"Solid Works" model of the Universal Valve Fixture illustrates valve body being clamped with tool access available from all four sides.

Berlin,CT. – Royal Machine & Tool combines the design concepts of two of their most popular fixtures…”C” Frame Fixture and Modular Fixture…into a Universal Valve Fixture. Specifically designed and developed for use in the Valve Industry, the new Universal Valve Fixture provides greater flexibility in covering a large range of Valve Bodies with a single fixture.

In making the announcement, General Manager, Guy Byrne stated, “By combining the Modular Chain Fixture with our current “C” Frame Fixture, the Independent Work Nests for specific parts are eliminated, thus reducing costs as well as improving change-over times in the process, yet maintaining positive gripping of the part(s). This new concept is ideal for families of parts as well as your odd run part.”

“In addition, our standard Royal “C” Frame Fixture is a design that cradles the part in a Work Nest which is specifically fitted to a particular part on the upper and lower portion of the fixture. Implementing the Modular Fixture as the Lower Work Nest provides ample adjustments to be made to grip many different sized parts without having to purchase custom fitted work nests that have to be unbolted each time and replaced with the correct Work Nest for an individual part number.”

Founded in 1956, Royal Machine & Tool Corporation is ISO9001:2008 & AS9100 Rev. “B” Certified and serves the world’s leading industries from its Berlin, CT corporate offices and manufacturing facility representing over 40,000 square feet including state-of-the-art CNC machine tools. All services and products are performed/produced in the USA and include the designing and building of custom and standard work holding devices from simple manual fixtures to sophisticated hydraulic fixtures with multiple faces. Custom and standard chucks of all types for rotating and non-rotating applications are also designed and built by Royal Machine &Tool…as well as a complete range of Contract Machining options/services from single prototype machining to high volume production requirements.

Solid Works” Software permits 3-D dimensional viewing...plus, clearer definition of work holding products and work areas.

Royal’s engineering staff can now communicate with 3-D models in most formats and have the ability to do basic finite element analysis. Also, the new software packages provide the capability to interface engineering 3-D models to the manufacturing area for the developing of machine programs.

In making the announcement, Guy Byrne, General Manager, stated, “These new upgrades enhance Royal’s position today and in the future as a leader in the manufacturing of work holding products. It is imperative that in today’s competitive market we provide our manufacturing facilities with the best state of the art equipment and programming resources available. In turn, our customers reap the rewards of our ability to reduce costs and still produce superior products.”
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Founded in 1956, Royal Machine & Tool Corporation is ISO9001:2008 & AS9100 Rev. “B” Certified and serves the world’s leading industries from its Berlin, CT corporate offices and manufacturing facility representing over 40,000 square feet including state-of-the-art CNC machine tools. All services and products are performed/produced in the USA and include the designing and building of custom and standard work holding devices from simple manual fixtures to sophisticated hydraulic fixtures with multiple faces. Custom and standard chucks of all types for rotating and non-rotating applications are also designed and built by Royal Machine &Tool…as well as a complete range of Contract Machining options/services from single prototype machining to high volume production requirements.

Karol Ziecina, Machine Specialist at Atlas Precision Manufacturing in South Windsor, CT prepares chuck top tooling on a 32” diameter 3-jaw manual chuck.

“This produces increased accuracies and wedge style gripping forces where it is pertinent to hold precision and close tolerances in the machining of parts and  products made of exotic materials with thin-walled geometries.”

In addition, this “Next Generation” design uses a readily replaceable pinion gear for added torque and also has improved chip protection to help reduce contamination and downtime for maintenance.

Byrne further stated, “These specific features and applications of our “Next Generation” design of Manual VTL Large Diameter Chucks are of particular interest and importance to specific industries such as.. Aerospace…Medical…Bearings…Energy & Technology.

