Product category:
Toolholders
News Release from: Zoller | Subject: Shrinking, presetting, measuring and cooling tools
Edited by the Manufacturingtalk Editorial
Team on 29 August 2003
Tool shrinking for HSM need not be
compromised
Making compromises when shrinking tools to nominal dimension is no longer necessary as developments in tool presetting and measuring technology now satisfies all needs in high speed machining.
Making compromises when shrinking tools to nominal dimension is no longer necessary Zoller 's latest innovative developments in the field of tool presetting and measuring technology satisfies all requirements in high speed machining
This article was originally published on Manufacturingtalk on 27 Oct 2003 at 8.00am (UK)
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Shrinking and presetting to nominal length - the use of inductive heating to clamp tools by means of shrink fitting for high speed machining is the current state of the art, but there is a problem.
It lies not only in the presetting of the tools to nominal dimension but also the shrink-clamping of a series of identical tools to the same length for use in multiple spindle machines.
There is a definite demand for a system that can perform the functions of shrink-clamping, adjustment, measurement and cool off the tools.
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The test and measurement specialist Zoller Germany introduced two systems that perform shrinking, presetting, measuring and cooling of tools.
The 'Redomatic' system is a combination of the Zoller presetting and measuring machine 'Venturion', the Zoller vision system 'Saturn' a sophisticated spindle system and the automatic tool length presetter 'ASZA' as well as a heat-shrink and water cooling system.
Heat-shrinking that protects the toolholder - this is made possible by an heating system that protects the toolholder and prevents heat transfer to the shaft of the shrinking chuck and as such into the spindle of the measuring machine.
There is no need for insulated adapters or a change in between shrinking and measuring processes.
This reduces the number of steps and improves accuracy.
The cleverly devised system that uses software and automatic length adjustment eliminates the presetting process during the shrinking process (heating period).
The tool is automatically measured before, then the length adjustment system is positioned and the operator places the tool in the shrinking chuck.
The tool is seated automatically to its nominal position, cooled and measured.
The resulting accuracy, the minimal heat energy input and the ease of operation are benefits that set new standards in high-speed machining.
For fully automatic operation Zoller offers the 'Redomatic-auto' system.
Based on the established 'Redomatic', the 'Redomatic-auto' system features in addition a tool magazine, handling system and 11 automatic axes.
This approach enables shrinking, presetting, measuring and cooling fully automatically without interference of an operator.
The magazine is simply stocked with shrinking chucks and tools and set into operation.
16 Tools are shrunk and preset in 30 minutes - it takes only 30 minutes to shrink, preset and cool-off 16 tools.
In one eight-hour shift this comes to about 250 tools.
Besides the two systems' exceptional software and mechanic, the shrinking and cooling technology also set new industry standards.
The induction heating system is designed so that it can handle all shrinking chucks that are conform to standard, independent from the manufacturer.
In addition, the 'Redomatic' evenly distributes heat over the entire shrinking surface.
This conserves energy, protects the clamping chuck and eliminates the notorious "banana effect." Conventional induction systems supply the heat centrally and therefore over a shorter length, which reduces the overall clamping force.
This approach also requires more time and heat to expand the shrinking chuck so that it can accept the tool holder.
Evenly distributed heat for longer life - ith uneven and excessive heat input comes the danger of affecting the microstructure of the shrinking chuck.
When this occurs, the tool can neither be placed into the shrinking chuck nor removed from it.
One way to get around this problem is to increase, by about 16 micron, the bore of the shrinking chuck.
This compromise, on the other hand, reduces the clamping force.
In addition, it increases the risk that the tool will be yanked out of the shrinking chuck during an actual machining operation.
Shrinking chucks conforming to DIN 69882-8 can tolerate torque levels up to four times greater.
The 'Redomatic' is designed to conduct heat rapidly to those areas where it is needed.
The result is maximum clamping force achieved at a maximum temperature of 250 degC (482 degF).
Cooling time in the shrinking process is also important.
Indirect cooling adapters that use intermediate pieces greatly reduce heat dissipation and therefore lengthen the cooling off period for up to three minutes.
The 'Redomatic' system cools the toolholder shaft directly by using a securely fitting cooling adapter with circulating cooling water.
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