In this week's highlighted CNC 4th Axis fixture, we are utilizing PAWS Workholding Wedge Clamps, the Stallion 9/20 Quick Change, the Lyndex Nikken CNC 302 Rotary Table and Jergens Ball Lock Workholding. Our main concern with this setup was cutting out time consuming setups and increasing part density. Prior to utilizing the tools mentioned above, our customer was machining just one part and one setup at a time. This particular part has 5 angles that need face-milled, as well as drilled and tapped. We were able to cut all of these out, allowing the operator to only open the doors on the machine once every eight parts!
The combination of the Lyndex Nikken Rotary Table and the Stallion 9/20 Quick Change Trunnion Table allowed us full 360 degree rotation of the aluminum blanks. Without this, we would not have been able to reach all 5 sides of the part. Customized for the CNC 302, the Trunnion Table 4th Axis fixture bolts directly to the faceplate of the rotary table. The entire assembly is also mounted on a baseplate, which allowed for an easy installation.
There are huge benefits to using modular workholding such as these PAWS Wedge Clamps. Should we have used a regular vise, we would have been limited to a maximum of two parts per cycle. While this is still better than the previous method of doing one part and one angle at a time, why machine two parts when you can machine eight? The small and low profile nature of the wedge clamps allowed us to truly utilize the entire 20" working surface of the Trunnion Table.
The Jergens Ball Lock Mounting System added an incredible amount of efficiency to this setup. While the wedge clamps do a fantastic job of increasing part density, the ball lock system allows the operator to load a second sub plate offline while the first is being machined. This cuts the time in between cycles to less than a minute. The thumb screws included with the Jergens product make swapping out the plates incredibly efficient and simple.
Overall, the partnerships that Martin Trunnion Tables holds with these forward-thinking companies allowed us to greatly increase the throughput for the end user.
Trunnion tables aren't limited to standard pneumatic clamping. These versatile and efficient machines can also be outfitted with automatic, hydraulic clamping systems to minimize loading error and greatly increase efficiency and spindle time. Over the years, we have made several hydraulic fixtures featuring Vektek Swing Clamps:
You may have seen the video via our instagram account of the Stallion 9/23 featuring the swing clamps in the image above. This trunnion was made for Mako Finished Products. In this case, six single acting clamps are fed with a manifold block that is hooked to an air over oil intensifier. By using a Trunnion Table fixture, the customer was able to machine all three sides of this part in a single setup, greatly increasing the efficiency of their machine, while simultaneously reducing the likelihood of scrap. In order to achieve full 360 degree rotation, we outfitted the HRT-210 with a riser block and created a larger outboard support. This, of course, created concern for tool clearance, but we were able to make it work in this customer's HAAS VF-2. Watch the video:
Similar to the above setup, the following Stallion 9/35 Trunnion Table is also a custom hydraulic fixture in which VekTek Swing Clamps were used.
In this case, the Stallion Trunnion also has a TS 1200 Hydraulic braking system on the outboard support. This created the need for a second air over hydraulic pump to allow both the brake and the vektek clamps to work simultaneously. Unlike the previous design, this part did not warrant a riser block, as 360 degree rotation could be achieved with the standard 6 inch center height of the HRT-210. Watch it in action:
If you are interested in setups similar to these, visit our Custom Fixturing Page. Watch the video here:
This week's highlighted Stallion fixture is a 9/23 Quick Change. The product was made for Timken, a company out of British Columbia, Canada. Using Jergens inc. Ball locks, the quick change option allows our customers to change setups quickly (within 60 seconds) and repeatably. The ball lock receiver bushings are mounted into 4 corners of the surface of the Stallion Trunnion Table. A 1" steel sub-plate, with hardened locater bushings in two of these corners, will act as the working surface. The sub-plate also includes a 2 inch grid pattern; this feature provides our customers with flexibility, as they are now able to mount virtually any vise or other workholding product onto their Stallion Trunnion Table. The trunnion is made from a one piece casting and is guaranteed flat and square within .001" over the entire surface.