All Royal Machine Large Diameter Power Chucks are now available in standard 2-Jaw, 3-Jaw, 4-Jaw and a combination 2/3 – Jaw configuration with both adjustable and non-adjustable Master Jaw styles as well as special requirements for 6 or 12–Jaw and self-contained applications.

Manufactured in the USA, the large load bearing surfaces of all Royal Machine Large Size Power Chucks reduce wear, increase accuracy and extend service life. Easy-access lubricating fittings in each master jaw and chuck body provide lubrication for all wearing surfaces. In addition, the large diameter chucks’ basic design maximizes chip and coolant protection.

Specifically, Large Diameter Chucks are offered with additional jaw configurations and are available:

• in Direct Mount to American Standard  ASA B5.9 Type A1, A2, B1, B2, DIN55026-1, DIN-55021-A, and ISO R 702-1 spindles.
• with American Standard Tongue and Groove or American Standard Acme Serrated Master Jaws.

Founded in 1956, Royal Machine & Tool Corporation is ISO9001:2008 & AS9100 Rev. “B” Certified and serves the world’s leading industries from its Berlin, CT corporate offices and  manufacturing facility representing over 40,000 square feet including state-of-the-art CNC machine tools. All services and products are performed/produced in the USA and include the designing and building of custom and standard work holding devices from simple manual fixtures to sophisticated hydraulic fixtures with multiple faces. Custom and standard chucks of all types for rotating and non-rotating applications are also designed and built by Royal Machine &Tool…as well as a complete range of Contract Machining options/services from single prototype machining to high volume production requirements.

Royal Machine’s New Steel Bodied Manual Large Diameter Chucks are manufactured in the USA in sizes from 24” to 72” and are custom designed and built to customer specifications.

In making the announcement, Guy Byrne, General Manager, stated, “Unlike older inferior designs using Cast Iron Bodies and Scrolls that have limited wear ability, this new design boasts its superior steel strength, induced wear resistant body, hardened and precision ground Master Jaws and Wedge.

This produces increased accuracies and wedge style gripping forces. Aside from these benefits, this “Next Generation” design uses a readily replaceable pinion gear for added torque and also has improved chip protection to help reduce contamination and downtime for maintenance.

These New Steel Bodied Manual VTL Large Diameter Chucks are particularly applicable to the medical, aerospace, and energy technology industries.

Karol Ziecina, Machine Specialist at Atlas Precision Manufacturing in South Windsor, CT prepares chuck top tooling on a 32” diameter 3-jaw manual chuck.

All Large Diameter Power Chucks are now available in standard 2-Jaw, 3-Jaw, 4-Jaw and a combination 2/3 – Jaw configuration with both adjustable and non-adjustable Master Jaw styles as well as special requirements for 6 or 12–Jaw and self-contained applications.

Manufactured in the USA, the large load bearing surfaces of all Royal Large Size Power Chucks reduce wear, increase accuracy and extend service life. Easy-access lubricating fittings in each master jaw and chuck body provide lubrication for all wearing surfaces. In addition, the large diameter chucks’ basic design maximizes chip and coolant protection.

Specifically, Large Diameter Chucks are offered with additional jaw configurations and are available:

- in Direct Mount to American Standard ASA B5.9 Type A1, A2, B1, B2, DIN55026-1, DIN-55021-A, and ISO R 702-1 spindles.

- with American Standard Tongue and Groove or American Standard Acme Serrated Master Jaws.

Royal Machine & Tool technician Dave Turek inspects a newly produced Steel Bodied Large Diameter, Manually Operated 3-Jaw Chuck with wedge and gear actuation

Founded in 1956, Royal Machine & Tool Corporation is ISO9001:2008 & AS9100 Rev. “B” Certified and serves the world’s leading industries from its Berlin, CT corporate offices and manufacturing facility representing over 40,000 square feet including state-of-the-art CNC machine tools. All services and products are performed/produced in the USA and include the designing and building of custom and standard work holding devices from simple manual fixtures to sophisticated hydraulic fixtures with multiple faces. Custom and standard chucks of all types for rotating and non-rotating applications are also designed and built by Royal Machine &Tool…as well as a complete range of Contract Machining options/services from single prototype machining to high volume production requirements.

