A traffic light for more safety

The extra-strong AMF K40-H modules are used for heavy-duty machining.

Eccentrics, shafts, covers and other parts for the rolling mills are machined by milling, turning or drilling. For example, Kocks also inserts complex lubrication grooves or carries out sophisticated spindle machining. Some workpieces, which are clamped directly with AMF clamping pins, take around three hours to machine. "We are happy to support our customers in determining the optimum positions of the holes for the clamping pins," says Gödecke. 15 to 20 tools are used. The machine retrieves them directly from the tool store and changes them automatically. Further core elements are waiting to be processed in various production states on a total of twelve pallet stations. These are pre-set at a set-up station during machining.

A normal hydraulic unit is used to open the clamping modules. For the milling/turning application, this is additionally equipped with controls and an easy-to-read traffic light. This signals the clamped state of the clamping station and releases the workpiece for machining. A total of three clamping operations are now required to complete the core elements. In addition to the set-up time saved as a result, the sources of error that are inevitably present during each clamping process are also reduced.

For even more power

"With the AMF zero-point clamping modules, we have greatly increased our flexibility in production," emphasizes Carsten Aeilts (center), Operations Manager at Kocks Manufacturing. Left Kai Staschen, Kocks Manufacturing, right Michael Gödecke, AMF.

Because the AMF zero-point clamping modules show such convincing results in reducing set-up times, Kocks uses the technology on two other machines, including a huge Union boring mill with a machine table measuring 2,000 x 2,000 mm and a clamping angle measuring 1,000 x 1,000 x 2,000 mm. Here, the extra-strong AMF K40-H modules are used for heavy-duty machining in a superstructure station for direct workpiece clamping and in a single station for holding base plates or fixtures. These achieve 40 kN pull-in and locking forces as well as 105 kN holding force with a diameter of 148 mm. The modules are opened hydraulically and locked mechanically by spring force. The module is clamped without pressure and the pressure line can be removed at any time.

The K40 modules for direct workpiece clamping are characterized by a special feature: At 300 mm, they are high enough to be able to machine the workpiece clamped directly via the clamping pins from five sides without the table being an interfering contour. In addition, two of the four modules are height-adjustable. The modules can be adjusted in steps of 0.05 mm using a thread with a pitch of 0.75 mm for diameters greater than 150 mm. This allows a total height adjustment of 5 mm (±2.5 mm) to be achieved.

Third shift: higher productivity

Kocks mainly manufactures bevel gears and levers on another DMG machining center. "The flexibility gained by the K20 zero-point clamping system is particularly noticeable here," reports Staschen. Because it is so easy to reclamp, unplanned spare parts that need to be produced in a hurry can be inserted into the process without any problems. The part whose machining was interrupted is then simply re-clamped and machined again without the need for long set-up times. The machining team leader also mentions another aspect. At the end of the second shift, the workpieces can now be unclamped in any machining state and make way for another part with a longer machining time. "This means we are planning a third shift with less manpower in the near future." am