Chuck clamping for fast machine setups

Workholding is especially challenging when machined quantities range from a few dozen to thousands of parts and when part sizes and weight vary considerably.

Coming up with the just right workholding solution at Leyden Transmissions using the Leader Chuck Clamping system from Kurt impacts everything in the manufacturing process. Machining centre and operator efficiencies excel, part output is faster, deliveries and customer satisfaction improve, and the bottom line is increasingly attractive. The Leader Chuck clamping system provides Leyden Transmissions with the ideal workholding solution for machining its broad line of large coupling components.

When Mike Robinson assumed the position of managing director of Leyden Transmissions in January 2010, he brought with him a wealth of lean manufacturing principles and experience from the automotive industry. One of the principles was initiating a quick-change philosophy to the company's machining operations. This change according to Mr. Robinson, was vital to accomplish the ambitious growth plans of doubling the company's sales volume in 3 to 5 years. Making the quick-change philosophy work was through Mr. Robinson's implementation of the Leader Chuck system from Kurt.

Leyden transmissions was ripe for the quick-change philosophy

"Our vision is a twenty minute maximum set up time for any part, from stopping one job and machining on the next," reports Mr. Robinson. "That includes loading any tools and workholding required and downloading the NC program. It's an aggressive target, but it is achievable once everything is in place."

"We started along that route by purchasing a new Doosan V850 five-axis turning center. It has a part size capacity of 500 x 1350 mm with a 60 tool carousel so that tools can be changed while the machine is operating. (Photo Three) For the workholding, we chose the Leader MMY MultiChuck system from Kurt because it best addresses our quick change workholding requirements. The machining center and everything that went with it was a significant capital investment, but we had a solid customer base, steady sales volume of a million and half dollars a year and minimal debt. We were in a strong position to make a strategic capital investment that would provide an immediate high return."

Leader multichuck low profile, top operated design facilitates fast setups

The Leader MultiChuck from Kurt provided "a proven stock solution," according to Mr. Robinson, that covers a majority of the workholding required for its families of parts. That, coupled with the Doosan's probing capability, allows automatic measurement of offsets.

The Leader Chuck's low profile and top operated loading features make it ideal for Leyden's part configurations. This is particularly true for the larger part sizes that weigh over 50 lbs and require an overhead hoist for loading and unloading into the machine workholding.

"For most of our coupling products we have to locate on the bore of the parts," reported Mr. Robinson. "The Leader Chuck system allows us to do that quickly. Starting with round bar stock, we bore a hole in the middle and then mill it square before any cross feed holes are drilled into it. That gives us a good size bore to locate and work from. It acts as an accurate datum with everything subsequently measured from it."

Part of the Leyden's new machining philosophy is to "hit five sides in one setup, which is where the 5-axis Doosan comes in," reported Mr. Robinson. "The six sequential machining operations are replaced and it can be done in just two, with just the back face being accessed after the cycle is completed on the 5-axis machine. This is a radAir Jordan Six Rings