Patent Pending Clamping Screw Cartridge provides greater gripping force and ease of maintenance is shown in underside view of jaw assembly.

The new clamping screw cartridge is also available on Royal’s independent adjustable jaw chucks which have been in service for a number of years.

The new QVC is designed with American Standard Tongue and Groove Master Jaws and is available in 400MM and 500MM sizes. The new design permits using existing top-tooling and “off-the-shelf standard blank jaws. Mounting features also can be supplied to the customer’s specific requirements

Royal QVC’s hold up to 8 parts and permit virtual continuous spindle use, decreased tool changes…and practically eliminate downtime for parts changeovers.

Information on special and custom requirements is available upon request.

Founded in 1956, Royal Machine & Tool Corporation is ISO9001:2008 & AS9100 Rev. “B” Certified and serves the world’s leading industries from its Berlin, CT corporate offices and manufacturing facility representing over 40,000 square feet including state-of-the-art CNC machine tools. All services and products are performed/produced in the USA and include the designing and building of custom and standard workholding devices from simple manual fixtures to sophisticated hydraulic fixtures with multiple faces. Custom and standard chucks of all types for rotating and non-rotating applications are also designed and built by Royal Machine &Tool …as well as a complete range of Contract Machining options / services from single prototype machining to high volume production requirements.

The ISO provides quality management system standards/guidelines aimed in assisting organizations to achieve customer satisfaction and continual improvement. Certificates to organizations in over 160 countries have been issued by ISO.

The two recertifications in accordance with the requirements of ASI9104A are applicable to Royal Machine & Tool’s design, manufacture, assembly and service of commercial and aerospace products.

In making the announcement, Royal President, Richard Ruscio stated, “Since 2003, we have been especially proud of our being certified in accordance with ISO and ASI requirements. Royal’s new recertification confirms the major commitment by our management in continually providing the necessary quality products and contract machining services required to meet our customers’ work holding needs.”

Founded in 1956, Royal Machine & Tool Corporation serves the world’s leading industries from its Berlin, CT corporate offices and manufacturing facility representing over 40,000 square feet including state-of-the-art CNC machine tools. All services and products are performed/produced in the USA and include the designing and building of custom and standard work holding devices from simple manual fixtures to sophisticated hydraulic fixtures with multiple faces. Custom and standard chucks of all types for rotating and non-rotating applications are also designed and built by Royal Machine &Tool …as well as a complete range of Contract Machining options / services from single prototype machining to high volume production requirements.

A typical Robot System integrated with a Machining Center…complete with safety fencing, monitoring and part queuing stations.

Like any new process, robots were introduced with many skeptics. Non-believers thought the human process could not be replaced…and that robots were too cumbersome to do the job at hand. Also, many felt threatened by the use of robots as they were perceived as causing the elimination of someone’s job and not improving the overall workplace performance.

Over time, the use of robotics has expanded as manufacturers realized the benefits that they can bring to manufacturing processes. Today robots are commonplace in the assembly of automobiles and many of their components. The benefits of robots include the ability to work 24/7, reduced labor costs, repeatability of the process, reduction of accidents and scrap.

Presently, the use of robots is finding itself in operating rooms doing surgical procedures where accuracy is a must. In manufacturing, their use has expanded beyond assembly, to the machining operations where they are used for loading and unloading parts from lathes and machining centers. This has brought change and challenges to the way parts are fixtured and processed.

With the use of robotics comes different design requirements of the fixturing.

Fixtures now have to provide enough clearance to allow robot arms to manipulate the parts into the work nest and provide better chip evacuation. In addition, fixtures have to provide the ability to retain the parts in a free state prior to clamping and unclamping. Lastly, fixtures must have the capability of knowing when a part is not sitting properly in the work nest.

