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
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60 ManufacturingEngineeringMedia.com | November 2014
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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November 2014 | ManufacturingEngineeringMedia.com 61
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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62 ManufacturingEngineeringMedia.com | November 2014
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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November 2014 | ManufacturingEngineeringMedia.com 63
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
64 ManufacturingEngineeringMedia.com | November 2014
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
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K
ERI AMERICA-11-14ME.pdf 1 10/17/2014 2:46:39 PM
November 2014 | ManufacturingEngineeringMedia.com 65
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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