Workholding and machining systems from workholding
and machining systems specialist, 1^st Machine Tool Accessories

Workholding and machining systems specialist, 1^st Machine Tool Accessories (1^st MTA) exhibited a wide variety of new productivity enhancing equipment for the first time in the UK, at MACH 2010.

Chucking and rotary table developments from Kitagawa Europe, the company's NV, QJR and DHP/DHF series collet chucks, as well as GT series rotary tables were exhibited. In addition, the company also showcased Chick's recently-launched One-Lok advanced CNC workholding system and the Darex XT3000 semi automatic drill refurbishment module, along with versatile Alpha Magnetics magnetic workholding equipment and the extensive range of Tecnomors automation grippers, indexing chucks and manual 5^th axis vices.

Kitagawa's new NV chuck range has been developed to meet demands for large vertical lathe power chucks. Produced in eight models for components from 62 to 1000 mm diameter, NV series units feature a protective jaw cover and scraper system that prevents the ingress of swarf or coolant into the chuck mechanism. They are rated for maximum speeds up to 2900 rev/min and are designed for use with standard range Kitagawa jaws and Y2035R type cylinders.

Kitagawa's latest QJR08, QJR10 and QJR12 quick change chucks are interchangeable with the company's popular large through-hole B208 / B210 / B212 and BB208 / BB210 / BB212 models. The new units' base jaws, which are rapidly and simply changed using a manually operated wrench, feature metric serrations to accommodate a wide variety of popular jaw types.

Recently-introduced Kitagawa DHP and DHF collet chucks
Recently-introduced Kitagawa DHP and DHF collet chucks provide secure and accurate clamping of components up to 65 mm diameter. DHP variants generate a powerful pull back action for first operation work, while DHF models feature a removable bore stop, fixed collet position and high accuracy to ensure precise second operation machining. The compact nw chucks are offered with standard A5, A6 and A8 mounts to suit all popular machine tool types and have been designed to be both compatible and quickly interchangeable with other popular quick change collet clamping heads, without the need for special purpose adaptors.

Left: Kitagawa's latest QJR08, QJR10 and QJR12 quick change chucks are interchangeable with the company's popular large through-hole B208 / B210 / B212 and BB208 / BB210 / BB212 models. Right: Recently-introduced Kitagawa DHP and DHF collet chucks provide secure and accurate clamping.

Kitagawa's new GT series heavy duty rotary tables
High clamping torques, extreme rigidity and fast operation are key features of Kitagawa's new GT series heavy duty rotary tables. Available in three models with tables from 200 to 320 mm diameter, the new units incorporate a novel piston design that delivers component clamping torques of up to 2800 Nm. Productivity is further enhanced by the tables' rigid yet compact design, which allows maximum metal removal rates to be combined with high indexing accuracy and repeatability. The GT series also features a rapid clamping action for reduced cycle times and maximum production throughput.

Chick's One-Lok
Providing the speed, precision and flexibility demanded by modern CNC machining operations, Chick's One-Lok eliminates the shortcomings of standard knee mill vices based on 1950's technology. Its maximum grip capacity of 17 in (432 mm) is complemented by Chick's new 'Boltfast' jaw system - enabling jaws to be replaced quickly and efficiently with a locational repeatability of 0.0008 in (0.02 mm). The system's compact, modular design also features innovative 'squeeze' clamping, which imparts a pull down action and virtually deflection-free clamping with a maximum retaining force of 4.5 tonnes.

The Darex XT3000 semi automatic drill refurbishment module
The Darex XT3000 semi automatic drill refurbishment module ensures rapid, accurate and cost-effective drill sharpening, regardless of operator skill levels. Fulfilling international aerospace standards for controlling key geometry, the new module delivers faster and more accurate regrinding of drills up to 21 mm diameter by ensuring precise control of drill set up, sharpening loads and cycle times.

Left: Chick's recently-launched One-Lok advanced CNC workholding system. Right: The Darex XT3000 semi automatic drill refurbishment module.

1^st MTA also marked its recent appointment as agent for US-based Alpha Magnetics with an extensive display of the company's magnetic workholding equipment. Products on show included the versatile A-pod workholding system, Eagle Lift magnetic lifting equipment and APB / AMR series milling magnets.

1^st MTA's comprehensive range of workholding solutions was complemented by a display of Tecnomors self-centring automation grippers, indexing chucks and 5^th axis manual vices. In addition, the company also demonstrated numerous examples from its long established and proven machining and workholding products ranges, including Abbott and Leave fixturing and clamping products; OK-Vises; Brighetti reduction bushes; CoolJet high pressure coolant systems; Micromag filtration units; machine mounts; and Overbeck deburring twister lathes.

