In making the announcement, Richard Ruscio, President, stated, “Our new Turn/Mill Center will be most beneficial in servicing our aerospace and bearing industry customers’ time sensitive delivery needs because of the immediate benefits gained from single set-ups.”

Standard features for the Doosa Puma 300MSC Turn Mill Center include:

• 30HP, 2800RPM Spindle with 4.0″ Diameter Bar Capacity
• Full C Axis with Live Tooling
• Sub Spindle with 5 Degree Index, Conveyor and Barfeed

Guy Byrne, General Manager, explained, “Purchasing the new Doosan Puma Turn/Mill Center is just one of several equipment improvements expected in 2008. It will greatly compliment our existing 35 cnc lathes and machining centers as well as the five new machines acquired during 2006 along with the Vision Wide Machining Center recently purchased in the fall of 2007. All of these are part of the successful formula that has made Royal a quality workholding manufacturer and recognized contract provider through our continually identifying critical areas for equipment improvements.”

The Doosan Puma Turn/Mill Center was purchased from Doosan Dealer, Able Machine Tool Sales of Agawam, MA and coordinated by Sales Representative Al Barile with Royal Machine executives.

Royal Machine & Tool Corporate is ISO9001:2000 & AS9100 Rev. “B” Certified and serves the world’s leading industries by designing and building custom and standard workholding devices from simple manual fixtures to sophisticated hydraulic fixtures with multiple faces. In addition, Royal provides custom and standard chucks of all types for rotating and non-rotating applications … as well as a complete range of Contract Machining options and services from single prototype machining to high volume production requirements.

Designed and built in the USA, these special right angle fixtures are part of a series of highly specialized hydraulic and manual operated fixtures designed and built by Royal to provide the aerospace industry with the correct clamping forces required in machining today’s exotic materials.

Information on special and custom requirements is available upon request.

Royal Machine & Tool Corporation is ISO9001:2000 & AS9100 Rev. “B” Certified and serves the world’s leading industries by designing and building custom and standard workholding devices from simple manual fixtures to sophisticated hydraulic fixtures with multiple faces. In addition, Royal provides custom and standard chucks of all types for rotating and non-rotating applications…as well as a complete range of Contract Machining options and services from single prototype machining to high volume production requirements.

Special Automatic Index Chuck.

Initially, you must first look at the work piece you want to hold. A round piece of bar stock is the most simple of geometrics to work with. However, not all parts come from bar stock…some come as castings or forgings with non-uniform shapes. And this is where the selection process requires some thought because of the wide variety of chucks and options available.

The most common chucks are Standard Two or Three Jaw Chuck and Collet Chuck. More intricate shaped parts may require an Anvil Type One Jaw Chuck or a Four or Six Jaw Chuck. Listed below are the various basic chuck designs and where they are best suited. Each design provides various options…but, for now here are the basic applications.

• 
  Multiple Spindle Chucks.
  One Jaw Chuck - used for parts having a qualified side surface as a datum.
• Two Jaw Chuck - used mostly on square shaped parts.
• Three Jaw Chuck - used mostly for round shaped parts.
• Four Jaw Chuck - used to stabilize the grip on square parts.
• Six Jaw Chuck - applied to thin-walled parts requiring wrap around clamping to avoid distortion.
• Collet Chuck - used with parts requiring wrap around clamping while not marking the part…yet still maintaining close concentricity requirements.
• Index Chuck - used for parts with various centerlines as reference.
• Diaphragm Chuck - used with parts requiring optimal grip while machining plus critical part tolerance while not allowing distortion and markings.

It would be great to have all of the above chucks available in your tool room arsenal. However, that is never the case.

To select the most appropriate chuck, you must first review the following categories and determine the best method of chucking based on each of these areas: The Workpiece, Machine, Production, and Process.

Let’s now take a more in-depth look into each of these categories.

