance and concentricity. Big Kaiser’s nut design also eliminates whistling noise and coolant splattering.

Giampaolo Roccatello, chief sales and marketing officer for Europe at Big Kaiser, says: “The HSK-EZ15 is an innovative way of integrating functions into small spindles that were previously only possible with much larger spindles, such as presetting outside the machine to save time and increase productivity. Big Kaiser was the first company to believe in this project and to develop an industrial tool holder that would allow these machines to be sold in series.”

More information www.itc-ltd.co.uk