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Chapter 5

Clamping Devices.

Learning Objectives

At the end of this course the student will be able to:

- Select the correct clamping device

- Identify the function of each clamping devices

- Differentiate the different between each clamping devices

Duration
1 Hour

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Chapter 4 Clamping Devices

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Four Considerations for Selecting Clamping Devices.

For many rotational part applications, both ID and OD, a standard three-jaw chuck is
sufficient. But if more specialized work holding is needed, here are some things you must
consider.

 The part
- The first workpiece consideration is whether the surface to be gripped is machined.
The part shape also needs to be considered.
 Operations
- Understanding what processes a shop is performing on its parts helps us determine
the best chuck or arbor for the application
 Material
- Material that hard to cut needs a good clamping system to withstand the forces
acting during cutting.
 Machine
- Machine performance is a critical factor in successful application of any work holder.
Matching the right chuck or arbor to the performance capability of the machine tool is
key to optimum productivity.

Forces
Forces acting on lathe clamping devices. The main tasks of the clamping devices on lathes
are:
1. To hold the workpiece.
2. To transmit the rotary motion from the lathe spindle to the workpiece.

The clamping devices must ensure that the workpiece does not move out of the clamping
position despite the different forces acting on the workpiece during the cutting process.

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The forces are:

1. Main cutting force

2. Feed force

3. Infeed force

4. Centrifugal force

5. Lever force

The centrifugal force mainly appears raw material is put in to the clamping device and the
machine runs with a high revolution. It also has a negative effect for the roller bearings of the
machine spindle and can cause vibration. The impact of me lever force is shown and
calculated in the picture beside.

The picture below shows how a workpiece should be clamped.

The two very negative forces, the centrifugal force and the lever force, are eliminated by
supporting the workpiece with a live center. .

The step on which the workpiece is clamped prevents the feed force to push the workpiece
into the chuck and at the same time guarantees the proper guidance and support by the life
center which is required to eliminate the danger of the workpiece being thrown out of the
chuck.

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The universal or self centering chuck

The most commonly used lathe chuck is the self-centering three jaws chuck. This chuck is
provided with three accurate self-centering jaws which are controlled by a bevel gear driven
crown wheel.

All three jaws are actuated by turning any one of the three bevel gear pinions. They are
simultaneously moved, so that they are in each position systematically to the axis of the
chuck. The self-centering four jaws chuck functions in the same way as the three jaw chuck.

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Chuck Type Advantages Disadvantages

3 Jaw Chuck  self-centering  can't hold square bar-stock
 Can hold hex bar-stock  run-out/off-center can't be easily fixed
 Quick and easy to use  can't hold irregularly shaped work
 can't turn off-center
4 Jaw Chuck  work can be centered to  slower/fiddlier to mount work (dial-
high precision indicator required)
 can handle square /  can't hold hex-stock
rectangular bar
 can turn work off-center
 slightly more grip on
round stock

System of Clamping Mechanism

This chuck is specially suited for holding round or hexagonal workpieces. Even casted. or
forged workpieces which are not exactly round can be damped best in this self-centering
three jaws chuck.

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The jaws of the chuck are not reversible. For that reason, two sets of jaws are provided for
each chuck (a+b = formal set, c = reversible set ).

Steps on the clamping jaws increase the clamping range. Smaller workpieces can be
clamped with the jaws in normal position.

(a) For inside clamping the workpiece may be clamped on the steps of the jaws by exerting
an outward pressure.

(b) For larger workpieces which must be clamped on the outer diameter, the second set of
jaws the reversible jaws must be used.

(c) If the workpiece is clamped on the outer diameter, the biggest workpiece diameter
which can be clamped is like the chuck diameter.

The jaws are numbered 1, 2 and 3 like the slots in which they are fitted.

The jaw number MUST correspond with the slot number if the workpiece is to be centered.
The jaws are made for a particular chuck and are NOT interchangeable with other chucks.
Make sure the chuck and jaws have the same serial number.

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Installing chuck jaws.

Clean the jaws, jaw slots and the spiral thread (seen in the jaw slots). Turn the spiral until the
first thread does NOT quite show in jaw slot # 1. Slide jaw # 1 into the slot as far as it will go.
Now, turn the spiral until the spiral engages with the first tooth on the bottom of the jaw
Repeat the operation at slot # 2 and slot # 3.

Remember! Make it a habit that whenever you let go of a lathe chuck key, the chuck key is
on the to_1 tray or lathe board. Never let the chuck key rest in the chuck. Universal chucks
lose their centering accuracy When too much pressure is used (by using an extension pipe
for the chuck key) to mount the workpiece or by clamping the workpiece too near the front of
the jaws.

Some chucks often have hardened and precision ground base jaws and different reversible
hardened top jaws or soft jaws.

The soft jaws can be formed to the requirements of the workpieces.

Some of the advantages of soft jaws are:

1. No clamping marks on already machined surfaces.

2. Minimum deforming of hollow workpieces by clamping-force (the clamping force is

transferred to a bigger clamping area ).

3. Short workpieces with big diameters can be turned exactly so that both faces are
parallel.

4. Steps on both sides of the workpieces are exactly centered.

5. Workpieces with same length can be easily machined to the exact length if the
machine is set. The jaws act as a stopper or shoulder.
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Three or four

Jaw combination chuck. This chuck is a combination of a self centering chuck and an
independent chuck. The function is shown beside.

If you turn the bevel gear pinion it works as a self-centering chuck. Each jaw can also be
additionally moved in or outward independently by turning the adjustment spindle. This chuck
is used for not exactly round or not symmetrical workpieces or for adjustments be made for
turning eccentrically workpieces.

