Longer tool life, less energy consumption

Many users in the metalworking sector have long been won over by this technology, which enables them to machine parts economically, efficiently and in a way that conserves resources. Hydraulic clamping toolholders are available on the market for every application. With this method, tools are clamped by a hydraulic mechanism where a screw is tightened to compress the internal pressure medium, causing the expansion sleeve to deform elastically. In this way, the tool shank is enclosed tightly. The high tension and radial rigidity make for a reliable hold and precise radial run-out.

SCHUNK and MAPAL each have decades of experience with this technology. Customised toolholder segmentation provides customers with the perfect hydraulic chuck for their specific requirements and application. All chucks are fine balanced as standard and are suitable for high spindle speeds. “Hydraulic clamping technology significantly supports companies in the machining industry on their decarbonisation journey”, emphasises Matthias Brenner, Director Product Sales & Product Management Clamping Technology at SCHUNK. “Industry, the economy and society at large must meet the urgent demand for lower emissions, energy consumption and use of materials”, Brenner says. “If the goal is sustainable production, you have to employ every possible measure to reduce your CO2 emissions. This includes new climate-friendly products and services as well as lowering emissions in your own factory as well as along the supply chain.”

“The use of hydraulic clamping technology contributes to sustainable production in ecological, economic and social terms”, affirms Dennis Minder, Global Head of Product and Application Management Clamping Technology at MAPAL, adding: “When it comes to sustainability, a major advantage of hydraulic chucks is a much longer tool life. If you want to manufacture responsibly, then you should consider switching to hydraulic clamping technology. For new purchases, hydraulic chucks are your first choice from a sustainability perspective.”
 

Hydraulic clamping technology features a design that stands for resource conservation and process reliability. The consistently radial run-out accuracy of a hydraulic chuck and effective vibration damping thanks to the inner oil cushion yield optimal workpiece surfaces, prevent micro chipping, protect the machine spindle, and result in longer tool life. This means that metalworkers benefit directly from cost savings and better quality. With hydraulic clamping technology, the radial run-out accuracy, clamping force and torque remain constant throughout the machining process. This process reliability protects both the workpiece and the equipment, especially the cutting edge. The overall result is a reduced need for follow-up steps, both on the workpiece and during machining setup.

Compared to shrink chucks, which are put under a significant amount of stress through constant warming and cooling, hydraulic chucks last much longer. As thermal stress is not a factor here, there is no material fatigue. “We at MAPAL have verified the longer tool life through comparisons”, explains Minder. “While shrink chucks lose their initial part quality after about 500 clamping cycles, a modern UNIQ hydraulic chuck can withstand between 10,000 and 15,000 cycles, maintaining its quality for the user.” This durability conserves resources, as metalworkers can use the equipment reliably for many years. Hydraulic chucks also perform well in terms of servicing and reconditioning thanks to the ability to replace installation parts and add hydraulic oil. This makes them ready for a second life and fit for another 10,000 to 15,000 machining cycles. “Hydraulic clamping technology is a highly effective lever for economic efficiency and material savings”, emphasises Brenner. Eliminating rejects directly reduces CO2 emissions, as resources that should not be wasted are already bound up in the valuable raw material. “The throwaway mentality is coming to an end. Hydraulic chucks directly support this change, as they are designed for long-term use”, says Brenner.
 

Neben der Langlebigkeit, dem Ressourcenschutz und der Arbeitssicherheit überzeugt die Hydrodehnspanntechnik auch durch die Energieeinsparung gegenüber dem Einsatz von Schrumpffuttern. Der hier übliche hohe Stromverbrauch entfällt – und damit direkt verbunden auch wesentliche Mengen an CO2-Emissionen. „Ein starkes Argument für einen Wechsel zum hydraulischen Spannen ist der hohe Energieaufwand beim Schrumpfen“, erläutert Dennis Minder. „Ein Verzicht auf Warmschrumpfen eliminiert sämtliche Energieverbräuche, mindert den CO2-Ausstoß und drückt die Energiekosten“, so der MAPAL Spezialist. „Wir haben in der eigenen Fertigung ermittelt, dass ein Schrumpfgerät, das täglich im Dreischichtbetrieb im Einsatz ist, jährlich auf einen Stromverbrauch von 10.000 bis 12.000 Kilowattstunden kommt – es ist also ein Stromfresser“, stellt Minder fest. „Das geht mit dem Hydrodehnspannfutter deutlich sparsamer. Jede Reduzierung des Energieverbrauchs hilft uns auf dem Weg, die Nachhaltigkeitsziele zu erreichen!“

So berücksichtigt der Einsatz der Hydrodehnspanntechnik in Zerspanprozessen viele Dimensionen einer zukunftsfähigen Produktion – vom Schutz der Ressourcen, beginnend beim Rohmaterial, über die Energie bis hin zu verbesserten und entlastenden Arbeitsbedingungen für die Betriebsangehörigen. Die Prozessverbesserung bestehender Abläufe im betrieblichen Alltag ist einer der großen Hebel, um die Produktherstellung egal in welchen Bereichen ressourceneffizienter zu gestalten. Entscheidend ist, dass Anlagenbetreiber alle Bereiche des Ressourcenverzehrs betrachten, jegliche Verschwendungen identifizieren und sie schließlich beseitigen. Schon kleine Veränderungen im Produktionsprozess können ohne großen Engineering-Aufwand umgesetzt werden und schnell spürbare Wirkung zeigen. Mit dem Einsatz von Hydrodehnspannfuttern können Anwender in zerspanenden Betrieben unmittelbar CO2-Emissionen einsparen und ihre Klimaziele umsetzen – im laufenden Betrieb und ohne aufwändiges Umrüsten. Weil die Geometrie der Hydrodehnspannfutter TENDO Slim 4ax (SCHUNK) und UNIQ DReaM 4.5° (MAPAL) exakt mit der von Warmschrumpffuttern übereinstimmt, können diese 1:1 ohne Programmierung ersetzt werden. Noch nie war der Umstieg einfacher.