Toolholders make the critical connection for productivity

Published
January 16,2020 - 01:00pm

Toolholders are the critical connection between a cutting tool and a machine tool spindle. A toolholder’s performance dictates productive output, part surface finish and cutter life. With the right toolholder for the application at hand, shops gain maximum benefit from their high-performance cutting tools and machine tools.

Different toolholder types provide different levels of performance, and depending on the specific machining application, some performance factors are more important than others. For precise work, a low total indicator runout (TIR) may be most important. When multiple setups are involved, quick change capability is essential to maximize productivity. In heavy cutting situations, tool retention force may be emphasized. And in most operations, the cost of the tooling system itself is a significant factor.

Photo of a powRgrip holder, which is aimed at high-performance machining applications, courtesy of AeroCision.

When it comes to the various toolholders and their qualities, ER collets are known for their gripping strength and accuracy. Collets in the ER system, developed and patented by Rego-Fix in 1973 and standardized as DIN 6499, provide a wide clamping range and high accuracy over an extended selection of operations.

Most shops select toolholding systems based on the parts they make and how they manufacture them. Depending on their product mix, shops generally use more than one holding system. An effective way to simplify toolholder acquisition and selection is with a family of toolholding technologies, such as those developed by Rego-Fix. The company’s original ER clamping system, comprised of the ER collet holder, collet and nut is engineered for traditional machining applications, while Rego-Fix’s powRgrip system is aimed at high-speed milling and drilling and other high-performance applications. That system consists of powRgrip toolholders with internal tapers that accept the matching tapers of powRgrip collets. Tools are inserted and removed from the holders using a fast-acting manual or automatic hydraulic powRgrip unit.

For tougher machining operations, Rego-Fix secuRgrip toolholders are made to fit powRgrip clamping units and prevent cutter pullout. The system utilizes a patented locking system and threaded cap, with the key element being a special collet configured to accept a threaded insert that locks into the Weldon flat on any tool with that feature. The system has a TIR of 0.0001". No modification of the tool shank is required, and existing powRgrip holders can be modified for use with the holders.

At the opposite end of the toolholding size spectrum, the Rego-Fix micRun system handles small-tool, micromachining applications such as those found in the watch making and medical industries. A symmetrical design without grooves or flats minimizes vibration and special threads keep the nut aligned with the holder for maximum rigidity and repeatability. The system provides runout of ≤3 µm at 3 times diameter, which enhances machining quality, overall productivity and tool life in high-precision applications.

No toolholding system is perfect for every machining circumstance. However, toolmakers have focused their tool development efforts to create systems that enable high productivity and cost efficiency across the wide range of manufacturing situations.

Related Glossary Terms

  • collet

    collet

    Flexible-sided device that secures a tool or workpiece. Similar in function to a chuck, but can accommodate only a narrow size range. Typically provides greater gripping force and precision than a chuck. See chuck.

  • flat ( screw flat)

    flat ( screw flat)

    Flat surface machined into the shank of a cutting tool for enhanced holding of the tool.

  • gang cutting ( milling)

    gang cutting ( milling)

    Machining with several cutters mounted on a single arbor, generally for simultaneous cutting.

  • milling

    milling

    Machining operation in which metal or other material is removed by applying power to a rotating cutter. In vertical milling, the cutting tool is mounted vertically on the spindle. In horizontal milling, the cutting tool is mounted horizontally, either directly on the spindle or on an arbor. Horizontal milling is further broken down into conventional milling, where the cutter rotates opposite the direction of feed, or “up” into the workpiece; and climb milling, where the cutter rotates in the direction of feed, or “down” into the workpiece. Milling operations include plane or surface milling, endmilling, facemilling, angle milling, form milling and profiling.

  • shank

    shank

    Main body of a tool; the portion of a drill or similar end-held tool that fits into a collet, chuck or similar mounting device.

  • toolholder

    toolholder

    Secures a cutting tool during a machining operation. Basic types include block, cartridge, chuck, collet, fixed, modular, quick-change and rotating.

  • total indicator runout ( TIR)

    total indicator runout ( TIR)

    Combined variations of all dimensions of a workpiece, measured with an indicator, determined by rotating the part 360°.

  • total indicator runout ( TIR)2

    total indicator runout ( TIR)

    Combined variations of all dimensions of a workpiece, measured with an indicator, determined by rotating the part 360°.

Author

Engineering and Technical Manager

David McHenry is engineering and technical manager for Rego-Fix Tool Corp., Whitestown, Indiana. For more information about the company's toolholding technologies, call 317-870-5959 or visit www.rego-fix.com.