Demonstrations of improved efficiency and accuracy at EMO

Visitors will be able to see first-hand the latest innovations, including Blue Photon, CARVEsmart, Jato Precision and Orange Vice, with Leader’s stand hosting static and dynamic demonstrations of the improved efficiency and accuracy available from all three of these pioneering technology providers.

Blue Photon is an innovative photo-activated adhesive method of workpiece clamping that offers engineers the opportunity to take a fresh look at challenging applications. Managing Director, Mark Jones, explained: “The concept of using Ultraviolet (blue) light to activate and create a high-performance adhesive reaction is not new, the dental industry has successfully used it for many years. However, its application within the manufacturing industry sectors does offer many key advantages.

“The adhesive workholding technology is the perfect solution for holding delicate workpieces that are prone to distortion in the machining process. Parts such as large, thin rings and turbine blades are easily held in place with Blue Photon without the distortion that is caused with many other workholding methods. Eliminating the need to reposition clamps or relying on operators to ‘gently’ clamp the part can be eliminated.”

On show at EMO will be the ground-breaking Universal Fixture Kit that allows workshops to begin using this novel fixturing technology immediately by easily adapting to most parts. It offers the ability to access 5- and 6-sides on any hard-to-hold part. And, this kit is simple to implement on existing machine tools including Turning to Grinding and EDM to Additive Manufacturing; it also has the capacity to hold parts for the heavy milling or high-performance machining strategies of many materials including titanium and superalloys.

Globally renowned for collet-type workholding and diaphragm chucks, the Jato Precision range has decades of experience covering workpieces mounted on almost every machine tool type and for a vast array of engineering materials. At EMO the spotlight will be on the ability of its rotary, static and 3-jaw diaphragm chucks. Offering high repeatability of concentricity, as well as low and adjustable clamping forces for efficiently loading and unloading fragile and thin-walled components, examples of Leader’s extensive Jato range will be on display.

Mark Jones points out why a diaphragm chuck might be preferred to a standard three-jaw or pull-down chuck for high precision turning: “The two major advantages of a diaphragm chuck are accuracy and consistency of the clamping force. Since there are no sliding parts in the diaphragm chuck, the accuracy is directly related to the consistent deformation of the diaphragm. This chuck relies completely on the diaphragm for opening and closing of the jaws. In a standard chuck there is a compound tolerance accumulation between the wedge, master jaws, and the chuck body. The centring accuracy of the diaphragm chuck is very important for high precision parts, it maintains the concentric relationship between the pitch line of the component and the machined centre bore.

“The diaphragm creates another great advantage in maintaining consistent clamping force. The absence of sliding parts means diaphragm chucks need no lubrication. Standard chucks gradually lose gripping force between lubrications. The grip force for standard chucks is constantly changing, creating varying dynamic conditions. Diaphragm chucks eliminate this problem by relying on the elasticity of the diaphragm.”

Many companies are surprised by how quickly the chuck can be changed. The workpiece specific clamping set, comprising jaws, workpiece location stops, maybe pneumatic part detection and coolant or air blast for clearing chips, can be changed in about one minute. The jaws and the part locator can be changed in about three minutes. Once an initial set-up of the chuck has been carried out to ‘dial in’ the jaws it will never need to be repeated.

Leader’s Orange Vice was launched in 2012 with the ethos of ‘perpetual innovation of CNC workholding’. EMO 2019 will witness the launch of its latest line, Orange Delta IV compact vices and zero-point subplates for use in multi-axis and high-density milling set ups.  

The Patent-pending Orange Delta IV Compact vices feature a small 150 by 100 mm footprint and an integral zero-point interface, cross compatible with the company’s proprietary locating systems, as well as 52 mm pull stud interfaces from other brands. Unlike self-centring vices common in the industry, the Orange Delta IV uses a unique serrated design that combines the best of self-centring vices and serrated fixtures, along with industry-leading gripping performance.

Orange Delta IV Compact vices and Zero-Point subplates are cost-effectively priced. “With the CNC machining industry currently trending towards palletized automation with large numbers of pallets, the need for reasonably-priced workholding becomes increasingly important,” states Mark Jones. 

Alongside the new Orange Delta IV, Leader will be demonstrating a range of high-quality Orange machining vices that feature, as standard, the CARVEsmart quick-change vice jaw system featuring QC dovetailed jaw technology.

CARVEsmart dovetail and clamp features are machined directly into the Orange Integrated Jaw System (IJS) vice, eliminating the need for master jaws. This saves 38 mm of opening. The 152 mm Orange IJS vice accepts all CARVEsmart dovetailed jaws. The fully machinable jaws result in a larger machinable workholding zone that permits holding larger parts deeper into the jaws of the vice for better performance.

The patented CARVEsmart system is designed for production and toolroom applications replacing the often cumbersome, conventional method of attaching vice jaws to a vice. Dovetailed jaw changes are fast and easy with the ‘from the top’ clamping system.

The clamp assembly pulls dovetailed jaws tightly into two axes, while a SMARTstop pin locates the jaw accurately in the third axis promising +/- 7.5µ relocation. The SMARTstop slot and pin is integral to the dovetail, allowing vices to be mounted side-by-side.

“We are A1 at EMO, and as well as the ranges demonstrated on our stand,” said Jones, “many of our other workholding and productivity partners will also be exhibiting new products at this key engineering business event. In Hall 6 with us are Balance Systems on Stand E34 and Exact on Stand K68; in Hall 5 we have AutoGrip on Stand D94 and Walmag on B87; Hall 4 is where visitors can find Homge Stand E95, PiranhaClamp Stand B94 and Rotomors on Stand C25; Hainbuch and ZeroClamp are in Hall 3 on Stand H20 and C6 respectively; and Cucchi’s Bar Feeding technology will be on Stand E14 in Hall 17.”