Innovative Tooling Puts Security into Tough Machining N · PDF filestory, according to Rose: ... of the patented TER ThermoGrip ER shrink collet by Bilz is intended to revolutionize

November 2014 | ManufacturingEngineeringMedia.com 57

Nobody likes the thought of cuts or smashed

fingers tooling up a job—before the ma-

chine is up and running, or tool and spin-

dle-damaging crashes afterwards. “Getting

the tooling right is the most important part

of running any job,” said Steve Rose, CNC

training consultant and former Swiss machine shop owner.

“It’s amazing how different shops can be in how much time

they allocate for tooling up. If done correctly, the process

saves time and is worth the effort it takes to find the right

round tool or insert, put it in the toolholder, set it (measure it)

correctly, get the dimensions right, and then choose the right

machining speeds and feeds.” But that’s the beginning of the

story, according to Rose: “The real challenge is how to short

circuit the process, reducing the time needed to tool up and

Varia VX Quick Change System allows the machinist to replace

cutting tools effortlessly, leaving the tool in the machine without

risk to hands. A release mechanism ejects the insert without

excessive force and makes single-handed operation possible,

minimizing risk of injury.

Innovative Tooling Puts Security into Tough MachiningStandards and special tooling vie to deliver high-precision performance

Jim LorinczSenior Editor

Toolholding

Photo courtesy Command Tooling Systems

guaranteeing quality machining results.” It isn’t just coming

up with a new VDI toolholder, but it sure helps when tooling

suppliers are developing innovative product approaches to

deal with some of the industry’s real challenges today. They

include guarding against pullout with quick-change tooling,

especially in machining the toughest titaniums and high-

temperature alloys, building rigidity into modular tooling, and

maximizing use of the available machine envelope,

Delivering Cutting Tool Accuracy and Superior TIR

Bilz Tool Co. Inc. (Lombard, IL) offers a full slate of new

products that are aimed at delivering quality, accuracy, and

superior TIR for challenging machining applications. “Our prin-

cipal focus is on the centerline of the toolholder for improved

cutting tool accuracy, cutting tool rigidity in medium to heavy

radial loads, and increasing metal removal rates while increas-

ing tool life,” said Tim Fara, managing director. “Development

of the patented TER ThermoGrip ER shrink collet by Bilz is

intended to revolutionize the use of collets and collet chucks in

the production process,” said Fara. “TER ThermoGrip col-

lets have solid bodies, unlike common slotted ER-style collets

and aren’t deformed or compressed when clamping, assuring

runout of less than 3 µm and significantly improving cutting tool

performance when machining tough materials like titanium.”

Tool change in Swiss-style machines and live tools when

holding a cutting tool in a flexible collet can be very time-

consuming. Downtime can be extensive and costly due to the

tight tool locations in most Swiss-style machining centers and

the need to disassemble and reassemble cutting tool, collet,

and collet nut on live tools. Bilz’s TER ThermoGrip shrink-fit

collet can be used for all ER live tools and ER straight shank

holders in Swiss machines. During the shrink-fit process the

cutting tool can be preset to required tool length in the collet.

All this happens outside of the machine, while the machine

continues to make parts. A tool change only takes seconds

and the machine is back up and running with single assem-

bly tools back in the machine in the same tool location, gage

length, and no concern that tool point location has moved or

over torqueing of the collet nut.

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58 ManufacturingEngineeringMedia.com | November 2014

Toolholding

Bilz Tool’s TER ThermoGrip shrink-fit collet can be used

for all ER live tools and ER straight shank holders in

Swiss machines.

Photo co

urtesy

Haimer,

Kennam

etal

For ultra-high-precision milling for small-to-medium volume

manufacturing, Bilz offers the Diebold UltraGrip milling chuck,

which combines the best possible cutting tool run-out (TIR)

with maximum clamping force. The UltraGrip system provides

a concentricity tolerance of ≤ 3 µm and the assembled

system of toolholder and cutting tool provides a

maximum TIR of ≤ 3 µm for high-performance

cutting for medical, aerospace, and die/mold

applications. Holders are all balanced with

G 2.5 accuracy and are available in CAT,

BT, and HSK tool tapers.

