G - Tool Holding Systems

G 1

Tool holding systems

A

B

C

D

E

F

G

H

Tool holding systems ............................................. G3

Manual tool changing ............................................ G3

Automatic tool changing ......................................... G4

Tool chucks ........................................................... G4

Coromant Capto ......................................................G5

Tooling systems overview ....................................... G6

How to select tool holding ...................................... G8

Modular holding tools ............................................ G9

Solid holding tools ................................................. G9

When to consider modular and solid tool holding ..... G9

Different clamping methods ................................. G10

Tool options ........................................................ G11

Minimizing vibrations with damped adaptors .......... G11

Special tools ....................................................... G11

Heavy duty assortment for taper 60 machines ....... G11

Balance of tool holders ........................................ G12

Prebalanced tool holders ..................................... G13

Tool holding range ............................................... G14

How to select tap holders .................................... G22

Chuck information ............................................... G23

Basic holder information ...................................... G24

Coupling details .................................................. G25

CoroMill modular cutting tools .............................. G28

Tool set-ups ........................................................ G28

Adjustable holder for rotating drills ....................... G30

Cassettes for tool handling .................................. G30

Modular quick change tooling for turning ............... G31

Coromant Capto for turning operations ................. G32

The basic clamping principle ................................ G33

Coromant Capto turning .................................... G33

The manual clamping units .................................. G35

How to choose shank type clamping units ............. G36

Manually operated clamping units ........................ G37

Design and build-in instructions ............................ G38

How to choose VDI clamping units ........................ G40

Coromant driven tool holders ............................... G41

Coromant capto - adaptors ................................... G42

How to adopt a modular tooling system ................ G44

ContentsTool holding systems

CoroGrip and HydroGrip tool chucks ...................... G45

Hydro.mechanical and hydraulic

precision chucks ................................................. G46

CoroGrip ............................................................. G47

Capacity values for chucks ................................... G48

CoroGrip function ................................................ G50

HydroGrip function ............................................... G53

CoroGrip range .................................................... G54

Hydrogrip range ................................................... G56

Individual balanced tool chucks ............................ G58

Hand pump system installation .......................... G59

Elements of operation hand pump ..................... G59

If problems should occur hand pump ................. G60

Do`s and dont`s CoroGrip pumps ...................... G61

Bench pump system installation ........................ G62

Elements of operating bench pump .................... G62

If problems should occur ..................................... G63

Clamping a tool ................................................... G63

Corogrip and Hydrogrip chuck handling hints ......... G65

G 2


A

B

C

D

E

F

G

H

G 3


A

B

C

D

E

F

G

H

Introduction

Holding, changing, storing, handling and administrating tools is a critical link in the chain that supports successful ma-chining. However good the cutting edge, insert-clamping method, toolholder or cutter-body, if the tool holding interface with machine spindle and turret is un-satisfactory, performance, reliability and quality will not be as good as it can be. An important potential for efcient pro-duction may not be utilized.

More and more machine tools are being built where the tooling system plays an increasingly important role CNC-lathes, turning centres, multi-task machines as well as machining centres, vertical turn-ing centres, boring mills, etc. In many of these machines, tool changing is man-ual and down-times are directly related to how long it takes to release a tool, replace it, clamp the new one and es-tablish the right cutting edge position. In many other machines, tools are changed mechanically with automatic tool chang-ers (ATC) from a magazine to tool spin-dle. For efciency in both cases, the tool-ing system is the key factor.

Manual tool changingIn machines where tools are manually changed, the time taken for these stop-

pages have a profound effect on ma-chine tool utilization and the time taken for completing batches of components. If by shortening the tool-changing time the time-share of actually cutting chips is increased, making the machine more ef-cient. Instead of tool changing and tool orientation for a new component set-up taking most of an hour (as it often has), tool changing with a quick-change tool-ing system is reduced to a fraction of an hour (minutes).

Similarly, stoppages for changing one or few worn tools during a batch is reduced dramatically with quick-change tooling. The effect this has is that the machining time is increased from typically around a third of the available production time to around half.


G 4


A

B

C

D

E

F

G

H

Automatic tool changingIn machine tools where tools are changed automatically, tool changing time is not the decisive factor. Instead factors such as tool stability and strength, accuracy, positioning, exibility, compatability, stor-ing and handling together provide the advantages that result in production benets. More competitive cutting data thanks to higher stability, fewer and bet-ter-organized tools, interchangability of tools between adaptors and machines, equal suitability for stationary tools and rotating tools and the ability to be an in-terface between tooling system and tool-spindle and tool-magazine are examples of vital qualities.

A modular tooling system having all the right qualities can give wide-ranging ad-vantages in not only individual machine tools but whole machine shops.

In both tool-changing cases - manual and automatic - the tooling system being modular with a state-of-the-art coupling is what makes the difference.

Tool chucksIncorporated in tooling systems and critical for performance - are tool chucks. The ability to securely and accurately clamp and present shank-tools for a ma-chining operation is decisive, not only for achieving the desired component quality and tool-life, but also for perform-ing roughing operations productively. In times when spindle speeds are continu-ally elevated towards high speed machin-ing (HSM) and new machining methods are being introduced as well as nish-milling is expected to reach new levels, the quality of clamping a solid carbide milling cutter and drill as well as index-able insert endmill will in many cases make the difference between competi-tive and uncompetitive machining.

G 5


A

B

C

D

E

F

G

HCoromant Capto is the only modular tooling system designed for all metal cutting operations without compromise. Equally effective in turning, milling, drilling and boring. The same cut-ting tools and adaptors can be used in different applications and machines, which makes it possible to standardize on one tooling system for the entire machine shop. There are many possibilities of assembling tools with a variety of lengths and design characteristics. The same system can also be installed in various machines types in different ways.

Coromant Capto modular tool system for stationary and rotating tools

CNC lathes can easily be converted to Coromant Capto quick-change tools using standard clamping units.

Coromant Capto can be integrated directly into the turret using the standard clamping mechanism.

Coromant Capto integrated into multi-task machines gives many advantages: one single system in the machine maximum power of the machine can be utilized thanks to

the rigidity of the coupling tools are relatively small in size and weight

Coromant Capto in machining centres, vertical lathes and bor-ing mills gives exibility and substantial reduction of inventory.

G 6


A

B

C

D

E

F

G

H

Coromant Capto/ Varilock

Damped milling adaptor

Coromant Capto extensions

Coromant Capto extensions

Coromant Capto integrated tools Coromant Capto adaptors

CoroGripFacemill Side & face HydroGrip Collet chuck

CoroMill 390 cutters CoroMill Century CoroMill 790 cutters Coromant U drills Boring tools

Front clamp

ISO 7388/1ISO 30 ISO 40 ISO 45 ISO 50

MAS BTISO 30 ISO 40 ISO 50

MAS BT

ISO 40 ISO 50

ISO 7388/1

ISO 40 ISO 50

DIN 69871

ISO 40 ISO 50

MAS BT

ISO 40 ISO 50

Form BForm BBIG-PLUS HSK 63-A/C HSK 100-A/C

BIG-PLUS

Coromant Capto basic holders

Tooling systems overview

G 7


A

B

C

D

E

F

G

H

DIN 2079

ISO 40

Coromant Capto basic holders Front clamp

ISO 7388/1ISO 40 ISO 50

MAS BTISO 40 ISO 50

DIN 2080ISO 40 ISO 50


HSK and Coromant solid holdersVarilock/ Coromant Capto

Coromant Capto adaptors


HydroGripCoroGrip

WeldonWhistle Notch Drill Drill Drill chuck Blank Tap holder

Camshaft

Drill

Coromant Capto basic holders

G 8


A

B

C

D

E

F

G

H

How to select tool holding

Select a tool holding systemSelect a modular AND/or solid TOOLING.

Select an adaptor styleUse the programme overview for the Coromant Capto system to choose an adaptor based on the type of machining and machine tool application.

Select a coupling size select the right coupling size select adaptor from mounting alternatives

Add extensions if necessaryAdd extensions where needed to complete gauge length requirements. Use the programme overview to nd suitable extension.

Select basic holderUse the programme overview to choose a holder type based on machine type.

Select the basic holderSelect the right specic holder from taper and coupling.

G 9


A

B

C

D

E

F

G

H

Modular holding tools: Solid holding tools:

When changing production there is a demand for exibility from the tool holding system, as different component sizes often lead to varying gauge lengths. Coromant Capto modular tooling allows the correct length of tool to be built, in order to maintain maximum performance.

When tooling is required for a variety of machines with differ-ent taper size or designs.

When component complexity demands a high number of spe-cial tools.

Coromant Capto offers reductions in tool inventory and makes it possible to have one standard system of modular tools for a variety of operations on lathes and machining centres.

On dedicated machines which produce components that will not be changed.

Tools that are unchanged for the majority of tooling set ups, such as facemill arbors and endmill holders of xed gauge length.

Solid holding tools are an important complement to modular tools, when for technical or functional reasons, modular solu-tions are either not suitable or unnecessary.

The right combination of solid and modular tools gives high performance with a minimum overall inventory.