WORKPIECE

Looking at the work piece configuration, we have to find the best way to hold the part. This is best determined by the tolerances and operations required to produce the workpiece. It would be ideal to be able to machine the part complete in a single clamping. In many instances this is possible with the proper choice of chuck because we all know that the objective is always to handle the part as little as possible. Looking at the variety of chuck styles available will help in making the right decision. Not all parts are symmetrical. Some have a flange or outrigger which is a concern with speed and balance. This situation may call for the proper means to counterbalance the part or to reduce the speed of the process.

Sometimes parts are thin-walled and will distort when clamped with a standard 3-Jaw Chuck. A Collet or Diaphragm chuck may be the answer. Or, it may just require a reduced clamping pressure to allow it to secure the part, but not distort the part. In most cases, where distortion occurs, it is because of extreme clamping pressure. The first concern is that the grip pressure be substantial to hold the part in a safe and secure fashion. Once we review the work piece, we can now proceed to determine the machine tool.

MACHINE

There are many considerations to review in selecting the machine. Unfortunately, the ideal situation would be to have any machine and chuck available. We all know this is never the case. If your part can fit a machine with the right capabilities, that is ideal. However, it may be that you are restricted to a certain machine. Now you have to make sure the chuck mounting is compatible with the machine. What is the machine’s speed and horsepower? Is there sufficient rpm to obtain the surface footage required? Does the machine cylinder have the necessary pressure for the chuck and is there adequate cylinder stroke to actuate the chuck? Finally, is there enough swing clearance for the chuck, part and the tooling to process the part? The envelope of the machine may also restrict your capabilities.

Modifications may have to be made to the machine if your application calls for special fixturing such as an Index Chuck or a chuck with retractable locators. In most cases, when looking at Index Chucks, they require a separate hydraulic unit, double-acting cylinders, cylinder adapter, and tubing in lieu of a standard cylinder and drawbar or drawtube. Therefore,
in some cases you may have to make changes to the machine. For high production applications these type of changes are usually permanent
and require another area to be considered.

PRODUCTION

In just making a single piece, it is most appropriate to use a Manual Operated Chuck and Universal Jaws to clamp the part. Cycle time is not an issue because it is only a single workpiece. The part can be pecked-away-at without concern for any load from clamping or tool pressure. Tolerance and finish are wide open. This scenario plays out every day in many small shops.

High volume production of precision parts may require it to run unmanned, with clamp/unclamp detection as well as pressure monitoring and sensing of proper part location. This is only for the chucking phase…and may also require Automatic Load/Unload, automatic tool offsetting and breakage.

PROCESSING

Once the process is determined, the clamping method can be checked for locating the part appropriately and allowing sufficient clearance for the tooling, coolant flow and chip evacuation. The process indicates the datums for the dimensions being machined. In turn, this determines how the part is located and gripped. Now look at the tools and their tool path to make certain clearances are available. Clearances can be made as long as the integrity in clamping the part is not breached. This also holds true when allowing room for chip evacuation or coolant.

In many cases the part can not be completely machined in a single clamping. When doing the finish operation, the part may have to be oriented more precisely or in a different fashion. For example, a part may be held in a 3-Jaw Chuck for the roughing operations to remove the material with heavy depths of cut. Where roundness or concentricity are vital for the finish operation, a Collet Chuck may be the best option.

Review of each of these four categories should assist in determining the appropriate Chuck and Top Tooling to produce a quality part in a timely fashion with safety always in mind.

High Speed Anvil Type Index Chuck.

However, with the demand for higher speeds and feeds, improved surface finishes and tighter tolerances  has come changes in manufacturing. CNC Controlled Machines replaced Manual Lathes. The tooling industry developed Coated Carbides to attain the higher demanded speeds and feeds.  In order to reach these goals, chuck manufacturers have had to respond with workholding devices that could meet the situation and its ever-increasing demands.

High Speed Counter-centrifugal Chucks, Index Chucks, Chucks with shifting Centers, Compensating Chucks with Collets or Mandrels are becoming the norm on lathes. As the lathes take on the look and capability of a “Universal Machine”, the situation requires versatility in the way a part is gripped.