A Robot loading parts on to the Hydraulic Fixture within the work area of the Machining Center.

To begin the process of the robot with the workholding fixture, the loading surface has to be designed with better chip evacuation and to be clean of any foreign material that would not allow the part to seat properly in the work nest. This may require an air or coolant source to remove chips or debris on the work area. In most cases the area is flooded with a coolant flush from the machine and then an air blast from the robot arm. Next the robot has to have the ability to load the part in the nest without the part falling out before it is being clamped. This requires a provision for some type of preload mechanism to hold the part in position for the clamping. This may be simple spring clips or a spring loaded low pressure clamp mechanism.

Once the part is now in the preliminary load on the work nest, the final clamping of the part takes place with the robot retracted. However, confirmation of the part being located and properly clamped is required prior to the machining process. This is usually done with air sensing on the Locator Pads and/or Part Clamps. Basically, a low air pressure is forced through a small hole in the locator or clamp. If the part is located properly (thus blocking the air passage), it will signal an increase in air pressure which, in turn, signals to the machine control that the part is located properly. If the part is not seating properly, the air pressure will drop off
and will signal an error in the process.

Adding to the intricacy of the fixture…

Providing the preliminary part locators and part sensing into the fixture design adds to the intricacy of the fixture. The hydraulic and air lines are normally internal to the base plates and work nests. This allows a cleaner fixture with better access and chip disposal. Hard piping is cheaper, but in the long run, takes up more space and tends to collect chips, and is susceptible to damage and leaks.

Once the machining is complete, the unload/load sequence of the robot is ready to complete the cycle. First the hydraulic clamping has to be disengaged allowing the parts to sit ready for unload. The machine control then initiates the coolant flush and the robot takes over the operation, grabbing each part and going through the load/unload sequence. This is a continued safe repeatable motion and timed process.

Today, as greater flexibility and quick changeover become the requirements to be competitive in manufacturing, the connection between Robots and the Fixtures will become much more sophisticated and an intricate part of the fixture design.Eventually, it is not that farfetched that a robot may become the fixture as well as the part handler.

Photos courtesy of Makino Production Machinery Group.

In announcing the newly designed QVC, Guy Byrne, General Manager, stated, “Older designed QVC’s required the replacement of the Master Jaw and the Adjusting Screw when thread damage occurred. With the new design, simply unfastening the old damaged cartridge and fastening in a new cartridge allows repair in the field and quickly returns the chuck to service. Thus, eliminating the possible downtime and costly expense of rebuilding. ”

QVC 500 Quad Vertical Chucking Fixture with American Standard Tongue and Groove Master Jaws and Cartridge Assembly.

Current chuck design problems virtually eliminated.

“Unlike prior chuck designs, where the thread is cut in the Master Jaw, the new design eliminates the thread in the jaw using the threaded cartridge inserted in a pocket of the Master Jaw. The problem of past chuck designs, which had the upper jaw threaded, is virtually eliminated, “ Byrne continued, ”by providing a cartridge assembly for clamping
a work piece securely and safely in a machine tool.”

“A replaceable insert, with any desirable machine-in thread, is mounted to the Upper Master Jaw. Thus, replaceable inserts may be used to accommodate adjusting screws having various complementary thread designs, including a full diameter Acme thread, in place of the square thread previously required for similar chuck designs. The Acme thread is much more economical to produce…is a stronger form of thread…and is easier to repair or replace.”

“While the Acme thread has a sloped thread side, it distributes pressure on the full diameter of the adjusting screw and is not forced into the lower operating jaw …as it would have were there only 50% contact with the upper master jaw in the
old design.”

Various alternative design options.

Design options to meet specific design requirements of the cartridge assembly include:

1. The threaded insert can be made with different style master jaws.
2. The clamping screw can be made of different materials and pitch.
3. The threaded replaceable insert may be mounted in the upper or lower jaw.