Modular tooling system

Solid tooling system

When to consider modular and solid tool holding

G 10


A

B

C

D

E

F

G

H Many of the latest machining centre tools have the option of an integral Coromant Capto coupling. This eliminates the need for a cutting tool adaptor, reducing the number of parts and the price of the tooling assembly. In addition the concept minimizes tool overhang.

In cases of extreme tool overhang the combined features of centre bolt clamping and front clamping is the best solution. The front clamping extension should be used at the cutting end of the assembly (as shown above) where the bending moment and torque is at its minimum.

Different clamping methods

Centre bolt clamping

Front clamping

Standard Coromant Capto is clamped via a large axial bolt re-tained in the basic holder by a counter-nut. The large size of the bolt permits high torque values allowing high clamping forces to be generated.

Centre bolt clampingCentre bolt clamping should be considered as the optimum so-lution for heavy machining, particularly when long overhangs are employed.

Front clampingFront clamping utilizes a differential screw and opposite sets of serrated clamping jaws to grasp and pull the adaptor/tool back into the coupling. Front clamping offers rapid and simple

tool build and is ideal when a fast tool change is required in the magazine or spindle.

The complete range of Coromant Capto cutting tools/adaptors can be clamped by the front clamp method, with basic holders and extensions maintaining their through-coolant capability.

The complete range of all existing cutting tools and adaptors can be held in the front clamping basic holder or extension by simply screwing in a standard drawbolt. Through coolant capa-bility is maintained.

G 11


A

B

C

D

E

F

G

H

Tools with long overhangs are becoming increasingly more com-mon, especially on machining centres where many operations are often performed on one machine. Vibration, an inherent feature of long tool overhang, is effectively reduced with tuned damped tooling that dampens vibration.

There are damped adaptors specially designed for facemilling and square shoulder facemilling as well as for boring.

Special tools are often needed in machining centre setups. To reduce the costs and time for manu-facturing such tools, the program includes blanks with the coupling already machined. This makes special tools as exible as all other tools.Many special tools are similar to stand-ard tools but have different dimen-sions. With Coromant Capto, such tools can be built out of standard parts, such as extensions, re-ductions etc.

There are many occasions, on taper 60 machines, when there is a need for rigid holders to withstand the high bending torque generated. Coromant Capto Heavy Duty basic holders and adaptors are dedicated to full these requirements.

The coupling itself is a Coromant Capto C8 coupling, but with ex-tended outer diameter of 107 mm, instead of standard 80 mm. Coromant Capto Heavy Duty basic holders are premachined for mounting of shims when spindle face contact against the ange is required.

Silent Tools is a trade mark of Teeness ASA, a partner of Sandvik Coromant.

Turn on the Silence

For productive vibration free machining

Minimizing vibration with damped adaptors

Heavy duty assortment for taper 60 machines

Special tools

Tool options

107

G 12


A

B

C

D

E

F

G

H

What can cause unbalance? Mass misalignment (grooves, slots etc) Eccentricity (distance between the rotational centre and cen-

tre of gravity for the tool) Additional components (e.g. a tool that is unbalanced) Fitting and tolerances between the spindle and the coupling

of the toolWithin the industry the level of balance is often specied with a balance quality class (a G-value) calculated according to ISO standard 1940/1.

Calculation of unbalance G-value ISO 1940/1

Unbalanceu = unbalance x radius

= m x r (gmm)

Eccentricity(distance between rotational centre and Centre of Gravity)e = unbalance/mass of tool

= u/kg (m)

n = spindle speed (RPM)G = e x n/9549

G value at 15 000 RPM = e x n / 9549 = G 25

m = 1.0 gr = 20 mmu = m x r = 20.0 gmmMass of tool = 1.25 kge = u / mtool = 16.0 mn = 15.000 RPM

G 2.5 is often requested for tool holders without considering the total weight of the tool holder, including the cutting tool the spindle speed the assembly should run at that the total unbalance mass in the example above should

be only 0.1 g and unbalance u = 2 gmm which is difcult and expensive to measure and repeat

All ISO (7/24 inches) taper tool holders have AT3 taper tolerance. Coromant Capto, HSK and metric solid ISO taper tool holders are Prebalanced (In previous catalogues Bal-anced by design)All these tool holders are marked with the Prebalance sym-bol. A prebalanced tool holder (ISO 40/HSK 63) can normally be used up to 15.000 RPM in a modern CNC machine with-out extra balancing. For Coromant Capto modular system the maximum recommended spindle speed is reduced to 8.000 RPM when extensions and/or reductions are used between the basic holder and adaptor.

Prebalance symbol

Balance of tool holders

Coromant tool holder balance qualities

G 13


A

B

C

D

E

F

G

H

Compensation for difference in depth of driving slots

Compensation for difference due to magazine orientation slot on ISO 7388/1 holders

Compensation for unbalance in the Coromant Capto coupling

Taper 40 basic holder with an assembled adaptor:The values gives approximately a balance value of G 16 at 10.000 RPM according to ISO 1940/1

Unbalance in gmm

SizeC3 2 13 C4 5 25 C5 10 35

min max

Unbalance values for an adaptorThe balance values in gmm for an individual prebalanced C3-C5 adaptor ucturates between these values.

Unbalance in gmm

Size

C3 0.3 8 C4 0.7 20 C5 1.0 30

min max

Compensation for the clamping screw hole and the clamping at on a solid carbide tool

Example for a Coromant Capto basic holder and a Weldon adaptor

Measured prebalance levels achieved for an adapter clamped in a taper 40 basic holder differ for the different Coromant Cap-to coupling sizes. Total weight and material movements in the heat treatment process also cause some uctuations in the values achieved.

All Coromant Capto C3-C5. HSK 63 and metric solid ISO 40 taper toolholders marked with the Prebalance symbol are de-signed as solid 3-D CAD models and the mass and the position of the unbalance is calculated for the tool holder.The controlled removal of material from exactly the correct lo-cations allows inbalance, to be counteracted. Special consid-eration to the way the holder is clamped during manufacture allows the different surfaces to remain concentric around the rotational centre.

Prebalanced tool holders

G 14


A

B

C

D

E

F

G

H

l1 = programming length

Cutting edge

Zero point

Basic holderISO 7388/1 (DIN 69871-A)390.140 390.140HD

Heavy Duty*)

BIG-PLUS basic holdersISO 7388/1 (DIN 69871-A)390.540

BIG-PLUS SYSTEM - Licence BIG DAISHOWA

Modied holder with A in the end of the code1)


Note! One drawbolt for each adaptor/cutting tool is required.

Basic holderISO 7388/1 (DIN 69871-A)Front clamp390.14004

Basic holderDIN 69871. form BCoolant through ange390.272



Tool holding range

G 15


A

B

C

D

E

F

G

H

Basic holderMAS 403 BT390.55/ .58


BIG-PLUS basic holdersMAS 403 BT390.555/ .558

BIG-PLUS SYSTEM - Licence BIG DAISHOWA


Basic holderMAS 403 BT, form BCoolant through ange390.369




Basic holderMAS 403 BTFront clamp390.5504/ .5804

Basic holderYamazaki390.85/ .83


Basic holder390.410

HSK A/C


Basic holderDIN 2080For manual tool change390.00



Basic holderDIN 2080For manual tool changeFront clamp390.0004


G 16


A

B

C

D

E

F

G

H

Zero point

DIN 2079For manual tool change, ange mountingFront clamp390.34704



Zero point

Basic holderDIN 2079For manual tool change, ange mountingCamshaft clamping390.34705


Extension adaptor391.01

Heavy Duty


Extension adaptorShort version, for segment clamping only391.01

Reduction adaptorShort version, for segment clamping only391.02

l1 = programming length l1 = programming length

G 17


A

B

C

D

E

F

G

H


Reduction adaptor391.02

Design 1 Design 2

Heavy Duty

Coromant Capto adaptor for Varilock tools391.01

Coromant Capto

Varilock


Varilock adaptor for Coromant Capto tools391.01/391.02

Coromant Capto

Varilock


Front clamp extension adaptor391.04

Note! One drawbolt for each adaptor/cutting tool is required. l1 = programming length

Front clamp reduction adaptor391.0204

Note! One drawbolt for each adaptor/cutting tool is required. l1 = programming length


Adaptor for facemills and square shoulder facemills391.05

dmt = 16Heavy Duty

G 18


A

B

C

D

E

F

G

H

Damped adaptor for facemills and square shoulder facemills391.06

Design 1

Design 2


Adaptor for side and facemills391.10

Heavy Duty


Collet chuck adaptorDIN 6499391.14

Short collet chuck adaptorDIN 6499391.14

Note: For segment clamping only. Cannot be used in basic holders and extensions/reductions.