To improve the ability to

bear radial forces and TIR

accuracy not available with

other systems, Bilz has

introduced the Diebold

CentroGrip collet chuck.

It provides concentricity

tolerance of ≤1 µm and the assembled system, including

toolholder, collet, and cutting tool, provides a maximum TIR

of ≤ 3 µm for medical, aerospace, and die/mold industry

applications. CemtrpGrip toolholders are balanced

to G 2.5 and are available in CAT, BT, and HSK

tool tapers.

“New tool clamping technology

allows shops to maximize machining

operations; however, spindle maintenance

is equally important. Any spindle taper wear,

tool clamping taper wear, or spindle misalignment

will have a negative impact

on tool clamping assemblies

[toolholder and cutting tool]

regardless of quality of the as-

sembly. Using spindle wipers,

Pull Force gages to routinely

check drawbar force, and

test arbors to routinely check

spindle alignment and spindle run-out

are equally important to maximum

machining conditions,” said Fara.

Kennametal, Haimer Team

Up on Carbide Cutting Heads

There is no shortage of innovative

toolholding solutions that have been

developed using either standard or

proprietary special toolholding designs.

Kennametal Inc. (Latrobe, PA) and

Haimer GmbH (Igenhausen, Germany;

Villa Park, IL) have entered into a joint

technology partnership in developing the

Duo-Lock modular cutting tool system

for carbide cutting heads. Design of the

Duo-Lock modular interface is intended

to make the modular connection as

solid as a carbide end mill and provide

maximum stability, increased load capac-

ity, and high run-out precision. Duo-Lock

features an innovative thread design with

a proprietary double cone connection

and an additional third supporting area in

the back of the interface. The connec-

tion overcomes the interface weakness

CAPTIS ClAmPIng SySTemThe modular and flexible system

Modular construction for maximum flexibility Quick conversion from external to internal clamping in less than a minute

High concentricity and repeatability of 0.005 mm

The modular and flexible system

RÖHM Products of America | www.rohm-products.com | [email protected] I 1-800-445-7656


Toolholding

Duo-Lock features an

innovative thread design

(blue) with a proprietary

double cone connection and

an additional third supporting area

(green) in the back of the interface for three

contact point connection.

of existing modular systems so that the carbide cutter can be

used to their full potential without breaking.

During IMTS, both companies introduced a new portfolio of

cutting heads and mono-block screw fit toolholders with Duo-

Lock technology in all relevant spindle

interfaces and extensions. Also new

modular cutting toolheads with longer

length than currently available in the mar-

ketplace will be added to their product

portfolio in order to take aggressive cuts

in the aerospace and energy industry.

“The system guarantees 5 µm run-

out accuracy and a Z accuracy of 1 µm,

which will eliminate most of the expen-

sive presetting processes,” said Doug

Ewald, Kennametal director product

management system tooling. “The supe-

rior features of the Duo-Lock technology

will provide significantly increased metal

removal rates at milling applications and

longer tool life. For the first time a modu-

lar milling system can achieve similar

high performance of a latest generation

solid-carbide end mill.”

The Duo-Lock system, which has

achieved milling performance of 1.5 × D

depth of cut, widens the application of

modular milling systems compared with

current competitive systems. The Duo-

Lock system can more than double the

metal removal rate (MRR) in common

milling applications.

The agreement between Kennametal

and Haimer is a long-term partnership

that involves cross licensing. Like

Haimer’s Safe-Lock toolholding system,

Duo-Lock will be offered as a license to

leading high-end cutting tool companies

to establish a compatible, high-

performance modular end mill system.

The partners are currently in discussions

with additional leading cutting tool

companies to offer customers multiple

sources of different manufacturers with

one compatible interface.