1^st Machine Tool Accessories in profile
1^st Machine Tool Accessories offer a comprehensive range of top quality products at competitive prices, 1^st Machine Tool Accessories is a leading supplier of workholding and machining accessories, including collets; chuck jaws; Kitagawa and Bison chucks, rotary tables and vices; Chick workholding equipment; Abbott and Leave fixturing and clamping products; Darex tool sharpeners; OK-Vises; Brighetti reduction bushes; CoolJet high pressure coolant systems; Micromag filtration units; machine mounts; and Overbeck deburring twister lathes.

1st MTA's extensive stock holding is backed by excellent warranty and service, provided by a dedicated team of technical engineers. Demonstrations of selected products are available from external sales specialists on request.

For further information, contact Catherine Kelly at 1^st MTA, e-mail: enquiries@1mta.com   Refer to page 32

Combined oil and vibration monitoring system detects early damage to gears

 A combined oil and vibration monitoring system is now available in the UK. The system enables the early detection of damage to heavy duty, oil-lubricated industrial gears, providing plant operators with a reliable system that prevents unplanned downtime and minimises maintenance, repair and overhaul (MRO) costs.
 
Industrial gears and gearboxes are critical to the smooth operation of most production environments and so maintaining these systems is often a high priority. If excess wear or damage is allowed to develop within a gearbox, this could result in secondary damage to other vital plant and machinery, leading to high repair costs, as well as costly production downtime.
 
The new FAG Wear Debris Monitor from Schaeffler (UK) Ltd is designed to solve these issues. This online condition monitoring system is capable of pinpointing the precise location of any damage or wear to gears, bearings and cages within a gearbox or other industrial gear unit. The system is therefore suitable for use in almost every industry sector, including wind power (gearbox drive train), marine (ship propulsion systems), oil and gas (top drives and draw works gearboxes), mining and quarrying (mills and rotary kilns), steel and aluminium (pinion stand gear units), pulp and paper (drying cylinder gears and wire drive roll gears).
 
The system's oil monitor works by utilising an inductive particle counter (sensor), which is able to distinguish between ferrous and non-ferrous metal particles that are present in the lubricating oil. On a typical industrial gearbox application, the particle counter or sensor is installed in the oil flow, directly before the oil filter, or as a separate circuit. The sensor operates on the principle that any wear to a component such as a bearing or gear tooth will result in small metal particles being rubbed off into the oil, often several months prior to an actual failure. The sensor provides information on the number of particulates present in the oil, and then classifies

these according to their physical size. Analysing the oil in this way enables damage and wear to the gears to be detected much earlier, even in planetary gearboxes, such as those used on wind turbines.
 
In addition to oil analysis, the FAG Wear Debris Monitor also monitors the vibration behaviour of the machine and its components, including rolling bearings and gear wheels. By installing sensors on the machine or gearbox that needs to be monitored, the new system detects changes in the operating behaviour, indicating early signs of damage. This enables the plant to start suitable repair work or plan some scheduled maintenance in order to prevent failure of the machine, resulting in costly production downtime.
 
This unique combination of oil and vibration monitoring provided in a single online condition monitoring system, means that users receive earlier warning signs of gear damage than if vibration monitoring is used on its own, or vice versa.
 
After any damage is detected, professional damage analysis is then required in order to determine the possible causes. The results of this work then lead to recommendations or remedial action that will prevent similar damage in the future.
 
Schaeffler UK is able to provide a wide variety of analysis methods to assist the customer. Endoscopy, for example, is used to determine the full extent or severity of any damage. Video endoscopes enable the internal components of a machine to be inspected, allowing the user to make a diagnosis of the damage based on the viewing of digital photos and video.
 
By using a special interface, the FAG Wear Debris Monitor can be easily integrated with other online condition monitoring systems from Schaeffler, including the FAG DTECT X1 and FAG ProCheck systems. These condition monitoring systems can be adapted or retrofitted to suit any customer requirements.
 
"The combined use of FAG oil monitoring products, vibration monitoring products and services from FIS [FAG Industrial Services], provides an efficient, cost-effective method of improving the protection of oil-lubricated gears. By detecting damage early, and by using the wide variety of analysis methods, the operational reliability of gears can be improved significantly, leading to similar improvements in productivity," commented Christian Meindl, Product Manager Oil Monitoring Products at FIS.
 
For further information on the Schaeffler Group, e-mail: info.uk@schaeffler .com or view website: www.schaeffler.co.uk   Refer to page 18