Collet chuck extensionDIN 6499Plain parallel shank393.14

G 19


A

B

C

D

E

F

G

H

Weldon shank adaptorFor shanks according to DIN 6535-HB391.20


Whistle Notch shank adaptorFor shanks according to DIN 6535-HE391.21


Adaptor for Coromant U and Coromant Delta drillsShank according to ISO 9766391.27


Damped adaptor for Coromant U indexable insert drillS-391.SDA


Drill chuck391.31


G 20


A

B

C

D

E

F

G

H

Blank adaptor391.50 391.50HD

Heavy Duty

Adaptors with internal Morse taper391.40/ .41/ .42

Design 1 Design 3Design 2


Tap adaptor391.60/391.61

Cx-391.61Cx-391.60

Tap holderwith friction clutch and for external / internal coolant supply393.03-SES ext./int.

Coromant Capto Cx-391.60


2)

G 21


A

B

C

D

E

F

G

H

Tap holderwithout friction clutch and for external / internal coolant supply393.03-SE393.61-SE



1)


393.03-SE 393.03-SE 393.61-SE

Tap adaptorsCollet type with internal coolant supplyFor synchronized machines391.60A


Tap adaptorsCollet type with external coolant supply391.60B"Slim" design, oating (for machining centres)


Tap adaptorsCollet type with external coolant supply391.60BShort design, oating (for turning centres)

2)l1 = programming length

G 22


A

B

C

D

E

F

G

H

How to select tap holders

Conventional tap. Cutting uid outside

tap

Coolant through

tap

393.03-SE393.03-SES 393.03-SE 393.61-SE

Cx-391.60 Cx-391.61

393.03-SES

With cutting uid through

Without cutting uid

through

Conventional tap

Tap adaptorsThe tap adaptors are designed for tapping operations in ma-chines equipped with automatic tool changing. A tension and compression design compensates for differences between spindle feed and thread pitch.

Tap holdersTwo styles are available Positive drive tap holder style SE Torque controlled tap holders style SESBoth with drive on tap square.Style SES has preset safety clutch that will slip when tapping torque exeeds preset valueAdaptors for left hand threads are available on request.Note! Pull studs without coolant through hole should be used in basic holders when using Cx-391.60.

G 23


A

B

C

D

E

F

G

H

When clamping tools with cylindrical shanks in old Coromant Capto collet chucks - with hole through the centre - be careful that the tool, if smaller than the hole through the adaptor, is not inserted past the the drawbar ejecting surface, as this will cause misclamping, create a faulty clamping cycle and thus enhance the risk of damage to the clamping mechanism.By using a stop screw this risk is eliminated and the function of both the adaptor and the clamping mechanism is maintained.All adaptors type 391.14, 391.15 and 391.20 have an internal thread to suit the stop screw.

Ordering code

Size Dimensions, mm

Dth l N

C3 5514 070-01 M12x1.5 8 5

C4 5514 070-02 M14x1.5 9 6

C5 5514 070-03 M16x1.5 11 8

C6 5514 070-04 M20x2.0 13 10

All new adaptors type 391.14, 391.15 and 391.20 manufac-tured from January 2003 have a permanent stop built in to the holder. Stop screws are not required.

For collet chucks 391.14 and 391.15 a special washer is perma-nently assembled in the holder

Correct mountingClamped tool, segments in correct position.

Stop screw

Wrong mountingDrawbar hits the tool instead of the ejecting surface when you insert the tool. Segments will not be in correct position. Tool can fall out during cutting process.

For the weldon adaptors 391.20 a pin is permanently assembled in the holder

391.14 391.15

391.20

Stop screws for old collet chucks and weldon adaptors

Permanent stop for new collet chucks and weldon adaptors

Chuck information

G 24


A

B

C

D

E

F

G

H

Basic concept

The BIG-PLUS Spindle System offers simultaneous dual con-tact between the machine spindle face and toolholder ange face, as well as the machine spindle taper and long toolholder taper shank.

BIG PLUS Conventional

MAS BT50 100 69.85MAS BT40 63 44.45

BIG-PLUS Conventional

Increased contact diameter (example of MAS BT)

Contact Space

Spindle taper

Working principleDue to the pulling force on the pullstud, the spindle of the ma-chine will expand from elastic deformation when the tool holder taper comes into contact with the machine spindle taper.

Reference data

Spindle taper Pulling force Axial movement

BT40BT50

20 m20 m

800 kg2000 kg

clamping

BIG-PLUSbefore clamping

BIG PLUSafter clamping

Contact

The above pulling force and axial movement are different on each model of machine.

elastic deformation

Axial movement is important for face contact

Space 20 m

100 69.85

Basic holder information

G 25


A

B

C

D

E

F

G

H

Machinedesign

Taper Dimensions, mm

ISO Bkw1 c1 c2 c3 db1 dg dhc dmm D1 D21 D22 lc lb lTh l21 l22 l23 Dth 30 16.1 16.4 19 15 13 7.00 31.75 50 44.3 59.3 47.8 5.5 18.5 3.2 11.1 19.1 M12 ISO 7388/1 40 16.1 22.8 25 18.5 17 7.00 44.45 63.55 56.25 72.35 68.4 8.2 23.8 3.2 11.1 19.1 M16 (DIN 69871A) 45 19.3 29.1 31.3 24 21 7.00 57.15 82.2 75.25 91.35 82.7 10 30 3.2 11.1 19.1 M20 50 25.7 35.5 37.7 30 25 7.00 69.85 97.5 91.25 107.3 101.6 11.5 35.5 3.2 11.1 19.1 M24

DIN 69871B 40 16.1 22.8 25 18.5 17 7.00 54 44.45 63.55 56.25 72.35 68.4 8.2 23.8 3.2 11.1 19.1 M16 50 25.7 35.5 37.7 30 25 7.00 84 69.85 97.5 91.25 107.3 101.6 11.5 35.5 3.2 11.1 19.1 M24 40 16.1 22.8 25 18.5 17 7.00 44.45 63.55 56.25 72.35 68.4 8.2 23.8 1 11.1 19.1 M16 ISO 7388/1 50 25.7 35.5 37.7 30 25 7.00 69.85 97.5 91.25 107.3 101.6 11.5 35.5 1.5 11.1 19.1 M24

Coupling details Coromant Capto Varilock Solid holders HSK

Zero point

Zero point

DIN 69871Form B

Big PlusISO 7388/1

ISO 7388/1(DIN 69871A)

Big Plus

Form B

Zero point

G 26


A

B

C

D

E

F

G

H


ISO Bkw1 c1 db1 dg dmm D1 D21 D22 lc lb lTh l21 l22 l23 l24 Dth

MAS BT 403 30 16.1 16.3 12.5 8.00 31.75 46 38 56.144 48.4 7 17 2 13.6 22 17 M12 40 16.1 22.6 17 10.00 44.45 63 53 75.68 65.4 9 21 2 16.6 27 21 M16 50 25.7 35.4 25 15.00 69.85 100 85 119.02 101.8 13 32 3 23.2 38 31 M24

MAS BT 403 40 16.1 22.6 17 10.00 44.45 63 53 75.68 65.4 9 21 2 16.6 27 21 M16 50 25.7 35.4 25 15.00 69.85 100 85 119.02 101.8 13 32 3 23.2 38 31 M24 40 16.1 22.6 17 10.00 44.45 63 53 75.68 65.4 9 21 1 16.6 27 22 M16 MAS BT 403 50 25.7 35.4 25 15.00 69.85 100 85 119.02 101.8 13 32 1.5 23.2 38 32.5 M24

Zero point

Zero point

Zero point

MAS BT 403

MAS BT 403

MAS BT 403

Form B

BIG-PLUS

Form B

Machinedesign

Taper Dimensions, mm

BIG-PLUS

G 27


A

B

C

D

E

F

G

H


Zero point

Zero point

HSK A/C

DIN 2080

Taper Dimensions, mmMachine design

ISO Bkw1 Bkw2 Bkw3 c1 c2 c3 db1 db2 dg dmm d23

Yamazaki 40 16.4 22.6 25 17 9.5 7 44.45 50 25.7 35.3 37.2 25 9.5 7 69.85

HSK A/C 40 11 9 8 17 12 4 30 50 14 12 10.5 21 15.5 7 38 63 18 16 12.5 26.5 20 7 48 80 20 18 16 34 25 7 60 100 22 20 20 44 31.5 7 75 ISO D1 D21 D22 lb lc lTh l21 l22 l23 l24 Dth

Yamazaki 45 63.55 56.36 72.32 7 68.25 23 3.18 11.1 19.1 0.5 M16 50 98.4 91 107.27 11 101.6 34 3.18 11.1 19.1 0.5 M24

HSK A/C 40 40 34.8 45 16 4 20 24 50 50 43 59.3 20 5 23 31 63 63 55 72.3 25.7 6.3 24.3 32.3 80 80 70 88.8 32 8 26 34 100 100 92 109.75 40 10 30 39 ISO D1 D21 D22 lb lc lTh l21 l22 l23 l24 Th

DIN 2080 40 63 8.2 93.4 23.8 1.6 11.6 M16 45 80 10 106.8 30 3.2 15.2 M20 50 97.5 11.5 126.8 45.5 3.2 15.2 M24

G 28


A

B

C

D

E

F

G

H

Coromant Capto ISO/ MAS HSK

CoroMill modular cutting tools

Slim, but rigid assemblies with accessibility for milling of deep and narrow cavities.Opportunities to optimise the total gauge length of the set-up for best performance in each application.Many tool solutions with minimum number of modules will re-duce inventory costs.Damped milling adaptor for high productivity at extremely long overhangs with no vibration.