In Haimer’s Safe-Lock proprietary system, special drive

keys in the chuck and grooves in the tool shank prevent the

milling cutter from spinning during extreme machining or

being pulled out of the chuck. In addition to the frictional

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clamping forces of the particular clamping

system, the tool is held using positive locking in

the tool holder through the constructive design

of the Safe-Lock system. The combination of

pull-out protection and best runout accuracy

lead to a low vibration and as a result very ef-

ficient machining. Due to the increased cutting

depths and feeds, the metal removal rate can

be increased by up to 100%, and to a similar

degree tool wear decreases.

Maximizing ER Collet System, More

Rego-Fix (Indianapolis, IN) has continued to

build on the success of its powRgrip and secuR-

grip product lines, as well as introduce products

that enhance performance of its ER systems.

The new ER MicRun Collet System has a TIR of

less than 0.00012" (0.003 mm) at 3 × D. The

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Toolholding

Using Pull Force gages to routinely check drawbar force (shown) and

test arbors to routinely check spindle alignment and spindle run-out

are equally important to maximum machining conditions.

Pho

to c

ourt

esy

Bilz

Too

l Co.

Inc.

MicRun’s self-locking design retains the collet in the nut for

easier insertion and removal, with no extractor required. To

ensure it maintains high repeatability and rigidity in challeng-

ing applications, Rego-Fix equipped the system with a special

thread that keeps the nut aligned with

the holder. Suitable for high-speed

machining, the MicRun is available in

standard taper types as well as standard

and mini-nut designs.

Part of Rego-Fix’s powRgrip product

line, secuRgrip brings simple, effective

tool locking to challenging metal removal

applications. The anti-pull system locks

the collet and cutter to the toolholder

body to eliminate cutter slippage. It does

so via a patented locking system that

includes a small, profiled locking key in-

sert that fits into a standard Weldon end

mill flat. secuRgrip has a TIR of 0.0001"

(0.003 mm) and enables manufactur-

ers to preset their tool heights. Rego-Fix

customers can modify their existing pow-

Rgrip holders for use with the system.

The secuRgrip locking system is now

also available for milling chucks.

To protect operators, especially

working in the confined work envelopes

of Swiss-style machines, Rego-Fix has

introduced the new slip-proof ERMX mini

clamping nuts feature a frontal milled

slot on their outside diameter that mates

effortlessly to a corresponding wrench

to prevent slippage during the tighten-

ing and loosening process. These new

clamping nuts, which are suitable for the

company’s sealing or cooling disks, have

a special surface treatment for increased

clamping force and a unique coating that

prevents corrosion. ERMX works with

ER collets in DIN 6499and ISO 15488.

Among the many benefits of this com-

pact product are lower injury risks due to

slip-proof clamping, internal and external

cooling, improved chip removal, reduced

tool costs and improved productivity.

Design Addresses Pull Out with Standard Tooling

“There are a lot of issues in addressing pull out, especially

when machining heat-resistant super alloys [HRSA] like titanium

or Inconel,” said Alan Miller, engineering manager, BIG Kaiser

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Precision Tooling Inc. (Hoffman Estates, IL). “We have taken the

existing standard of Weldon flats for end mills and applied it to

be compatible with our high-performance milling chucks. We

came up with a new milling chuck product line called the Mega

Perfect Grip milling chuck. A special keeper key is positioned

into the Weldon flat of the end mill and together the key and

cutter are inserted into the bore of the milling chuck with three

axial grooves that accepts the keeper key. Once the cutter and

key are inserted to the bottom, a 20° twist clockwise places

the key against a hardened pin and into a stop groove of the

milling chuck. Final tightening of the clamping nut closes the

milling chuck, making it impossible for the cutter to pull out,”

said Miller. The Mega Perfect Grip milling chucks combine the

cutting performance of heavy-duty milling chucks with security

against pullout of solid side lock tool holders. High-pressure and

high-volume jet-through coolant is a standard feature.