Pending Clamping Screw Cartridge provides greater gripping force and ease of maintenance is shown in underside view of jaw assembly.

The new QVC is designed with American Standard Tongue and Groove Master Jaws and is available in 400MM and 500MM sizes. Mounting features can be supplied to the customer’s specific requirements. and the new design permits the use of “off-the-shelf” standard blank jaws or, better yet, customer’s existing top tooling. “

Royal QVC’s hold up to 8 parts and permit virtual continuous spindle use, decreased tool changes…and practically eliminate downtime for parts changeovers.

Bernie McAloon, Sales Manager, stated, “Our new QVC provides the ideal workholding solution for today’s high volume industries to meet their ever-increasing demands to manufacture high volume, uniquely shaped, varying sized quality products …on time and still be competitively priced.”

Information on special and custom requirements is available upon request.

Founded in 1956, Royal Machine & Tool Corporation is ISO9001:2000 & AS9100 Rev. “B” Certified and serves the world’s leading industries from its Berlin, CT corporate offices and manufacturing facility representing over 40,000 square feet including state-of-the-art CNC machine tools. All services and products are performed/produced in the USA and include the designing and building of custom and standard workholding devices from simple manual fixtures to sophisticated hydraulic fixtures with multiple faces. Custom and standard chucks of all types for rotating and non-rotating applications are also designed and built by Royal Machine &Tool…as well as a complete range of Contract Machining options / services from single prototype machining to high volume production requirements.

In making the announcement, Richard Ruscio, President, stated, “In this time of difficult economic decisions, replacing existing worn or damaged chucks with new chucks is not always the best decision. Reconditioning a chuck costs less than 50% of buying a new chuck. This allows having two chucks reconditioned like new for the same price as a new replacement chuck and includes a one year full warranty (the same as a new chuck).

“And this is exactly the reason we’ve expanded our reconditioning and repairing services…to assist our customers in making the right decision when chucks become worn or damaged.”

“First, contact us to discuss your requirements. Then, we will evaluate your chucks at no charge. Should they not be too badly worn or damaged, we will recommend either reconditioning or repairing and then provide a cost estimate. Once the decision is made to go ahead, we will quickly deliver the reconditioned chuck with like- new tolerances…and with a one year full warranty.”

Reconditioning or Repairing…time to consider is when a chuck begins to perform improperly.

“Obviously, safety considerations are first and foremost in determining the overall results to be achieved.” stated, John Darling, Chief Engineer. “Then it must be decided whether the chuck has to be operated for a short period of time or for a long period of trouble-free use. And, most importantly, how will the cost difference between a new replacement compared to the less than 50% cost for a reconditioned chuck, effect your overall decision.”

Faulty Chuck

“In addition to the savings in cost, there are four specific reasons to consider reconditioning or repairing a chuck:

1. does the chuck visibly appear to be worn?
2. has an accident broken something
   in the chuck?
3. has the chuck begun to lose its gripping force or its accuracy?
4. is the chuck design incapable of holding a part specifically designed to meet the part’s process and tolerances.”

Making the Right Decision – Reconditioning or Repairing

Darling further stated, “The final decision must be based on what is functionally and financially best for the situation.”

Reconditioning

“This is the preferred choice for less than 50% of the price of purchasing a new chuck. A correctly maintained and lubricated power chuck will usually age gracefully and only show wear by loss of accuracy and/or gripping force. When sent in for an examination and/or testing, all the major wear surfaces will be inspected. If found to be worn, they will require rebuilding of one form or another.”

“The forms for building up worn surfaces are either chrome plating or welding. After the worn surfaces are built-up and the parts are carefully checked for any possible cracks, the new surfaces are ground to like-new chuck tolerances. Master jaws are also qualified to like-new chuck tolerances.