To meet today’s demands, workholding manufacturers have met a whole new challenge.

Originally, production requirements were high volume. The situation allowed multiple operations over a number of machines. Each machine was somewhat specialized in the sense that achieving changeover required much downtime. Therefore, when a changeover was required, it was limited so as to not disturb the production. This, in turn, caused machines not to work efficiently at the available speeds or feeds  because the tools were “OK” or the chucks could hold a variety of parts efficiently.

These lathes not only have the capability to turn parts at high speeds and feeds with better accuracy and repeatability, they also have the capability for drive tools, milling capabilities, automatic gaging, tool offsetting, automatic load/ unload, spindle positioning and backworking. All these options allow for many parts to be completed in a single operation, with one setup and one clamping.

Now, let’s look how all these demands and objectives can be accomplished by going through the thought process and determining the best possible method to hold our part.

The obvious goal is to make your product in a single setup…in the fastest time…at the least cost… and of the best quality.

It sounds simple. However, that is one loaded objective. In most situations, all the ingredients are not available. The machine may not have all the needed capabilities.  The costs may not be justifiable, or the required quantities may determine the process. The variables go on and on.

Initially, the chuck size has to be established. You want to make sure the part will fit safely and securely within the chuck envelope. Like everything else, there may be exceptions. The part may not always be round, or may have an extended arm, which will require a counterbalance.

Next, the type of chuck has to be determined. A common 3-Jaw Chuck is appropriate for most turning applications. However, if the part is rectangular in shape, a 2-Jaw Chuck may suit the part better for gripping. Another option may be a Collet Chuck or Mandel to maintain concentricity requirements between operations.

Review the part print and the tolerance requirements to define the process method(s) and  to obtain your objective…a consistent quality part in the least time. To accomplish this goal is to establish the process suited to the dimensional and finish requirements of the part. Datums are established for a reason. Know where they are and use them accordingly in your setup.

Production will dictate the process and tooling more than anything. If you have a job of major volume, you will want a power actuated fixture that allows the ease and quickness to load/unload in the shortest possible time. On the hand, if you are going to make only one or two pieces, you would use a manual chuck with top tooling capable of holding the part at the speeds and feeds necessary to cut the part. However, this is probably not the most efficient method.

Selecting the proper workholding method is just as critical as determining the correct cutting tools, speeds & feeds, and process. Like the aforementioned items, there are references, recommendations and many vendors with expertise to assist in the selection process. It would be to your benefit to use these knowledgeable and experienced resources to guide you.

The New Vision Wide Machining Center with its programmable, semi-automatic right angle head permits the complete finishing of vertical and horizontal operations in the same setup…and now allows Royal Machine & Tool to expand their product line of chucks up to a 72” diameter. In addition, the reductions in setup and handling will combine cost savings in labor with the faster completion/delivery of orders allowing Royal to offer more competitive pricing to its customers.

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.

In making the announcement, Richard Ruscio, President, stated, “Purchasing the new Vision Wide will allow us to enter into new markets which were previously unattainable due to capacity limitations. In addition, it will greatly compliment our existing 35 cnc lathes and machining centers as well as the five new machines acquired during 2006. The purchase of the Vision Wide is part of the successful formula that has made Royal a quality workholding manufacturer and recognized contract provider through our continually identifying critical areas for equipment improvements. ”

Royal Machine & Tool Corporation is ISO9001:2000 & AS9100 Rev. “B” Certified and serves the world’s leading industries by designing and building custom and standard workholding devices from simple manual fixtures to sophisticated hydraulic fixtures with multiple faces. In addition, Royal provides custom and standard chucks of all types for rotating and non-rotating applications…as well as a complete range of Contract Machining options and services from single prototype machining to high volume production requirements.

Before: typical Defective Chuck.

