Core competence in complete machining: focus on chucked parts

The complete machining of chuck parts from the aerospace industry is one of the core competences of WFL. For chuck parts where the diameters are often the same as or considerably larger than the workpiece length, WFL has been able to gain quite an advantage over the years. The most suitable chuck parts include discs and rings. The latest developments have enabled the complete machining of chuck parts with a diameter of up to 2000 mm.

When it comes to the machining of chuck parts, most production specialists immediately think of vertical machining. It's true that the vertical machining of chuck parts, particularly ring- and disc-shaped parts, offers a few advantages. Above all, the convenient loading and unloading of workpieces. Chip removal in vertical machining is often problematic, however, whereby chips and cooling lubricant often remain in the workpiece and disrupt the machining process. This is where horizontal machining creates considerably better conditions.

The most important issues when it comes to producing complex chuck parts usually not only relate to the machining itself but to the loading and alignment of the parts in the clamping device. The vertical setup and alignment of the parts are also an important condition of horizontal machining. WFL has embraced this concept and challenge and is developing innovative complete solutions for the horizontal complete machining of chuck parts, which has many strengths in comparison with vertical machining.

The innovative WFL solution for the horizontal complete machining of chuck parts

Based on a high-precision, rigid and fully variable clamping system. Clamping devices such as workpiece-specific pallets, power chucks, clamping mandrels and collet chucks can be manually or automatically changed as required. With this solution, the workpiece is clamped and aligned on the clamping pallet on a vertical external clamping table or setup station. The setup station is equipped with exactly the same interface as the headstock in the form of a stable short taper mounting with a high degree of repeat accuracy. The clamping device including the workpiece can be changed automatically. Alternatively, when using power chucks, the workpieces can be changed directly into the chuck by the robot and the workpieces can also be transferred to the counter spindle, thus enabling full 6-sided machining.

This automation solution from WFL enables extremely stable clamping with a high degree of repeat accuracy. This concept also practically eliminates the need for clamping device setup times in the machine.

The benefits are clear – quick and, above all, precise changing of the equipment including the workpiece in the machine.

The advantages of the horizontal machining of power chucks at a glance

• Simple and efficient clamping of workpieces
• Higher efficiency thanks to setup in parallel to machining time
• Maximum flexibility thanks to optimum preparation outside the machine (parts can be prepared in parallel to machining time and stored in temporary storage)
• Optimum chip flow thanks to horizontal machining
• Higher productivity thanks to 4-axis machining with a turning-boring-milling unit and tool turret or a single tool holder on the lower system
• When the chuck parts are transferred to the counter spindle, machining is possible on the rear
• Flexible change between pallets and hydraulic power chucks
• Option to use the prismatic tool system on virtually all WFL machines, e.g. when using special tools or heavy internal machining tools

Depending on the machine model, additional tool carriers such as turrets are used in addition to the turning-drilling-milling unit. This second processing unit is located on the lower system. Machining can therefore take place simultaneously on both turning spindles or 4-axis on one spindle at a time. A special feature of all WFL machines is the integrated measuring probe, which is used for both horizontal and vertical machining and ensures advantages in the quality of the components.

The special characteristic of the M20 MILLTURN when it comes to machining chuck parts

With the new M20 MILLTURN, the lower system also features a turning-machining unit with B-axis and automatic tool change. Particularly when metal-cutting demanding materials (stainless steel, titanium, HRSA, etc.) with a high degree of tool wear, it is therefore possible to work fully automatically without interruption for very long periods of time. Thanks to the external tool magazine, a larger tool stock is available. The unproductive downtime required in order to retrofit the turret tools is completely eliminated.

A production increase of up to 80% can thereby be achieved during turning. The combination of these advantages results in a significant increase in productivity when machining chuck parts. External setup and alignment of the workpieces on the setup station, automatic change of clamping devices and workpieces by robot, significant reduction in machining time thanks to the second single tool holder and no downtimes for setting up the workpieces or tools (EWT) below.