“To improve upon the ER standard, we developed the

Mega ER solid nut which is a slot-free clamping nut without

ball bearings as a lower cost option to the standard Mega ER

Nut. We’ve incorporated a friction-free surface treatment of

the internal collet raceway to minimize collet distortion during

clamping. The slot free nuts use our popular Mega Wrench

that improves balance and tool holder symmetry. The result is

that it allows us to make a replaceable ER collet nut for any-

body with ER product and it’s available in ER16, ER20, ER25,

and ER32 sizes,” said Miller.

When it comes to building tools to fit into the available ma-

chining space, BIG Kaiser has developed an extension system

that is designed to eliminate up to 40% of the weight of a very

large boring tool assembly. “Larger diameter tool assemblies

with long projections can be built up with both steel and

aluminum components, providing an ideal length to weight

ratio for most machines with automatic tool changers,” said

Miller. It could make the difference between using the existing

machine with the largest tool and travel available for a job, or

having to make a capital investment to buy a larger machine.

Another way to maximize the machine’s

available work envelope is BIG Kai-

ser’s Smart Damper for face mills that

eliminates unwanted vibrations inherent

due to excessive toolholder length and

cutting conditions. The modular design

provides versatility for gage lengths up

to16" (406 mm) and is available for

BIG-PLUS CAT 50 or BT50, and HSK-

A100 metric face mills.

Leave the Tool in the

Machine for Quick Change

Command Tooling Systems (Ramsey,

MN) has introduced its Varia VX Quick

Change System that allows the machin-

ist to replace cutting tools effortlessly,

leaving the tool in the machine without

risk to hands. The Varia VX utilizes three

contact points to pull the Varia VX insert

into position. A release mechanism

ejects the insert without excessive force

and makes single-handed operation

possible, minimizing risk of injury. Tool

change times take as little as 20 sec-

onds with a single screw solution. The

modular system allows tool preparation


Toolholding

during machine operation and doesn’t require block realign-

ment after changing the Varia VX insert.

The Varia VX quick-change system is now available for

the complete bandwidth. The taper/planar support interface

ensures maximum concentric accuracy.

The torsional moment happens with a

positive polygon that transfers up to 200

N//pd//m. Tightening and release take

place via a turn gear segment with three

multifunctional cams. When a radially

attached tension screw is tightened, the

three-point tension pulls the tool insert

evenly into position. When releasing, the

insert is mechanically loosened via slid-

ing cams and released from the holder

for removal.

For use in inner cooling, a dia-

metrically acting membrane seal ensures

the leak-free coolant transfer between

adapter and VX insert, thus bringing the

medium directly to the cutter. Advantag-

es to the VX system include preset cutting tools are laying ready

at the machine; quick change through only one clamping point;

no risk of injury when changing tools; clamping of the inserts

without any radical force; safe torque transmission. ME

Complete Live Tooling Solutionsby

www.eri-america • [email protected] 877-374-8005

ERI AMERICATOOLHOLDING SOLUTIONS

• DMG/Mori Seiki• BMT45 - 85• VDI 25-60• Haas & many more

• Tool Discs• TestRapid quick change• Machine spindles• 2 year warranty

C

M

Y

CM

MY

CY

CMY

K

ERI AMERICA-11-14ME.pdf 1 10/17/2014 2:46:39 PM


BIG Kaiser Precision Tooling Inc.Ph: 847-228-7660

Web site: www.bigkaiser.com

Bilz Tool Co. Inc.Ph: 847-734-9390

Web site: www.bilzusa.com

Command Tooling Systems LLCPh: 800-328-2197

Web site: www.commandtool.com

Haimer USAPh: 630-833-1500

Web site: www.haimer-usa.com

Kennametal Inc.Ph: 724-539-5000

Web site: www.kennametal.com

Rego-Fix Tool Corp.Ph: 317-870-5959

Web site: www.rego-fix.com

Rose TrainingE-mail: [email protected] site: www.rose-training.com

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Innovative Tooling Puts Security into Tough Machining N · PDF filestory, according to Rose: ... of the patented TER ThermoGrip ER shrink collet by Bilz is intended to revolutionize