Basic holders

Intermediate adaptors

CoroMill cutters

Solid carbide extension

A system of small CoroMill screw type cutters and a variety of shanks for demanding die and mould making.

CoroMill 390 CoroMill 300 CoroMill Ball Nose

Damped milling adaptor

Coromant Capto HSK

Tool set-ups with CoroMill performance

G 29


A

B

C

D

E

F

G

H

Coromant Capto adaptorShank with threaded coupling391.T

Balanced by design


Coromant Capto Damped milling adaptorShank with threaded coupling391.TD

Reduction adaptorShank with threaded coupling391.02T

Extension adaptorShank with threaded coupling391.01T


CoroMill 390 CoroMill 300 CoroMill Ball Nose CoroMill 390 CoroMill 300 CoroMill Ball Nose

Cylindrical solid carbide shank extensionsShank with threaded coupling393.T


Morse taper extensionsShank with threaded coupling393.42T


G 30


A

B

C

D

E

F

G

H

Accurate adjustment makes it easy to manu-facture to tighter tolerances than specied for the

drill larger holes than the nominal drill-diameterSetting is done by turning the scaled ring to de-sired value. The adjustable holder is then locked to set value by tightning screws marked with padlock lables.The scale-zero denotes nominal diameter.

Adjustable holder for rotating Coromant U drills

For ISO 9766 shanksDeveloped for rotating applications

Adjustable in increments of 0.05 mm to nominal diameter + 1.5 mm.

Adjustable Coromant U drill adaptors391.277

l1 = programming lengthNote: Drill should not be adjusted below nominal diameter.

Diametrical adjustment in increments of 0.05 mm: 0.4 +1.4

Coromant Capto

Cassettes with tapered polygon seating for tool handling

Plastic storage cassettes (red)

High grade plastic in-machine tool storage (black)

Aluminium cassette blanks

Active locking mechanismFor storage at all angles: vertical upwards and downwords or horizontal.

Passive locking mechanismFor vertical upwards and horizontal storage. NEVER upside down storage.

-5000

-4000

-6000-B

-PL-01

-AL-01

G 31


A

B

C

D

E

F

G

H

Coromant Capto integrated multi-task machines

Tooling alternatives for stationary tools

Manually operated Coromant Capto clamping units Camshaft activated Screw activated Centre bolt activated

Shank type clamping units Square and round shank tools as well as Coromant

Capto units for external and internal operations

Coromant Capto clamping units for DIN 69880 (VDI) turrets

Angled and straight clamping units for external and internal operations

Hydraulically operated clamping units Manual push-button tool changing

Fully automatic tool changing possible

C

A

B

Conventional turrets

Coromant Capto modular tooling Fully automatic tool changing possible with Coromant

Capto

Modular quick change tooling for turning

C

B

A

G 32


A

B

C

D

E

F

G

H

Coromant Capto system for turning operations

Pioneer of modular quick change toolingSandvik Coromant pioneered the development of modular quick change tooling a large number of machines around the world are equipped by Coromant. Such installations can involve any-thing from a few positions on a single lathe to every cutting tool on all machines in a large workshop.

First universal modular quick-change tooling systemCoromant Capto is a modular quick change tooling system. Based on the experience of the Block Tool System for turning and Varilock for rotating tools, it is designed to be equally effec-tive in all types of machining. It is the rst truly universal modular tooling system for all types of machines.

Quick-changeCoromant Capto offers a wide range of advantages: Shorter downtimes thanks to reduced time for setups. 200 extra productive hours per year is typical in lathes and

turning centres.

ModularityCoromant Capto tools can easily be built together to form a large range of combinations. Tool inventory can be reduced and with it handling and investment costs.

StabilityIncreased productivity thanks to maximum stability. For example, an increase in feed of 0.1 mm/r can give a productivity increase equal to 250 extra machining hours a year.Improved surface nish and tool life hence products with a higher and more consistent quality.

VersatilityThe same tools can be used in other machines giving unique exibility and minimized tool inventory.

The unique tapered polygonThe unique tapered polygon with a ange location face is pre-tensioned in the clamping unit with a clamping force of several tons. The resulting joint is extremely strong with regard to both bending and twisting.The high precision of the coupling ensures a repeatable accuracy of 2 m in the x, y and z axes, for one and the same cutting unit in the same clamping unit.

AccuracyThe need for measuring cuts is all but eliminated thanks to: the excellent repeatable accuracy of the coupling pre-measuring of the cutting units. Elimination of measuring cuts can typically give an increase of 200 productive machining hours a year.The polygon coupling is self-centring which minimizes run-out and always gives the insert correct centre height.

G 33


A

B

C

D

E

F

G

H

Through tool coolantCoolant directly to the cutting edge eliminates downtime due to interruptions for the adjustment of cooling tubes. An effective and consistent supply of coolant also improves insert life.

The basic clamping principleThe clamping system is based on the interplay between a segmented expandable bushing in the clamping unit. Lips on the outer periphery of the segments locked into an inner groove on the cutting unit and locks the two components together.On a few types of clamping units, a centre bolt is used instead of the expandable bushing.

In the unclamped positionWith the drawbar in the forward position, the forward ends of the segmented bushing move towards the centre line of the coupling. The diameter is reduced and the lips on the outer edge of the bushings disconnect from the inner groove of the cutting unit. The drawbar pushes the cutting unit out.

In the clamped positionWith the drawbar in the retracted position, the forward ends of the segmented bushing are forced outwards away from the centre line of the coupling by the shoulder on the drawbar. The lips on the outer edge of the bushings lock into the inner groove of the cutting unit which is pulled into its working position.

G 34


A

B

C

D

E

F

G

H

External cutting units

Extensions/Reductions

Manual and Automatic clamping units

Anti-vibration boring bars

Internal cutting units

Adaptors for turning tools Blanks for turning tools

Turn-Mill centre

Exchangeable cutting heads.

General turning General turning

Threading Threading

Parting/Grooving

Coromant Capto driven toolholders

Multi-task tooling

Shank tools Boring bars

Coromant Capto turning

G 35


A

B

C

D

E

F

G

H

The manual clamping unitsOn manually activated units both drawbars and centre bolt mechanisms are used.

Cam shaft activated drawbarThe movement of the drawbar is generated by a cam acting from the side of the unit which rotates in a slot in the drawbar. A hexagon key is used to lock/unlock the cutting head (less than a half turn is required).

Screw activated drawbarThe movement of the drawbar is controlled by a screw acting from the rear of the unit.A hexagon key is used to lock/unlock the cutting head (one turn is required).

Centre bolt clampingA rear activated centre bolt is used to clamp/unclamp the cut-ting head.A hexagon key is used to lock/unlock the cutting head (six turns are required.)

Shank type clamping units for conventional turretsRound shank units for internal operations:

The 2000 type features Expandable segmented bushing clamp design. Screw activated drawbar.The 3000 type features Centre bolt design. (Budget version.)Installation is simple Both mount in the turret like a standard boring bar.

Shank units for external operations:

Easily adaptable to most machines using 20, 25 or 32 mm square shank tools.The 2085 type features The expandable segmented bushing Cam shaft activated drawbar.Installation is simple Remove the square shank tool and machine wedge. Slide the Coromant Capto 2085 clamping unit into place

and tighten the wedge.These tools feature No special adaptation to tool or turret. Through tool coolant. Minimum overhang allowing maximum working envelope. Same key for clamping external and internal units. Adjustable shank length (cut off if necessary).

Manual clamping units for special applications

The 2090 type clamping unit is designed for special adapta-tion to the machine.

Clamping units for DIN 69880 (VDI) turrets

These tools feature: No special adaptation to tool or turret. Through tool coolant. Minimum overhang allowing maximum working envelope. Same key for clamping external and internal units.

VDI clamping units for external and internal operations

Expandable segmented bushing clamp design. Quick change 1/2 turn to lock/unlock. Same length dimension for corresponding angular ltz and

straight l1z units to avoid risk of collision. Two different l1x dimensions available on angular units.

G 36


A

B

C

D

E

F

G

H

How to choose shank type clamping units 2000, 3000 and 2085

External machining Internal machiningUpper turret

Right hand cutting units

Clamping unit RC2085

Clockwise spindle rotation

Right hand cutting units

Clamping unit NC2000/3000 Upside-down

Clamping unit NC2000/3000

External machining Internal machining

Clamping unit LC2085

Left hand cutting units

Clamping unit LC2085 Upside-down

Anti-clockwise spindle rotation

Clamping unit NC2000/3000 Upside-down

Application guide for type 2000 and 3000A cover plug (CX-CP-01) must be used in a clamping unit when no cutting unit is installed. As can be seen from the diagram and table there is no risk of collision between the workpiece and cover plug during facing operations using clamping unit CX-R/LC 2085.