1. It is important to note that once an original chuck has been reconditioned to new chuck standards, it has a one year full warranty (the same as a new chuck)…and for most situations is equal to new chucks in reliability.
2. It usually can be done in half the time it takes to have a new chuck built and it may be such that a part has to be replaced, welded or plated. However, you have most of the chuck already completed. “

Repairing

“Usually, this is the least expensive service and the quickest to get back in production. If there is a broken master jaw or a broken jaw activator caused by an accident, then replacing the broken part and cleaning up some damaged surfaces can make the chuck serviceable at little expense.”

“However, an exception to this service is when the broken part is a special part. Then it may have to be reverse engineered and manufactured which is more time consuming and costly.”

Repaired Chuck

“The repairing procedure provides a very serviceable chuck….returned to its original condition prior to breaking. However, the repaired chuck is still a somewhat worn chuck with a warranty only on the replaced parts and workmanship. A final consideration is that replacement parts may not have the same fit with worn parts which, in turn, may not provide the best situation for holding parts.”

Expanded Service Provides the Advantages of an Efficient Team Approach.

“Our workholding customers are able to draw from a team of varied backgrounds and experience in engineering, designing and machining. Each individual’s analysis will be reviewed and discussed among team members having over 100 total years workholding experience serving the needs of specialized groups including the aerospace, ammunitions, automotive, firearm, medical, recreational, flow control and petroleum industries.”
stated Bernie McAloon, Sales Manager.

For complete information on Royal Machine’s reconditioning/repairing of chucks, contact Royal Machine & Tool Corporation at (860) 828-6555 or
at www.royalworkholding.com.

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Extra Large Size Chuck Body

In making the announcement, General Manager Guy Byrne, explained, “The VF-2000 Machining Center’s programmable, semi-automatic right angle head permits the complete finishing of vertical and horizontal operations in the same setup, thus reducing the handling and additional setups.”

“Previous to the purchase of the VF- 2000, we had to schedule two or more pieces of equipment to perform these separate operations. This required additional lead-time, fixturing and labor. Now, performing in a single operation assures greatly improved control of the process and quality in the product.”

Multiple Fixture Plates and Parts produced in a single operation.

“In addition to now producing large chuck bodies and fixture plates,” Byrne continued, “we have increased our capacity to also produce multiple fixture plates and parts simultaneously in one operation. In many cases Royal Machine is producing in quantities of 4 or 6 chucks for multi-spindle machines. Utilizing the complete work area permits our having a single set-up machine.”

“These reductions in setup and handling combine cost savings in labor with the faster completion/delivery of orders to allow Royal to offer competitive pricing to all its customers.”

Multiple Chuck Body Set-up

Specifications for the VF-2000 Machining Center are:

axis dimensions: “X” – 86.6 inches, “Y” – 90.5 inches, “Z” – 36 inches

6,000 rpm gear driven spindle…and 20,000 pounds weight capacity

Bernie McAloon, Sales Manager, stated, “In addition to the needs for larger size work pieces by the Energy Technology and Aerospace Industries, there are ever-increasing demands by all industries for providing faster work piece deliveries. Smaller chucks for multiple spindle machines can now be made in one machining center setup. The capacity of this workholding center allows Royal Machine to quote competitively on small multiple production orders.”

Information on the capabilities of the VF-2000 Machining Center is available from Royal Machine & Tool Corporation and from www.royalworkholding.com.

Founded in 1956, Royal Machine & Tool Corporation is ISO9001:2000 & AS9100 Rev. “B” Certified and serves the world’s leading industries from its Berlin, CT corporate offices and manufacturing facility representing over 40,000 square feet including state-of-the-art CNC machine tools. All services and products are performed/produced in the USA and include the designing and building of custom and standard workholding devices from simple manual fixtures to sophisticated hydraulic fixtures with multiple faces. Custom and standard chucks of all types for rotating and non-rotating applications are also designed and built by Royal Machine &Tool …as well as a complete range of Contract Machining options / services from single prototype machining to high volume production requirements.