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Modern steering systems are based on exactly tuned interaction between precise mechanics and finely controllable hydraulics or powerful electronics. ZF Lenksysteme GmbH is one of the world’s leading manufacturers of steering mechanisms for passenger and utility vehicles. In the manufacture of highly precise pinions for passenger car steering mechanisms at the Schwäbisch Gmünd site in Germany, ZF Lenksysteme puts its trust in the TENDOturn hydraulic expansion holder from SCHUNK.

Modern production needs modern clamping systems

An oversized spanner wrench is like a relic in the hands of Dionys Müller, NC programming and planning operator in the ‘K valve’ business unit at ZF Lenksysteme GmbH: "We used to clamp our tool with this in the past. Precise tool presetting on the collet chucks is critical every time. During the clamping operation, the tool changes its position by a minimal amount – but still too much." The ER collet chucks securely clamped the tools but the spanner wrench and excessive force caused problems. "Today, tool presetting with TENDOturn from SCHUNK is child's play."

TENDOturn clearly reduces rejects

Quality is the absolute priority at ZF Lenksysteme with a robot loading and unloading the
Gildemeister CTX 400 series CNC universal lathe every 30 seconds. Steering pinions are machined from 16 MnCr5 and are then individually checked 100% automatically. There are no compromises when it comes to safety-related parts, like steering mechanisms. SCHUNK’s TENDOturn is used on the machines for turning and drilling. Design specification P7 is easily complied to, when boring out an M12 diameter without reworking. "Rejects have been drastically reduced by switching over to the hydraulic expansion holder from SCHUNK. In addition, we could increase the feed from 0.08 to 0.15mm. This way, we save around 50% machining time. At the same time, we also achieve a much better surface quality and profit from the prolonged service life of our tools,” continues Mr Müller.

The pinions produced with TENDOturn are part of a complex steering system that can be found in various car designs from numerous manufacturers. As a joint venture between Robert Bosch GmbH and ZF Friedrichshafen AG, the company has over 9000 employees at 18 production sites in eleven countries, and is the technological and innovative leader in this area.

The higher price of the SCHUNK TENDOturn compared to an ER collet chuck is absolutely justified, as far as the experts at ZF Lenksysteme in Schwäbisch Gmünd are concerned. The precision toolholder pays for itself within a very short time, and furthermore ensures reliable performance and top class machining quality. TENDOturn VDI 30 and 40 are used in Schwäbisch Gmünd.

The hydraulically clamped precision tool holders from the TENDO range ensure maximum vibration dampening. The user profits from brilliant surfaces and from the considerably prolonged service life of the used tools. The vibration dampening drastically reduces the possibility of the cutting edge of the tool breaking, thus drastically reducing tooling costs.

When considering whether to retrofit a production system with a precision clamping device, time is a decisive factor. With TENDOturn hydraulic expansion holders the tool is clamped with an Allen key, which is fully precise and still conceivably simple within a minimum amount of time and without a peripheral device. In addition to more reliable performance, the set-up times are also reduced.

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