Clamping unit RC2085 Upside-down

Lower turret

Upper turret

Lower turret

Upper turret

Lower turret Lower turret

Clamping unit NC2000/3000

Upper turret

f1 ltz l1z l23C3-R/LC 2085 22 18 C3-NC2000/3000 18 21C4-R/LC 2085 27 23 C4-NC2000/3000 20 24C5-R/LC 2085 35 32 C5-NC2000/3000 24 29

Cover plug

Clamping unit CX-R/LC 2085

l1l23l1z

l23

ltz

f1

Left hand cutting units

G 37


A

B

C

D

E

F

G

H

Manually operated clamping unitsSquare shank Type 2085

Type 2000

Round shank

Type 3000

Segment clamping Centre bolt clamping

Square shank Type 2080

Right hand style shown. Left hand style reected.

Right hand style shown. Left hand: hexagon clamping socket on opposite side of the tool.

Round shank

G 38


A

B

C

D

E

F

G

H

For special applications

Right hand style shown.

Design instructions for application of clamping unit RC/LC 2090

Material hardness min. 270-HB

Front of clamping unit

Cutting height

Coolant outlet

Tool presence air

Coolant

Air blast inlet

Coolant inlet

Air inlet tool presence system

Air blast

Build-in instructions

Regarding detailed build-in instructions see the "Coromant Capto Hydro-Mechanical clamping unit type 5000 maintenance and service handbook".

G 39


A

B

C

D

E

F

G

H

VDI angled

VDI straight

Hydraulically operated clamping units, type 5000

Min. bore

With probe contact, type 5000Min. bore

G 40


A

B

C

D

E

F

G

H

How to choose VDI clamping units

External machining

Clockwise spindle direction Anti-clockwise spindle direction

Internal machining

Clockwise spindle direction Anti-clockwise spindle direction

Note: Polygon sleeve must be turned 180.




-L -RC

-L

180

-LC

-R

180

180

-RC

-R -LC

-L-LC

-L-RC

180

-R-LC

-R-RC

G 41


A

B

C

D

E

F

G

H

Special

With external coolant supply (type E).

Tool system to be used

Coromant Capto tool system size30 mm40 mm50 mm 60 mm

Shank diameter

Coolant supply

C6

Coromant Capto driven tool holders provide the key to dramatic improvements in machining economy by allowing milling, turn-ing and drilling operations to be carried out in a single setup.

Coromant Capto driven tool holders

VersionStraight Angular

Left hand

Left handRight hand

Right hand

Mounting conguration

Straight, type 1

Angular (), type 2

Angular (+), type 3

Shank specications

DIN 69880 DIN 69881 VDMA ISO

Drive coupling

DIN 1809 DIN 5481 DIN 5482

Specials Specials

Spindle dimensions

machine type and model maximum turret swing diameter maximum tool length

C5C4C3

Compared to conventional driven tool holders, Coromant Capto drastically reduces time lost for tool changing etc., and the time utilized for productive metal cutting increases signicantly.

Various licensed manufacturers of these units are available from Sandvik Coromant and on the Internet.

G 42


A

B

C

D

E

F

G

H

Blanks for production of cutting unitsNR

Coromant Capto blanks have a "soft" front, which allows machining to special shapes.

Equilibrium temperature: 840870C Cooling medium: Polymer Tempering: 1 hour 200C

Note: If localized hardening is required, induction type hardening is to be used. Max. hardness which can be attained with this material 50 HRC.

Adaptor for solid boring bars131

ASHA C6-ASHA-50071-32Adaptors for shank toolsRadial mounting

ASHSASHR/L

ASHR/L3

Axial mounting

Right hand styleNeutral style

Angular mountingAdaptors for shank tools

Coromant Capto adaptors

G 43


A

B

C

D

E

F

G

H

Adaptor for CoroCut and Q-Cut parting blades

For blades with cutting edge height 25 mm type N123xxx-25A2 and 151.2-25-xx

Radial mounting

Axial mounting

Extension adaptor391.01

Short version, for segment clamping only391.01

Reduction adaptor

When Coromant Capto cutting units for turning are mounted on reduction and coolant is required, a separate centre screw has to be ordered.

391.02

Design 1 Design 2

Short version, for segment clamping only391.02

For blades with cutting edge height 25 mm type N123xxx-25A2 and 151.2-25-xx

G 44


A

B

C

D

E

F

G

H

How to adopt a modular tooling systemA system can be adopted either through retro-tting machines or as part of the equipment in new machinery. The following checklist provides a guide to the most important factors when adopting a modular tool system.

- make sure that real universality provided for today as well as tomorrow, to utilize exibility and rationalizing the potentials in handling and inventory.

- invest in a system that, without any compromises, can be used for any type of machining operation, stationary tools as well as rotating tools

- ensure that the system is suitable for all foreseeable machine tool types and machining requirements

- make sure of the best stability and repeatability in the system and for tools not to be limited by any operational demands

- check for best function as regards manual and automatic tool changing, storing, handling, administrating and coding

- establish values for built-in safety margins, especially for heavy-duty applications

- test for effect on workpiece quality

- determine elimination of measuring cuts

- have quick-changing facility of tools as high priority when manual tool changing is involved. Modular systems vary in speed and complexity which will affect the practical utiliza-tion of the system and the ability to reap benets of higher productivity and rationalization

- choose a system that provides coolant through the tools as the standard method. This is often a crucial requirement in those operations needing swarf removal and cutting uid to be directed to the right spots on the tooling

- select a system from a supplier, who can provide technical support, a sufciently broad program of products today and for future needs and who can provide application support of machine tool investments as well as improving exisiting applications.

Effect on component quality.

Facility for coolant supply through tooling.

Equally suitable for rotating and non-rotating tools.

G 45


A

B

C

D

E

F

G

H

CoroGrip and HydroGrip tool chucksThese chucks are hydro-mechanical and hydraulic chucks respectively, for holding endmills and drills. Characterized by high clamping strength, precision and stability the CorGrip chuck uses hydraulic pres-sure to actuate the mechanical clamping function, thereby providing unique tool holding capability. The HydroGrip chuck uses hydraulics as the clamping means. As good stability is the rst pre-condition of any machining operation, these chucks provide a reliable basis for continued op-timization.

For precision to prevail in a machining op-eration with rotating tools, radial run-out, bending strength, torque transmission and balance for high spindle speeds are essential factors. There are several tool holding methods that have been devel-oped through the years, involving various collet chucks, hydraulic chucks, shrink t holders, etc. and all have advantages and disadvantages. The CoroGrip and Hy-drogrip chucks have been developed so as to provide an improvement on what these have to offer. The bench-mark be-ing to provide chucks that give the best of what all these have to offer.

Machining in many industrial applica-tions depends upon good tool holding and with the evolvement of high speed machining, tool holding is increasingly being focused as a key factor. Providing tools with optimum stability by being as close to the rotating tool-spindle inter-face as possible is often a determening factor as is the ability to provide high

stability of long reach tools into or past components being machined.

Tool-life of cutting tools is, in most cases, directly related to the amount of run-out of cutting edges in relation to the centre-line of rotation. Hundredths of a mm have a profound effect on how cutting edges will last during machin-ing. In nishing operations with solid cemended carbide tools, the effect is es-pecially marked. The level of precision in tool holding is therefore critical not only to the resulting component quality but also the predictability and reliability of tool performance.

High clamping forces in tool-holding de-termine how secure the cutting tool is held and torque transmitted during ma-chining. As cutting forces act on the tool, the tool will tend to slip in the holder. The capability of the tool holder can then be related to how tight the tool-shank is clamped.

As spindle speeds tend to rise, balanc-ing becomes a critical factor. Centrifu-gal forces will act on tool holder and cutting tool, trying to make use of any im-balance to create vibrations. Individually balanced tool holders are critical when spindle speeds approach those of high speed machining.

Run-out effect on tool-life.

Clamping force determines torque transmission.

Higher speeds need more balancing.

vc

G 46


A

B

C

D

E

F

G

H

Hydro-mechanical and hydraulic precision chucksThe CoroGrip hydro-mechanical precision chuck programme provides all-round tool chucks for milling and drilling performing nishing to roughing operations. The tool shanks that can be clamped range from 6 to 32 mm in diameter, with slitted col-let options of down to 3 mm. All types of shanks can be clamped and the chucks are available for most tool holding sys-tems. CoroGrip chucks provide a large amount of application exibility also by being available in a normal (HMD) and

A pencil-type chuck provides slender tool reach into and past components. The tool shank capacity is 6 to 32 mm diam-eters with collet options down to 3 mm. Both the CoroGrip and HydroGrip chucks are individually balanced with spindle speed capabilities up to 25.000 rpm - depending upon size and tool holding system. The CoroGrip and HydroGrip chucks are individually numbered, bal-anced and certied as regards run-out values minimum torque transmission and unbalanced values in gmm.

short (HMS) version as well as a long, slender plain parallel shank version. The clamping function is actuated by hydrau-lic pressure acting on a wedge-type me-chanical tool-gripping method.

The HydroGrip hydraulic precison chuck has a different mechanism, which ac-tuates the tool gripping through the pressure acting on a membrane that envelopes the tool shank. The HydroG-rip chuck (CG) provides a lower torque transmission value than the CoroGrip chuck, which makes it suitable for nish-ing to medium-duty operations in milling as well as all types of drilling operations.

