Most chucks with conditions such as excess wear…looseness of fit… improper gripping pressure…imbedded chips can be sent directly to Royal Machine & Tool for evaluation by qualified technicians who will disassemble, clean and determine the condition(s) required to refurbish chucks back to their original accuracy and repeatability. A firm quote advising of the required services and delivery schedule will then be supplied at no charge.

Rebuilt and/or reconditioned Royal Machine and other brand name chucks come with a full one year warranty.

Before deciding whether to recondition or repair a defective chuck, companies can initially contact Royal Machine & Tool for suggestions. It may be recommended to have the chuck forwarded to the factory where they will provide a free evaluation and proposal.

After evaluating the defective original chuck, reconditioning was recommended to provide new chuck standards, one year full warranty (the same as a new chuck)…and up to a 30-40% cost advantage over of a brand new chuck

In addition to its repair program, Royal builds a complete line of replacement chucks for other chuck manufacturers.

Complete information on the rebuilding and/or reconditioning of various style chucks is available on the website – www.royalworkholding.com.

Founded in 1952, 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 Steel Bodied Manual Large Diameter Chucks are Manufactured in the USA, in sizes from 24 inches to 84 inches in diameter and are custom designed, and built to, and beyond customer specifications.

In making the announcement of the newest size 84 inch chuck, Guy Byrne, General Manager, stated, “We’ve had the ability to manufacture up to the 84 inch diameter Chucks since 2007, as far as milling, grinding and assembly were concerned. Where we had an issue was in the turning operation. Until recently, one of our key suppliers, Duel Manufacturing in Southington, Connecticut, which Royal has teamed up with for over the past 15 years, purchased another VTL with a 96 inch Diameter capacity. The newest VTL solved our issue. With the turning issue no longer holding our latest design back, it continues to evolve.”

“Unlike older inferior designs using cast iron bodies and scrolls that have limited wear ability, our design boasts its superior steel strength, induced wear resistant body, hardened and precision ground master jaws and wedge. This produces increased wedge style gripping forces and accuracies. 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.”

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

All Large Diameter Chucks are now also available in power operated, 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 Diameter Manual and/or 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 1952, 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 facilities representing over 30,000 square feet including state-of-the-art CNC machine tools. All services and products are performed and/or 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.

Original 8,000 square foot manufacturing facility employing 20 people is still owned by Royal Machine.

Recently added products and services include a new “Universal Valve Fixture” providing greater flexibility in covering a large range of valve bodies with a single fixture…a new “Solid Works” 3-D Software upgrade permitting 3-D dimensional viewing and clearer definition of workholding products and work areas…new Larger Size Power Chucks in sizes ranging up to 84”in diameter for power or manual operations and rotating/non-rotating applications…new Manual VTL Chucks to provide close tolerance capabilities required in machining of thin-walled products…new Hydraulic QVC Fixture providing up to 50% more production improvement and more consistent gripping forces for high volume production applications.

During the past three years the company has also expanded its manufacturing capabilities with the addition of a 1,200 square foot building to its 30,000 square foot corporate headquarters and manufacturing facilities. Plus, invested in five new pieces of equipment for its turning, milling and quality departments in order to expand its capacity and machining capabilities.

In making the announcement of its 60th anniversary, Richard J Ruscio, Royal Machine & Tool president and son of its late founder, John L Ruscio, said “In the future, the combination of our recently added new services and equipment and our 60 years of experience in designing and building custom and standard workholding devices will make us even stronger in providing our customers quality finished products…and time-sensitive deliveries.”

In addition to the new products previously described, Royal Machine during the following decades initiated the introduction of these new products to meet the special needs of its customers in the Petroleum, Medical, Automotive, Valve and Aerospace Industries…

Current 30,000 square foot manufacturing facility employs 48 with over 35 state-of-of-the-art CNC Machine Tools.

Since its 1952 founding in a backyard barn with five employees, the company had expanded to over 50 employees with modern administrative & manufacturing facilities in Berlin, CT representing 30,000 square feet including over 35 state-of-the-art CNC Machine Tools. It is ISO9001:2008 & AS9100 Rev. “B” Certified and serves the world’s leading industries and all services and products are performed/produced in the USA.

Products and services include the design 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 630 MM 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 1952, 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.