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HAINBUCH clamping devices take charge in the machine shop
HAINBUCH clamping devices take charge in the machine shop
HAINBUCH clamping devices take charge in the machine shop
HAINBUCH clamping devices take charge in the machine shop

HAINBUCH clamping devices take charge in the machine shop

Added to MTDCNC by HAINBUCH UK Ltd on 01 August 2015

With a converted Mori Seiki NZ 2000 machine, HeBa Fertigungstechnik GmbH & Co. needed an all-round, no-hassle clamping device for its production facility. Its existing 3-jaw chucks were too big and difficult to continually set-up. So, a different system that would be smaller, more flexible and easier to set-up was needed. This is where Hainbuch stepped in with its modular system and  its many adaptation possibilities.

HeBa was the opportunity in the crisis

The young firm sprung from Paul Henkel GmbH & Co. KG following bankruptcy in the economic crisis of 2009. Jürgen Balting the HeBa CEO was the Plant Manager at Paul Henkel and he took over the company. He describes it concisely: 'If you have a leased car and then you are asked if you want to buy the car, then you know whether it had problems in the last three years and whether it would be worthwhile to take it over.'

Marking a new beginning, the company needed to be turned completely inside out and adapted to the requirements of the market. Jürgen Balting progressively invested in new machines, new clamping devices and new employees. Today the firm has approximately 20 employees and a manageable, ultra-modern machine shop, consisting of eight turning centers and three machining centers.

To supply its automotive customers with bushes for engines and various turned and milled parts, the firm works in three-shift operation. The batch sizes vary between 100 and one million parts. This only works because the machine shop is highly automated. For a small manufacturer this is level of automation is extremely important, to counter high employment costs and to remain flexible. This level of automation requires the right tools and clamping devices.

In 2011 Hainbuch joins the party

Jürgen Balting ordered his first new machine in 2010, a Mori Seiki NZ 2000 DL T2. The fully automated machine can do bar work or be robot loaded.  The twin spindle machine is programmed so that it can be quickly switched over depending on capacity and the part required. When the machine was delivered, and due to the 80 large capacity on the main spindle, the company specified a 3-jaw chuck. However, when the firm went into production, it turned out that the chucks were not ideal.

The chuck was too big for a lot of the tooling and the set-up process was time consuming. Something better was required. 'The most important thing was precision and adaptation possibilities. I did not want to always take off the entire chuck to change the workholding. Also there was not enough room in the machine to get a crane in. So, we employed Hainbuch's modular system. The advantages were clear. We could clamp from the outside, inside or in front of the chuck with the modular system elements with fast set-up and easy handling. No other clamping device manufacturer had this amount of possibilities,' explains Balting.

Everything perfectly matched

HeBa equipped the machine with the size 100 hexagon Toplus collet style chuck on the main spindle and sub spindle. This worked with the Toplus chuck, the Mando Adapt [mandrel] adaptations, as well as the clamping heads. According to Mr. Balting, the result is: 'Even if the jaws were cleanly serrated, you always had to re-machine when you remount the top jaws. Now, we no longer have problems with the interference contour because the Toplus chuck has a far smaller profile than the large 3-jaw chuck. Initially we could only clamp to 100mm diameter, but we employed the jaw adapter, so there was no longer anything stopping us from unmanned machining. All machining steps, from milling the contour, inserting transverse and diagonal bores, to inner and outer turning - the full program is now possible without major workholding changes.

Problems eliminated

All difficulties were eradicated with the Hainbuch clamping devices. The set-up time was significantly reduced, the interference contour was improved and large throughput was achieved. Also, short-notice program changes are no longer a problem, thanks to the modular system, as changing from O.D. clamping to I.D. clamping is quick and simple. In addition, there is less scrap and the quality of the parts has improved.

Next generation – jaw module

The jaw adapter combined with the Toplus chuck has performed well for a long time, and was actually good enough. But when the new jaw module came out in 2013, it was clear, the jaw adapter would be superseded. Why? The jaw module had crucial advantages such as a larger stroke, a larger clamping range, clean radial clamping, hard jaws and standard serrations.

Other clamping devices are out of the running

The Hainbuch clamping devices and the service provided, led the company to implement the Toplus 65 chucks on all bar-working machines. Now HeBa saves 25 minutes set-up time, when swapping out a clamping head. The latest Mori Seki NLX machine arrival has also been fitted with a Toplus chuck size 100 on the main spindle and sub spindle.

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