CoroGrip HMD CoroGrip HMSCoroGrip parallel shank

HydroGrip CG HydroGrip pencil chucks

G 47


A

B

C

D

E

F

G

H

CoroGripThe CoroGrip chuck is continually being and the most recent version is character-ized by high reliability and accuracy, with runouts of a few microns. A larger axial face support and chuck diameter pro-vides bending stiffness that has been in-creased ten-fold. The bending stiffness is especially important in preventing tools from climbing out of the chuck during machining. The tool clamping and releas-ing functions are simple using a pump-handle and operating a valve-handle.

On the HMD chucks the chuck overhang is smaller compared to many other so-lutions, while on the HMS chucks, the overhang has been kept to an absolute minimum. The distance is shorter from spindle bearings to chuck-face, with in-creased stiffness and resistance to side forces. This leads to longer tool exten-sions being possible and for higher cut-ting data to be considered.

The clamping force of Corogrip chucks is extremely high with precision values on the same level. The CoroGrip chuck is also less dependent upon the tool-shank tolerances, with shank tolerances of h7 being clamped satisfactorily.

Recommended maximum spindle speeds are specied for each chuck type and size. The high clamping forces in com-bination with the precision and balanc-ing, provide possibilities for high speed machining.

The use of collets in CoroGrip chucks inuences the level of torque transmis-sion possible. In the example, a cutting tool with a shank diameter of 12 mm

CoroGrip torque transmission by spindle speed(Tool shank tolerance h6)

Spindle speed rpm

Torque (Nm)

Shank diameter, dmt

10000

1000

100

10

10 20 000 40 000 60 000 80 000 100 000 120 000 140 000

12

20

25

32

is clamped directly in the chuck and alternatively in a 20 mm chuck with a reduction collet to 12 mm. The torque transmission is improved with the collet clamping. However, the use of collets will add a couple of microns to the run-out of the chuck.

Chuck overhang difference. Clamping and unclamping of tools in the chucks.

l1

D21 D21

l1

G 48


A

B

C

D

E

F

G

H

Capacity values for CoroGrip and Hydrogrip chucks

CoroGripMinimum torque-transmission required for machining

Material : low-alloy steel (CMC02.2) Operation : full slot milling Tool : CoroMill 390 indexable insert endmillTorque values in Nm

Diameter: mm 12 12 16 16 20 20 25 25 32 32 Rough Light Rough Light Rough Light Rough Light Rough Lightfz 0.2 0.15 0.2 0.15 0.2 0.15 0.35 0.15 0.35 0.15ap 10 10 10 10 10 10 15.7 15.7 15.7 15.71 insert 13 10 x x x x x x x x2 inserts x x 34 27 43 34 127 67 163 863 inserts x x x x 64 52 191 101 244 129

Diameter mm / ap 12 / 12 16 / 16 20 / 20 25 / 25Z fz / Nm 2 0.035 / 6,5 0.059 / 18 0.083 / 36 -3 * 0.072 / 5 0.047 / 18 0.063 / 35 -4 0.034 / 9 0.054 / 24 0.078 / 50 0.055 / 79 * 12 / 4

Bore with reduction sleeves mm Bore 12 16 20 25 32mm Nm 12 60 - - - -16 94 155 - - -20 195 260 365 - -25 273 373 473 670 -32 290 387 471 681 1220

Bore mm 500 bar6 1312 6016 15520 36525 67032 1220

Tool : CoroMill Plura solid carbide endmill

Operation : drillingTool : CoroDrill Delta C solid carbide drill

Torque at direct clamping in chuck

Torque increase with reduction sleeve

Diameter: mm 6 8 10 12 16 20 fn 0.25 0.38 0.38 0.44 0.5 0.5 Nm 4.1 10 16 25 50 78 Normal Torque Nm 8.2 20 32 50 100 156 Peak torque at chipjamming

For rough machining and/or using demanding cutting data, it is recommended to consider the option of using a large enough chuck that will allow the use of a collet. The larger chuck will improve stability and the use of a collet considerably increases the clamping power on the tool shank. The clamping power of the chuck is applied on a larger area than that of the inner di-ameter of the collet and this provides an increase per area-unit on the shank of the tool.

G 49


A

B

C

D

E

F

G

H

Bore Clamping length X number of diameter Minmm 1.00 1.25 1.50 1.75 2.00 length6 3 4 5 7 8 1812 28 38 48 58 60 21.516 74 100 126 152 155 28.520 170 231 292 353 365 3625 322 433 545 657 670 44.532 610 813 1017 1220 1220 56

Bore with reduction sleeves mmBore 12 20 25 32mm Nm 12 60 - - - 20 95 260 - -25 140 235 480 -32 190 350 520 820

Bore mm Torque Nm12 6020 26025 48032 820

Bore Clamping length X number of diameter Minmm 1.00 1.50 2.00 2.50 3.00 length12 5 15 25 40 60 3520 45 100 175 260 260 46.525 110 235 440 480 480 50.532 260 585 820 820 820 53.5

Minimum torque-transmission at different tool clamping lengths

Torque at direct clamping in chuck

HydroGrip

Torque increase with reduction sleeve

Minimum torque-transmission at different tool clamping lengths

12

20

12

G 50


A

B

C

D

E

F

G

H

Valve handle in position T for entering and releasing of tool.

Valve handle in position T after clamping of the tool.

Pump and valve handles in position A for clamping.

Pump and valve handles in position B for releasing

CoroGrip provides a safe grip in all applications from nishing to roughingExtremely high torque transmission capability prevents the tool from slipping. This also applies to roughing operations, and as the mechanism is self-locking, no hydraulic pressure is retained in the mechanism during machining. The clamping force remains consistent both during the entire operation and over long term use.

The CoroGrip chucks are manufactured with close tolerances, resulting in a maximum run out at the cutting edge of only 0.002 - 0.006 mm - measured at a length of three times the tool diameter. The run out is consistently maintained through-out its extensive operation, enhancing tool-life and component quality.

All types of cutting tools with cylindrical, Whistle Notch or Weld-on shanks are safely retained in the CoroGrip chuck even if the shank is only clamped along half of its length. Many shanks can be clamped directly into the holder with or without any collets.

G 51


A

B

C

D

E

F

G

H

The CoroGrip pencil collet allows an extended reach for long overhangs such as in die and mould applications. Available in a 20 mm outer diameter, the collet can accept four different sizes of tool shank: 6, 8, 10 and 12 mm.Using the CoroGrip pencil collet gives a three-fold advantage: Machining in cavities and pockets with improved productivity No compromise in stability with improved bending stiffness. Improved tool-lifeA laser marking on the collet indicates the maximum recommend-ed protrusion for undiminished clamping force. This positioning should never be exceeded.

Tool change can take place in less than 20 seconds. The high clamping force required for the CoroGrip system is generated by an external hydraulic pump. This provides a pressure of 500 bar for operating the clamping and up to 800 bar for the releas-ing mechanisms. As the mechanism is self-locking, no hydrau-lic pressure is retained during machining.Two different hydraulic pumps are avalable for changing tools in the CoroGrip holder - a manual hand pump and a pneumatic motor driven pump. The latter uses the regular pneumatic air available in the machine shop (min. 6 bar required). By using either of these pumps, tool changing is ergonomically and eas-ily performed in less than 20 seconds - and the same gripping force is always applied to the tool shank.

Extended reach

Also pre-setting of the tool is an easy operation with the Coro-Grip concept. By using an optical reader, and depending on its accuracy, the tool length can be set within +/- 3-5 microns. The tool is guaranteed to maintain its axial position during the whole clamping process.

Easy handling

Pre-setting

CoroGrip pencil collet.

Pumps for achieving clamping high pressure in chucks.

Precision setting of tools in chucks.

G 52


A

B

C

D

E

F

G

H

The HydroGrip chuck is a complementary chuck to CoroGrip and comparable to the CoroGrip chucks as regards accuracy and handling. This provides ample tool clamp-ing strength for all drilling and some 80% of milling operations and where machin-ing space is unlimited. Compared to col-let chucks and Weldon and Whistle Notch adaptors, where run-out values are meas-ured in hundredths of a mm, the CoroGrip and HydroGrip chucks provide run-out val-ues that are measured in microns.

The Hydrogrip pencil chucks provide a combination of reach and stability for nar-row-space operations, such as often found in die and mould cavity machining, but also when tools have to reach past and close to a shoulder in many other applications. In-dividual balancing provides very high qual-ity machining results.

The range of short, medium and long reach pencil chucks provide the best choice for applications depending upon reach de-mands but also has different limitations on the maximum spindle speed capability. Maximum spindle speeds are recommend-ed for each chuck type and size.

HydroGrip pencil chucks represent a slen-der tool holder, developed to reach into and past component or xture obstacles. Many complex components or those with cavities require long reach tooling to per-form narrow-space operations. Clamping of tools in the Hydrogrip chuck is performed from the rear of the holder. It is a precision chuck and should be combined with other precision chucks such as the Corogrip and Hydrogrip. One of the main features then is the possibility to adjust the length and thereby the tool overhang.

