5-axis clamping solutions

Options in the field of 5-axis prismatic machining are particularly prolific, with workholding solutions from the USA, Germany and Italy on offer specifically targeted at this area.

Although not normally associated with fully interpolative machining in five axes, a US-made Chick System 5 Qwik-Lok twin-station clamping system was demonstrated assisting the manufacture of a bicycle pedal at the Mazak open house last November – see the video on the PES website at: https://www.pesmedia.com/chick-system-1st-mta-demonstrates-5-axis-capability/

Choice of an aluminium rather than a cast iron base helps to keep down the overall weight on the table and enhances accuracy when a part is being machined at a compound angle.

With the Qwik-Lok dual-station arrangement, two components are secured each time the jaws are tightened using a removable handle, ideal for completing ops 1 and 2 efficiently at a single clamping. Machinable soft jaws provide the ability to retain workpieces of complex shape securely.

Another mechanical clamping system in 1st MTA’s portfolio that is particularly suitable for 5-axis machining is the range offered by Best GmbH in Filderstadt, Germany. The company manufactures low-profile, centric (self-centring) vices with high clamping forces up to 100kN. Other notable qualities are an ability to clamp on only 3mm of material; and ±0.01mm centring accuracy with 5µm repeatability for manual and pneumatic vices, and 1µm repeatability for hydraulic types.

Vices range in length from 115mm to 500mm and have up to 50mm stroke. Faceplates and adapters allow them to be fitted to any machine table, pallet or rotary table. Depending on requirements, they can be screwed conventionally to the table or used as a zero-point vice on the Best Realpoint quick-change system (or other manufacturers' zero-point clamping systems after simple adaptation).

Most recently added to the 1st MTA range of workpiece clamping options is the Italian-produced Tecnomagnete programme of permanent-electromagnetic clamping systems. It includes the compact MillTEC Grip designed for 5-axis and 5-sided metalcutting applications.

The low profile, frameless clamps have a double magnetic circuit that allows uniform clamping between the workpiece and the magnetic surface and at the same time between the magnetic system and the machine table. The system avoids the drawback of conventional mechanical workholding, whereby machining is restricted by the need for clamps to secure the workpiece.

A patented feature is the sealed construction with a monolithic, all-metal top section into which an array of sacrificial magnets is embedded for holding the workpieces. It eliminates bending and deformation that can be caused by mechanical clamping, ensuring stability and structural uniformity of the whole assembly. Five sides of a component are freely accessible for milling and drilling and the light weight of the clamping system means that heavier components can be processed for a given maximum table load.

A further advantage is the thinness of the MillTEC Grip magnetic plate, which maximises Z-axis travel on a vertical machining centre or Y-axis travel on a horizontal spindle machine, allowing taller components to be manufactured. For added versatility, the workpiece can be raised from the working surface by a steel block carrying the MillTEC module.

1st MTA’s comprehensive range of workholding solutions is complemented by Abbott and Leave fixturing and clamping products from the US and the OK-Vise product range from Finland. They also have potential applications in 5-axis machining.

1^st MTA www.1mta.com