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Haimer SAFE-LOCK Tool Clamping System is met with Wide Acceptance

Haimer SAFE-LOCK Tool Clamping System is met with Wide Acceptance

Added to MTDCNC by MTDCNC on 26 July 2012

Haimer, the market leader in tool holding has developed an innovative tool holding system for high-performance machining called Safe-Lock&trade. It is proven in the most varied of applications and is continually gaining more license partners. Leading cutting tool manufacturers have incorporated the Safe-Lock&trade system into their product range and are already recommending it as the safest solution for increasing productivity in roughing applications. Widia, Walter, Sandvik Coromant, Seco, Kennametal, Helical, HAM, Emuge Franken and Data Flute are all cutting tool manufacturers that have already acquired licenses for the Safe-Lock&trade system from Haimer.

These cutting tool partners provide customers with access to the advantages of the Safe-Lock&trade system, as Andreas Haimer, member of the Board of Directors assures: &ldquoWith the Safe-Lock&trade system, we have established integrated pull-out protection for round tools that unites frictional clamping force and positive locking. With regard to process reliability and high material removal rates (MRR), attainable results are much better than when using conventional tool holders. This has been proven by a number of tool manufacturers and end users and we are convinced that Safe-Lock&trade is on its way to becoming the standard for roughing.&ldquo

How the SAFE-LOCK&trade System Works

The Safe-Lock&trade principle works with spiral-shaped grooves that are ground into the cutting tool shank. In combination with corresponding carbide drive pins in the tool holder (shrink fit, collet or hydraulic chucks), they prevent the tool from twisting or even being pulled out of the chuck during extreme machining. The interplay of pull-out protection and the best run-out accuracy leads to low-vibration and thus very efficient machining. This enables a doubling of metal removal rates by considerably increasing cutting depths and feed rates whilst reducing tool wear.

The end of the Weldon holder era has begun

Safe-Lock&trade was developed for heavy duty roughing as is routinely performed in the aerospace and power generation industries. In such sectors, many workpieces are milled from solid. To optimize the process and achieve high material removal rates, high torques and low rpm are usually ed. However, such high performance cutting (HPC) generates high tensile forces. Coupled with high cutting and feeding forces, they lead to twisting movements of the cutting tool in the chuck, posing the danger of the cutting tool being pulled out of the chuck.

A customer will often get a false sense of security when higher holding torques in Nm are cited as Franz Ziegltrum, engineer and Quality Manager at Haimer, warns: &ldquoA slipping of the cutter cannot be prevented through clamping force alone. This is a slow and creeping process. If the clamping force of a chuck were exceeded, the cutter would turn inside the chuck and break immediately. You can&rsquot master dynamic processes in heavy machining simply with frictional clamping forces.&rdquo

Until now, many users opt for Weldon holders, whose clamp screw causes positive locking. This allows the generation of infinitely high torques, until the cutter ultimately breaks. However, these Weldon tool holders also bring unprecise radial runout, poor clamping, poor balance properties and a short tool life for HPC tools.

Only the Haimer Safe-Lock&trade system offers relief and can replace Weldon as the standard with unique advantages. This is true for all Weldon applications, from titanium to aluminium to conventional tool steel.

SAFE-LOCK&trade generates competitive advantages

The Safe-Lock&trade system has proven its practicality on several occasions. For instance, a comprehensive endurance test with impressive results was conducted at Boeing in Portland, USA. The Safe-Lock&trade system has been employed as the standard system there since 2009. A Safe-Lock&trade shrink-fit chuck with a 32mm clamping bore and a length of 120mm was used on a vertical portal milling machine with an HSK-A 100 interface. For roughing and fine machining, one and the same coated solid carbide tool was used, having an effective cutting length of 83mm. A critical airplane component made of titanium alloy was used as a test workpiece.

The results showed at no time was there a danger of the tool being pulled out of the chuck. Moreover, the tool life was more than doubled. In addition, remarkable differences were noted on the surface finish. During roughing and finishing operations, using the Safe-Lock&trade system, no vibration and consequently no chatter marks were generated. In 2009, Boeing Portland became the first of Haimer&rsquos end customers to be licensed to grind Safe-Lock&trade grooves into their own special tools that they had developed or produced themselves.

Notable license partners are sold on SAFE-LOCK&trade

As Haimer offers this patented solution to as many customers as possible, a number of official co-operations with cutting tool manufacturers have already been established. Sandvik Coromant was one of the first global tool manufacturers to the new tool holding system by Haimer. Since March 2012, Sandvik Coromant has incorporated this tool holding system into their current program, under the product name iLock&trade, to primarily supply solid carbide end mills with the grooves.

Kennametal has also discovered Haimer&rsquos Safe-Lock&trade system and signed a licence agreement regarding the patented Safe-Lock&trade system in 2011. Keith Wiggins, Leader of Global Tooling Systems Product Management, is very familiar with the problems encountered in heavy duty machining: &ldquoFor years now we have been investigating a holding solution that has best possible accuracy with a fail-safe security clamping system that would gain the full potential from our cutting edge performance. With the Safe-Lock&trade we now have a high precision guaranteed non-slip holding solution to complement our tool holder offering.&rdquo

Walter AG is another tooling manufacturer with a licensing agreement with Haimer, presenting its security system to a wide audience for the first time at EMO 2011. Walter will soon incorporate Safe-Lock&trade tools into their own product range with Walter Xpress, as well as special solutions and the corresponding tool holders.

Further suppliers of precision tools with Safe-Lock&trade include the American tool manufacturers Helical and Data Flute, WIDIA and the German company EMUGE-FRANKEN.

SAFE-LOCK&trade available in all clamping systems

The principle of the Safe-Lock&trade system is not limited to shrink fit chucks. It can also be integrated into collet chucks and hydraulic chucks. In order to serve customers without shrink fit machines, Haimer offers an expanded collection of high-performance collet chucks. Depending on requirements, the market leader in tool holding and balancing technology recommends its low-vibration Power Collet Chucks for HSC or Heavy Duty Collet Chucks for heavy machining.

In addition to the Power Collet Chucks previously available in the standard range in the interfaces of SK40 and HSK63, Haimer will also offer the sizes BT40, SK50, BT 50 and HSK A 100. Heavy Duty Collet Chucks are also offered as an HSK A 125 interface.

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