Chucks are individually balanced and avail-able in three different types to suit ex-tension requirments: short, medium and long for medium-, light- and very light-duty machining, respectively, and with spindle speed maximums of 25.000, 15.000 and 10.000 respectively. The longer the chuck, the lower the cutting data for milling opera-tions, while for drilling normal cutting data can be used. Positive cutting action tooling contributes towards satisfactory perform-ance as does a good centre point geom-etry for drilling.

HydroGrip

Milling: Medium duty Light Very lightDrilling: Normal data Normal data Normal data Max RPM: 25.000 15.000 10.000

Application ranges:

HydroGrip chucks.

0.02 - 0.04 mm

Weldon/Whistle Notch

0.01 - 0.03 mm

Hydro-Grip/CoroGrip

0.002 - 0.005 mm

G 53


A

B

C

D

E

F

G

H

The run-out at the front of the chuck is less than 3 m.At a distance of 4 tool diameter from the front, the run-out is less than 10 m.With each chuck an individual measuring report is enclosed, which contains:- radial run-out at the front of the chuck- radial run-out at a distance of 4 d from the front- measured clamping power (Nm)

The clamping power of HydroGrip is several times that of con-ventional chucks. The chuck is capable of spindle speeds of up to 25.000 rpm. depending on type.

Axial tool stop can be provided as the hole through the taper is threaded in the front end. In this hole a M8 screw can be insert-ed to act as tool stop. When cutting uid is required through the ange, the screw will act as a spindle seal. If cutting uid is required through the spindle, a 3.5 mm dia hole should be drilled through the screw.

Dia. 3.5 mm

M8

Note!For hydroGrip, 6 mm diameter chuck.Never tighten the pressure screw without having a tool with the right shank diameter and style in the chuck.Direct clamping without collet is only permitted with cylindrical shanks.

Minimum clamping length

Max. 3 mm

- accuracy- clamping force- rotating speed- handling- Versatility

HydroGrip satises high demands regarding:

G 54


A

B

C

D

E

F

G

H

Individually balanced, Taper 40. G2.5 at 25 000 rpm Taper 50. G2.5 at 14 000 rpm

CoroGripPrecision Power ChuckShort design392.140HMS/ .55HMS

392.140HMS

392.55HMS

CoroGripPrecision Power ChuckCoromant Capto391.HMD

Individually balanced, C3, C4, C5 and C6, G2.5 at 25 000 rpm C8, G2.5 at 14 000 rpm

Individually balanced, G2.5 at 25 000 rpm

CoroGrip chuck extensionPlain parallel shank393.HMD

Individually balanced, 63-A/C, G2.5 at 25 000 rpm 100-A/C, G2.5 at 14 000 rpm

CoroGripPrecision Power ChuckHSK form A/C392.410HMD

Note: Hole for data carrier is not standard.

CoroGrip range

G 55


A

B

C

D

E

F

G

H

Individually balanced, G2.5 at 25 000 rpm

CoroGripPrecision Power ChuckHSK form E392.417HMD

CoroGripPrecision Power Chuck392.272HMD/ .55HMD/ .369HMD

Individually balanced, Taper 40, G2.5 at 25 000 rpm Taper 50, G2.5 at 14 000 rpm

CoroGripPencil collet393.CGP

Max recommended protrusion

Cylindrical collets for CoroGrip and HydroGripSlitted393.CG

Sealed 393.CGS

G 56


A

B

C

D

E

F

G

H

Coromant HydroGripHigh precision chuck adaptorCoromant CaptoShort version391.CGA

lc2 = Min clamping length, l1 = programming length

Coromant pencil HydroGripHigh precision chuckCoromant Capto391.CGB


Design ADesign B

Design C

dmt 6 32

16 32

Dimen-sions, mm

Handle

Hand pump*Manual switch with pressure gauge included.

Ordering code: 391.HPUMP-01

Pneumatic bench pump*

Manual switch with pressure gauge included.

Ordering code: 391.BPUMP-02

Hydralic pump equipment CoroGrip

* Operating pressure: Unclamp up to 800 bar, Clamping 500 bar

HydroGrip range

G 57


A

B

C

D

E

F

G

H

l1 = programming lengthPrebalanced

Coromant pencil HydroGripHigh precision chuckCylindrical shank393.CGA

Prebalanced

Coromant HydroGripHigh precision chuck392.140CG/ .272CG/ .55CG/ .00CG

Coromant HydroGripHigh precision chuck adaptorHSKShort version392.410CGA


Coromant pencil HydroGripHigh precision chuckHSK392.410CGB

Design B

Design A


G 58


A

B

C

D

E

F

G

H

Individual balanced tool chucks for High Speed Machining

1. Low run-out. A rule of thumb is that the tool life decreases by 50 % if the run-out is increased by 0.01 mm.

2. High clamping force. Both tool and component can be destroyed if the tool is moving in the holder during machining. Many holding concepts can not be used at high rpm due to the fact that the centrifugal forces reduce the transmittable torque to unacceptable levels.

3. Balanced holders. Too much imbalance creates vibrations which can have poor inuence on tool performance and spin-dle life.

For spindle speeds over 15000, individually balanced holders are recommended.All CoroGrip high precision power chucks are individually balanced to a quality of G 2.5 at 25000 rpm for small sizes (Taper 40, HSK 32-40-50-63, Coromant Capto C3-C6), and G 2.5 at 14000 rpm for larger sizes (Taper 50, HSK 100, Coro-mant Capto C8). All tools for use with CoroGrip are required to be symmetrical and well balanced.CoroGrip also fulls demands when it comes to excellent run-out and high clamping force. Due to the very high clamping force it is possible to clamp tool shanks with h7 tolerances, which is not recommended for shrink t holders.

Note!The CoroGrip chuck is individually balanced to specied balance quality levels. But an unbalanced tool, collet or retention stud will inuence the total balance of the assembly. Complemen-tary balancing can be required for very high speeds.

Low run-out gives high precision.

High clamping forces gives high transmission torque capability.

Balanced holders needed for high rpm.

Individually balanced

1.

390

1.5

2.

3.

C5-391.HMD-20 070 4

Modern machines and tools have greater demands on tool holders. Particulary if cemented carbide endmills and drills are used at very high speeds, where a very low run-out is required to achive long tool life.CoroGrip and HydroGrip fulll all the de-mands on a tool holder for HSM.Three requirements have to be fullled when using holders with cemented carbide endmills or drills at high speed

G 59


A

B

C

D

E

F

G

H

All rules and regulations valid for the system stand itself must be observed and respected. The oor space dimensions must be checked before the system is installed in order to be able to secure the operation for the personnel as well as for the sys-tem itself. The high pressure hand pump must be assembled in a way that a safe and durable operation is guaranteed. All exposed parts and hoses have to be assembled in such a way that there is no injury risk. Only specially trained instructors are allowed to assemble, commission and store the system.

Hand pump System InstallationThe system should be put and operated onto a horizontal oor/basis. Also, the system has been built to be used in rooms which are not exposed to the effects of the weather.The storage of the system in an aggressive and excessively moist surrounding or out of doors can lead to corrosion or other forms of damage for which we cannot accept any liability.

High precision power chuck with assembled handle High pressure hand pump

Handle

Reversing valve

The handle has to be positioned in a way that the marked connections A and B match with the marks of the precision power chuck.

Use the sleeve to x the handle hand-tight. The nozzles are pushed automatically onto the chuck by means of hydraulic pressure.

Insert the tool into the chuck. Put the reversing valve to position A. Use the high pressure hand pump until the hydraulic pres-

sure of 500 bar is reached.

Clamping a Tool

Put the reversing valve into position T. The hydraulic pressure now descends to zero bar.

Take the handle off the chuck. The chuck is now ready to be implemented into the tooling

machine.

Elements of Operation hand pump

Handle HMD or HMS

Note!More information is given in the Operating Manual and Short Users Guide.


Sleeve

Pressure gauge

Pump lever

Reversing valve

G 60


A

B

C

D

E

F

G

H

If problems should occur hand pump

Fault

High pressure hand pump has very little or no pressure

Tool can not be clamped

Tool can not be unclamped

Possible causes

Oil level too low (hydraulic)

Leakage

Soiled oil

Wrong position of reversing valve


Wrong mounting of the handle onto the power chuck

Check if valve of power chuck is broken



Check if valve of power chuck is broken

Elimination

Top up until the oil level window shows half full

Check and if necessary change hoses and ttings

Clean tank, rell with new, ltered oil and release air

Reset valve into position A or B

Put valve into position A

Marks of the handle must be identical with the ones of the chuck

Check power chuck

Put valve into position B


Check power chuck

G 61


A

B

C

D

E

F

G

H

Dos and donts CoroGrip pumpsDos

Donts

Work in accordance with the operating manualShort user guide for hand pumpShort user guide for B-pump

- Assemble the handle onto connector A + B correctly. Dont screw only half way! (The connectors have a valve inside which opens only if the connection is 100% perfect.)

