International precision tool supplier Mapal announced in August that its HighTorque Chuck (HTC) with narrow contour has successfully combined the benefits of hydraulic expansion technology with the 3° back taper of a shrink chuck.
The development of the HTC was made possible owing to the additive manufacturing process employed at Mapal in the form of selective laser melting (SLM). SLM is a powder-bed-based process during which loose metal powder is melted layer by layer using a laser, which allows for parts to be fabricated from the bottom up.
During the production of the hybrid HTC with narrow contour, the functional area is applied to the conventionally manufactured tool body using SLM. Owing to the additive manufacturing, the clamping range can be positioned very close to the chuck tip, which would not have been possible with conventional manufacturing.
The new HTC provides an improved radial run-out of < 3 µm at the location bore and < 5 µm at 2.5 times the diameter, as well as shape accuracy with improved vibration damping. Damping in the system reduces microstructure cracking at the cutting edge, which, in turn, ensures longer tool life and less strain on the machine spindle. Further, the additive manufacturing eliminates the need for soldered joints.
The HTC also has significant thermal stability properties and can operate in temperatures of up to 170 °C, further improving process reliability.
The new chuck not only offers significant benefits for mould making, but also for applications in the automotive and aerospace sector, as the narrow contour of the HTC is suitable for all machining operations in contour-critical areas, which allows for quick and simple clamping of the tool.
The HTC with narrow contour is available in clamping diameters of 6 mm, 8 mm, 10 mm and 12 mm for HSK-A63 and SK-40. Intermediate sleeves enable additional diameter ranges to be covered. In addition, the chuck is optionally available with dynamically balanced HSK, which is an industry first, because the mass imbalance caused by the different depths of the key block slots has been eliminated in the improved HSK.
Mapal is one of the leading international suppliers of precision tools for the machining of practically all materials. The company was founded in 1950 and supplies leading companies in the automotive and aerospace industries, as well as machine and plant engineering companies.
The family-owned Mapal sees itself as a technology partner, supporting its customers with the development of efficient and resource-conserving machining processes using individual tool concepts. The company has production facilities, sales subsidiaries and representatives in 44 countries worldwide. In 2014, Mapal Group employed 4 500 people, generating €510-million worth of sales.