In the tapping operation, the tap chuck, which is optimally controlled by modern CNC equipment, can increase the service life of the tool to 150% while ensuring the highest process safety and the best surface quality. In high speed machining, the axial force is also better damped than before.
The REGO-FIXER and POWRGRIP tool holding devices are able to demonstrate their superior capabilities in terms of clamping force, rigidity, balance, vibration damping and roundness in daily industrial processing. In tapping operations, HSK and cylindrical clamping devices are used to help improve quality, operational safety and economy. Whether it is a through hole or a blind hole, there is no room for error in the error and quality when machining the thread. This is because the tapping process is often a long and expensive end of the production chain that determines the quality of the workpiece. In view of the greatest impact on process safety at this stage, companies are looking for a fast and good processing route – the new REGO-FIX tap chuck is the key to opening the door.
Control axial force
For taps, the European EN22857 standard already specifies the size and tolerance range of the machined thread, which also specifies a pitch error range of ±8 μM for a given number of threads. For example, a M10 tap with a pitch of 1.5 mm uses seven threads as a test length, with an allowable error range of ±8 μM. In the most unfavorable case, an axial force of up to 1300 N can theoretically be produced due to the change in the length of the tap. Synchronization errors occur under the power of the spindle and linear drive. This small difference and the error on the tap can be caused by a rigid threaded tool, causing distortion of the system, resulting in one-sided wear and material welding of the threaded tool to shorten the service life; it can also result in a dirty side of the threaded profile being cut or The thread does not meet the gauge tolerance.
The greater the damping of this large axial force and the better the control, the better the impact on the entire system components and the better the quality of the threads. The optimal simultaneous electronic adjustment between the spindle's rotary motion and the feed drive is achieved by the interlocking of the synchronous shaft with the custom thread cutting chuck, which is a path to higher efficiency and better quality. This recognition has been implemented in the new REGO-FIX tap chucks and in the use of specially adapted transmission systems and rigid clamping taps or extrusion taps.
Tap chuck with length compensation
The tap chuck with length compensation can be used on machines with feed motion and tapping. Therefore, such a machine tool requires a tap chuck having a length compensation in the pressing and pulling directions, thereby balancing the difference between the tapping and the spindle feed. In addition, the tap chuck with length compensation features a pressure point mechanism that ensures the taps are safely cut and achieve a uniform, repeatable thread depth. Through a special design structure, the coolant can be directed to the tap at a pressure of 50 BAR (5 x 106 PA), and the length compensation function of the tap is not affected at all. The tap chuck has excellent versatility due to its compact construction and small protruding length.
The SOFTSYNCHRO tap chuck is developed for a modern CNC machining center with a synchronous spindle and direct thread cutting. The synchronous control system calculates the rotational movement of the spindle and the feed axis and synchronizes the two, so that the thread can be machined without the length compensation function of the tool holding device. This is because, in the case of synchronicity errors, only a very small length compensation is required to compensate for the difference in the pressing and pulling directions between the spindle feed and the tapping. Depending on the application, the user's threaded tool life can be increased up to 150% by the above method.
Compared to rigid clamp holders, the REGO-FIX-SOFTSYNCHRO tap chuck can be used as a damping element between the synchronous shaft and the tap or extrusion tap to equalize the tapping difference between the threaded tool and the synchronous shaft. This achieves high roundness accuracy, protects the machine's spindle and extends tool life.
Long service life and reduced tap volume
After the cost comparison, it can be clearly found that when the 2×D blind hole tapping is performed for the GAISI9 material, the tap with the SOFTSYNCHRO tap chuck can realize 70,000 threads; and the tap chuck with the minimum length compensation function is used. At the time, only 30,000 threads can be achieved; if a rigid clamping holder is used, it is 28,000 threads. From the annual average, the number of taps required by the user in the above process is significantly reduced due to the extended service life of the tap; that is, only 150 pieces, instead of 350 pieces (competitors) or 375 pieces (rigid clamps) . From a conservative point of view, users can save 19,375 euros compared to rigid clamps; if compared with competitors' products, users can save 2,075 euros per year.
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