- Dont damage the nozzles or the inlet shape when assembling the handle on the chuck!

- Dont mix up connectors A with B as clamping will result in 800 bar.

- Dont pump too fast with the hand-operated pump when reaching the maximum clamping pressure! The over pressure valve works with a tight tolerance when working with lower speed (no peaks!).

- Dont work with dirty oil!

- Dont store the handle in a dirty place or or where the nozzles could get damaged!

- Dont bend the hoses to excess as the handles have special high pressure hoses which are still exible at 800 bar even with the protection safety hose.

- Dont kink the hose! The hose will break when kinked.

- Dont leave the pump under pressure! After clamping and unclamping always release the pressure by switching the reversing valve to T (neutral position).

- Dont take the handle off the chuck before you have released the pressure!

- Dont work with a handle on which the cup protection is missing!

- Dont forget: The maximum recommended clamping pressure is 500 bar.

Start up/Operating instructionsStart up/Operating instructions

G 62


A

B

C

D

E

F

G

H

Bench pump System installationAll installation an operating instructions for the system stand must be adhered to. The oor space dimensions must be ob-served before the system is installed, in order to ensure com-plete safety for both personnel and the system itself.

The high-pressure pump must be assembled in a way that a safe and durable opera-tion is guaranteed. All exposed parts and hoses have to be assembled in such a way that there is no risk of injury. Only specially trained personnel are allowed to assemble, commission and store the system.

To operate the system it must be positioned on a at and hori-zontal surface. The system has also to be used in conditions which are not exposed to effects of the weather.

The storage of the system in an aggressive and excessively moist surroundings or out of doors can lead to corrosion or other forms of damage, for which we cannot except responsibility.

Pneumatic High Pressure Pump

Reversing valve

High precision power chuck with assembled handle (not in-cluded in scope of delivery, has to be ordered separately)

Elements of operating bench pump

Push button for vacuum function

Reversing valve with pres-sure gauge for hydraulic pressure

Pressure gauge showing pneumatic pressure

Regulation of pneu-matic pressure control valve to adjust the unclamping pres-sure of 800 bar.

Pull the regulation knob to change the pressure

increase pressurereduce pressure

Regulation of the pneumatic pressure control valve to adjust the clamping pres-sure of 500 bar.

Pull the regulation knob to change the pressure

increase pressurereduce pressure


G 63


A

B

C

D

E

F

G

H

If problems should occur bench pump

Fault

High-pressure pump does not start

High-pressure pump produces little or no pres-sure

High pressure pump doesnt stop

Tool can not be clamped

Tool can not be unclamped

Possible causes

No air pressure

Safety coupling is not properly connected

Contaminated maintenance unit

Pressure control valve: clamping misad-justed

Pressure control valve: unclamping misadjusted

Oil level too low (hydraulic)

Contaminated maintenance unit

Leakage

Soiled oil

Dirty oil lter

Not enough air pressure


Pneumatic tripping valve (assembled on reversing valve) is clamped



Damaged precision power chuck



Elimination

Control air pressure supply

Connect safety coupling properly

Clean or exchange lter

Adjust the pressure control valve to 3.5 bar (rising) to get 500 bar hydraulic pressure

Adjust the pressure control valve to 5.6 bar (rising) to get 800 bar hydraulic pressure

Top up oil up to max. level

Clean or exchange lter

Controlling of hoses and ttings

Clean tank, rell with new, ltered oil and release the air

Clean oil lter

Check air pressure net

Reset valve into position A or B

Check pneumatic tripping valve

Put valve into position A


Check power chuck

Put valve into position B


G 64


A

B

C

D

E

F

G

H

Clamping a tool The handle has to be positioned in a way that the marked con-

nections A and B match with the marks of the precision power chuck.

Use the sleeve (handle screw) to x the handle onto the power precision chuck hand-tight. The nozzles are pushed automati-cally onto the chuck (hydraulic pressure).

Insert the tool into the chuck.

Switch the reversing valve to A. The pneumatic high-pressure pump starts automatically and pumps until the dened clamp-ing pressure of 500 bar on the power precision chuck has been reached.

Switch the reversing valve into position T. The hydraulic pres-sure now de-scends to 0 bar.

Press the push button for the vacuum function during about 10 seconds to pro-duce a vacuum in the high pressure hoses.

Take the handle off the chuck.

The tool is now ready to be put into the machine tool.

Unclamping a tool.

Sleeve (Handle screw)


G 65


A

B

C

D

E

F

G

H

CoroGrip and HydroGrip chuck handling hints

- Before inserting the tool-shank, always make sure that the shank is undamaged, holds the correct dimensions and is clean especially the bore of the chuck.

- If possible, insert the tool-shank all the way. The transmit-table torque will be reduced in relation to the reduction of in-stick.

- When storing the chuck, protect it against corrosion by spraying it with oil.

- Never use excessive force when trying to insert a tool-shank into the chuck.

- These chucks are precision tool holders and should be handled with care.

- The chucks should never be heated to temperatures to above 75 degrades C (167 degrades F). (This to make sure the sealings are not damaged).

CoroGrip

- Do not exceed 500 bars in clamping pressure in the CoroGrip chuck as this can result in the chuck jamming. If more clamping pressure is needed, consider using a larger chuck with reduction sleeves.

HydroGrip

- On the HydroGrip chuck, tighten the pressurizing screw to the stop by using the recommended wrench.

- Keep the HydroGrip chuck in vertical position and turn the cutter slightly when tightening the pressurizing screw. (This to achieve the very best accuracy.)

- If, in the HydroGrip chuck, a correctly, dimensioned, tool-shank is not clamped when the bottom position is very close - less than a turn - the chuck is in need of service.

- Never use the HydroGrip chuck in an environment where temperatures exceed 50 degrades C (120 degrades F). (This may increase the internal pressure of the chuck and affect it negatively.)

- Never remove the pressurizing screw on the HydroGrip chuck. Untightening by a few turns is enough to release the tool.

- Never turn the small (M6) air-release screw on the Hydro-Grip chuck as this will make the chuck unfunctionable.

G 66


A

B

C

D

E

F

G

H

MAINPAGEHELPSEARCHMain Catalogue(A) General TurningChoosing tools and insertsInsertsOverviewCode keyT-Max P, negative basic-shape insertsCoroTurn 107/111, positive basic-shape insertsInserts for advanced cutting materials

External machiningOverviewCode keyCoroTurn RC rigid clampingT-Max P lever clampingCoroTurn 107 screw clampingCoroturn RC rigid clamping for ceramics and CBN insertsCoroTurn 107 screw clamping, for small part machining

Internal machiningOverviewCode keyCoroTurn RC rigid clampingT-Max P lever clampingCoroTurn 107/111 screw clampingBoring bars for medicalCoroturn SL cutting heads and boring barsCoroTurn SL quick change cutting heads and boring barsCoroTurn XS boring bars and inserts for small part machiningEasyFix sleeves for cylindrical bars

Build-in toolsOverviewCode keyCoroTurn RC rigid clampingT-Max P lever clampingCoroTurn 107 screw clamping

Spare partsExternal machining - Shank tools and Coromant Capto unitsHolders for negative basic-shape insertsCoroTurn RC rigid clampT-Max P leverT-Max P screw and top clampT-Max P wedge clamp

Holders for positive basic-shape insertsCoroTurn 107 screw clamp

Holders for ceramic insertsCoroTurn RC rigid clampT-Max top clamp

Internal machining - Shank tools and Coromant Capto unitsBoring bars for negative basic-shape insertsCoroTurn RC rigid clampT-Max P leverT-Max P screw and top clampT-Max P wedge clamp

Boring bars for positive basic-shape insertsCoroTurn 107 screw clampCoroTurn 111 screw clamp

Boring bars for ceramic insertsT-Max top clamp

CoroTurn SL - Cutting heads and boring barsCutting heads for negative basic-shape insertsCoroTurn RC rigid clampT-Max P lever

Cutting heads for positive basic-shape insertsCoroTurn 111 screw clampCoroTurn 107 screw clamp

Boring bars and adaptorsBoring type 570-2C and 570-3CReduction adaptorCoroPlex SL mini-turret

CoroTurn SL quick changeBoring bars and adaptorsBoring bar580 Boring bar adaptorAdaptor for CoroTurn SL cutting headsAdaptor for square shank tools

Build-in toolsCartridges for negative basic-shape insertsCoroTurn RC rigid clampT-Max P Lever clampT-Max P wedge clamp

Cartridges for positive basic-shape insertsCoroTurn 107 screw clampRound shank boring tools, screw clamp

Cutting dataCutting depth and feed recommendationsCutting speed recommendations

Grade descriptionsTools for small part machining overviewCoroTurn SL (570) system overviewTools for multi-task machining overview

(B) Parting And GroovingChoosing tools and insertsInsert overviewInsert geometriesTool holders, overview

CoroCut 1- and 2-edgeCode keyInsertsExternal toolsInternal tools

Date post:	01-Oct-2015
Category:	Documents
Upload:	edsareg
View:	269 times
Download:	9 times

G - Tool Holding Systems

Documents