There are still many chucks manufactured fifty years ago that are still working today and making  quality parts. However, when (or if) a chuck(s) begins to perform improperly, you must make an important decision as to either repair, recondition or replace the defective unit. And there are many considerations to evaluate in making that decision.

Obviously, safety considerations are first and foremost in determining the overall results you are looking to achieve. Then, you must decide whether the chuck has to operate for a short period of time or for a long period of trouble-free use. And, most importantly, how will the cost difference of each of the three “R’s” effect your decision?

Now, let’s look at your reasons to consider repairing, reconditioning or replacing the 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 to meet your part process and tolerances?

If the answer to any of these questions is “YES”, then you should consider the three “R’s”.

REPAIRING

Usually, this is the least expensive service and the quickest to get you 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.

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.

RECONDITIONING

This is the midrange expense of the three “Rs” and is recommended when the cost of reconditioning is 60% or less of the price of purchasing a new chuck   A correctly maintained and lubricated power chuck will usually age gracefully and will 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.

After: Reconditioned Chuck.

Reconditioning usually can be done in half the time it takes to have a new chuck built. It may be such that a part has to be replaced, welded or plated. However, you have most of the chuck already completed.

It is important to note that replacement chucks still retain the old chucks’ design with any problems and/or deficiencies inherent to the old design. Any desired changes usually require replacement.

REPLACING

Quite often the cost of reconditioning exceeds 60% of the cost of a new chuck or it’s simply time to update and replace with a new design chuck.

The new chuck will have all the advantages of the latest designs and materials plus many times your operations have changed and you require redesigns to improve performance.

In addition to receiving a full one year factory warranty, possible considerations for selecting new chucks are:

1. The need to operate chucks at a higher RPM.

Today’s selection of coated carbide tooling requires much higher speeds and feeds than before. Current designs take high speed in to consideration, using counterweights and counter centrifugal mechanisms.

2. The additional travel required in master jaw strokes.

The usual stroke of a standard chuck is 3/8″ per jaw which in most cases is substantial.  However, with the long stroke chucks this can be up to 1″ per jaw. This permits gripping parts where a flange may have restricted gripping only a certain area which may not be the ideal situation. Also, the longer stroke will allow the gripping of more part diameters with the same set of jaws…thus reducing  setup time. With automation, the long stroke chuck allows part to be loaded more easily and also permits chips to escape more easily.

3. The ability to mount locators on chuck facings.

Newer chuck models allow Locators or Locator Bungs to be mounted on the face of the chuck which provides a stationary repeatable flat surface for the part to locate. Usually the locating face is on the moving top jaw and may yaw when clamping. Thus giving inconsistency from part to part.

4. The adding of new options such as Part Sensing, Chip Blasting, and Automation.

Today, in order to stay competitive, many companies have to run “Lights Out” with robots or automation which requires a great deal of sophistication throughout the whole process, …including the chucking. Monitoring the chucks actions is critical to preventing a problem which would shut down the process. Feeding air pressure thru the locating surface is a common  way, to detect if a part is not located properly. A drop in air pressure signals that the part is not seated properly, thus allowing the air to escape. Air may also be fed thru the the spindle to blow off chips from the mounting surface and part. Today, sensors can be
used to indicate clamp/unclamp, part location, and clamping pressures.

Making the right decision is critical and it would be beneficial to ask the assistance of a knowledgeable vendor in guiding you to make this most important decision.

Naturally, the final decision is yours and must be based on what is functionally and financially best for your situation…REPAIRING, RECONDITIONING, REPLACING…they all have their place.

Specially Designed Hydraulic Fixture.

In making the announcement, Richard Ruscio, President, said, “Our workholding specialists are experienced In the engineering, designing, machining and providing of highly specialized and custom-built hydraulic and manual operated fixtures designed to conform to the unique (and exotic) shapes and sizes found in today’s Aerospace Industry. These specially designed fixtures provide the rigid clamping forces required when machining ultra quality aerospace materials.”

Over 100 years workholding experience.

