This applies to a wide range of industries and sectors. The greatest potential for saving costs and increasing productivity lies in set-up times. Reducing them can really boost machine running times and therefore production.

Reach any point with the modular zero point clamping system

As a pioneer of zero-point clamping technology, AMF has consistently and thoughtfully modularized its systems so that they can easily adapt to the increased requirements of complex geometries. A modular system of elements from four categories meets every challenge.

The modular system consists of basic elements, base elements, intermediate elements and superstructure elements. This allows different heights, uneven free-form surfaces and complex geometries to be achieved directly, safely and stably and fixed using direct clamping for collision-free five-sided machining.

For the clamping bolts for direct clamping, the necessary holes are drilled directly into the blank. Visualization in the 3D model in advance is a great help here. This allows any interfering contours for five-sided machining to be identified at an early stage. Designers plan the bushings in such a way that there is no risk of collision.

Machine running time increased by 75 percent

For example, a tool and mold maker has equipped a five-axis machining center with a rotary pallet storage system with 13 pallets. The workpieces are clamped directly on the pallets. The clamping bolts with catch screws in the hardened bushes of the clamping pallets hold the clamping bolts of the superstructure and intermediate elements. These are available from 20 to 100 millimeters.

With a defined grid spacing, pallets offer the greatest possible flexibility when positioning the elements. Finally, a K10 zero-point clamping module is positioned at the top, which pulls in and locks the M8 or M10 clamping bolts screwed into the workpiece with 10 kN and holds them with 25 kN force.

Components are often first rough machined and then usually hardened. After finishing and other processes such as drilling or threading, erosion is often required. AMF's modular zero-point clamping technology offers real time benefits for all of these process steps, as the zero point can be used for all other machines and processes once it has been measured.

With the help of AMF technology, the company has drastically reduced set-up times and increased machine running times by an initially unimaginable 75 percent from 80 to 140 hours. With appropriate planning, production can also be carried out unmanned at weekends.

Converted to machine hour prices, the annual costs are reduced by almost 50,000 euros per machine and shift due to the saved set-up times. The customer uses the modular zero-point clamping system from AMF on a total of 22 machines. This AMF clamping technology, which has proven itself at the German sites, has now even been introduced at the subsidiary in China.

Less vibration leads to better surface quality

What is so impressive in the case described here can also be realized in other applications. Typical areas of application in which the tangible benefits of modern clamping technology can be seen are, in addition to direct workpiece clamping, fixture changes for small, medium and large series, vice and jaw chuck changes, adapting a dividing head or upgrading a 3-, 4- and 5-axis machine.

In addition to enormous time savings, there is often an additional advantage during machining: If the complex workpieces are clamped quickly and stably with AMF zero-point clamping systems, there is less vibration during machining. This leads to a better surface quality, which shortens process times or makes subsequent processes completely superfluous. But that would be the subject of another presentation.