“Our aerospace customers are able to draw from workholding specialists with varied engineering backgrounds and experience. The ideas generated can be reviewed and discussed among specialists having over 100 total years workholding experience serving the needs of specialized groups including the aerospace, automotive, firearm, medical, recreational, flow control and petroleum industries.” stated Bernie McAloon, Sales Manager.

New Equipment and Software purchased…New Building Addition…to meet the increased fixturing needs of the Aerospace Industry.

In the past 12 months, Royal has invested in five new pieces of equipment for their turning and milling departments to expand their capabilities in capacity and machining. The engineering department has upgraded to Solid Works Software which enables solid  modeling in their designs…a features most vital in optimizing the fixture at the design phase by the offering of 3-dimensional viewing.

A 1,200 square foot building addition has been recently completed to provide additional manufacturing space by consolidating operations and improving work flow.

Complete information on the newly expanded aerospace services can be obtained by telephoning Sales & Marketing at (860) 828-6555.

Royal  Machine & Tool Corporation is ISO9001:2000 & AS9100 Rev. “B” Certified and serves the world’s leading industries by designing and building custom and standard workholding devices from simple manual fixtures to sophisticated hydraulic fixtures with multiple faces. In addition, Royal provides custom and standard chucks of all types for rotating and non-rotating applications…as well as a complete range of Contract Machining options and services from single prototype machining to high volume production requirements.

A Wide Variety of Production Components.

“The recent additions of automatic bar feed and sub-spindle capabilities to Royal’s Turning Centers now allow us to offer faster service and even more competitive pricing”, stated Bernie McAloon, Sales Manager. “In addition, the acquisition of five (5) Coordinate Measuring Machines…including larger capacity and programmable features…insures our customers of receiving the quality product expected in today’s highly precision market.”

In making the announcement of expanded service, Richard Ruscio, President of Royal Machine & Tool stated, “the combination of 50 years in providing contract machining service utilizing our workholding experience …and our having over 40,000 square feet of modern manufacturing facilities in CT…allows us to provide our customers high quality finished products and time-sensitive delivery.”

Complete information on the newly expanded program can be obtained by contacting Sales and Marketing  at (860)828-6555.

Royal Machine & Tool Corporation is ISO9001:2000 & AS9100 Rev. “B” certified and serves the world’s leading industries by designing and building custom and standard workholding devices from simple manual fixtures to sophisticated hydraulic fixtures with multiple faces. In addition, Royal provides custom and standard chucks of all types for rotating and non-rotating applications.

The 40 horsepower Supermax VMC features a 10,000RPM spindle with thru-spindle coolant and has a table capacity of 34” x 59”…allowing it to accommodate larger size power chucks in standard 2-Jaw, 3-Jaw, 4-Jaw and a combination 2/3 -Jaw configurations with various Master Jaw styles.
. .
In making the announcement, Bernie McAloon, Sales Manager, said, “We purchased the Supermax VMC because we identified from our sales inquiries an increasing need for larger size power chucks. The new machine will allow our Milling Department to produce more horsepower, higher speeds and feeds and, obviously, far better quality than the two (2) older VMC’s it has replaced.”

Royal Machine & Tool Corporation is ISO9001:2000 & AS9100 Rev. “B” Certified and serves the world’s leading industries by designing and building custom and standard workholding devices from simple manual fixtures to sophisticated hydraulic fixtures with multiple faces. In addition, Royal provides custom and standard chucks of all types for rotating and non-rotating applications …as well as a complete range of Contract Machining options and services from single prototype machining to high volume production requirements.

The 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, the 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 Corporation is ISO9001:2000 & AS9100 Rev. “B” Certified and serves the world’s leading industries by designing and building custom and standard workholding devices from simple manual fixtures to sophisticated hydraulic fixtures with multiple faces. In addition, Royal provides custom and standard chucks of all types for rotating and non-rotating applications…as well as a complete range of Contract Machining options and services from single prototype machining to high volume production requirements.