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Independent 4jaw chucks

These chucks are used for holding workpieces of irregular shape, heavy parts or parts with
large diameters. The chuck body has four independent chuck jaws which can be reversed.
Powerful clamping forces can be produced by the adjusting spindles, which have a square
thread.

The fixing slots in the plate make it possible to clamp irregularly shaped workpieces with
bolts and clamps. Special clamping devices designed for particular parts can also be
attached. Alignment is assisted by circular grooves on the surface of the plate.

The independent 4-jaw chuck is attached to the lathe spindle in the same manner as any
other chuck. The versatility of the independent 4-jaw chuck gives it many advantages. But
clamping workpieces is time-consuming, since they need to be aligned in order to run
concentrically.

Examples of workpiece which need to be fixed with an independent 4 jaw chucks.

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Alignment of workpieces

Use some shims adjust the distance between the workpiece and the chuck face so that it is
equal at all points. For rough-worked workpieces a scriber is used to check the centricity.
When the scriber touches the workpieces at c, jaw 2 is loosened by half of the amount of the
eccentricity and jaw 4 is tightened

When the scriber shows an equal light

gap over the whole circumference and on
the face of the workpiece, the workpiece
is properly aligned.

Fixing workpieces to the independent

4jaw chuck with special tools.

Clamping Devices

The angle plate

This is suitable for fixing pieces with a flat base, which must sit parallel to the axis of rotation.

The angle plate is fixed to the chuck with the jaws removed and the workpiece fixed to the
angle plate. In order to prevent the angle plate from slipping, a piece of paper is placed
between the angle plate and the faceplate of the chuck.

If the weight is distributed unevenly, the resulting imbalance must be corrected by counter
weighting.

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Clamps and Clamping

Many irregularly shaped workpieces can only be secured with bolts and clamps. Clamp
plates and bolts must not be bent or damaged in any way. In order to prevent localized
pressure, the height of the packing piece must be the same as that of the workpiece.

Where clamp plates have two bolts, the bolts must be tightened evenly. Clamp plates with
one bolt distribute the damping pressure over the workpiece and the packing piece.

The clamping bolts should exert their pressure as near as possible to the workpiece. The
clamping bolts should not extend beyond the workpiece more than is absolutely necessary.
This makes it possible to have a short cutting tool setting. In this way better metal cutting
without vibration is achieved. In addition, the danger of accidents which may occur as a
result of work clothes caught in projecting parts is reduced.

Two-part workpieces

These require particular care when clamping. The soldered joints must not be opened
(damaged) by the clamping pressure and, therefore, should not lie in the direction of two
chuck jaws.

The two-part workpiece is aligned firstly horizontally with a perfectly flat base strip and a
marking gauge according to the soldered joints, and then by turning the chuck 180° to the
middle position.

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This centring process is called "rotational centring". It is essential to obtain two exactly equal
workpiece halves. Caution is required when clamping thin-walled workpieces. The workpiece
should not be clamped over the whole adjustment length of the jaw, as this makes it
practically impossible to align it horizontally.

Parts to be turned to obtain equality should not be gripped at the joint line. Otherwise the
overlap error cannot be clearly revealed.

Accident Prevention.

The maximum speed of rotation of the chuck must not exceed that specified by the
manufacturer. Due to powerful centrifugal forces arising, there is a danger of the chuck
breaking if the speed of rotation is too high.

Care should be taken to ensure that all four jaws are tightened evenly to prevent uneven
clamping forces which may cause damage to the chuck (i.e. distortion).

Caution is required when stopping the machine where chucks are attached to the working

spindle with a V-thread.

Caution!

Special care is required when cutting threads. If the direction of rotation is suddenly'
changed, chucks and faceplates can easily become loose by themselves.

The chuck or faceplate must never be slowed by hand. Supports or counterweights must be
secured in such a way that they cannot fly off or outward.

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Collet chuck

The collet chuck is very often used to clamp workpieces with smooth, regular shaped and
accurate surfaces. The collets are made of tool steel, hardened and tempered.

They are accurately ground both inside and outside so that the inside diameter, which
provides the gripping surface, the body and the tapered end are concentric.

2
The tapered end of the collet is slotted:  of the hole length of the collet. The other end of
3
the collet is threaded. A key way is cut in the threaded end to fit in a key. The collet is guided
directly by the spindle head of the main spindle of the lathe machine an adapter to hold and
centre the collet in the lathe spindle.

The function of a collet chuck is as follows:

If the tapered end of the collet is pulled or pushed into the inside taper of the main spindle or
the adapter, the elastic part of the collet that is the tapered and slotted will contract and
clamp the workpiece.

If the pulling or pushing force is released, the collet will expend and the workpiece can be
taken out. Clamping or releasing the collet can be done by a hand wheel/lever or by pushing
a button which activates a pneumatic or hydraulic clamping system.

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The advantages and disadvantages of using a collet is as follows:

Advantages Disadvantages

1. Faster. 1. Each diameter needs a different collet.

Diameter tolerance only: 0.2 mm
2. Simpler, easier.
2. Clamping force less than in a chuck
3. Safer (no chuck key).
3. Feedforce may push the workpiece into
4. No clamping marks.
the collet.
5. No deforming of thin, sensitive parts.

6. Cutting force nearer to spindle

bearings (less vibration).

Standard-collets are available in diameter steps of 1 mm. Special form - collets are also
available as well as soft collets which can be machined to the required diameter or form.
Special inside or outside step collets for bigger diameters are also available.

The step collets are very useful if thin and accurate workpieces must be clamped without any
deformation.

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Power activated collet clamping device for CNC-Lathes

The mounting plate, chuck body and the clamping head are manufactured from height quality
alloy steels and are heat treated to a hardness of Rc 56-60.

All parts are precision ground to extremely close tolerances. After grinding, the clamping
head (collet) is separated into segments which are bonded with vulcanized rubber to form a
single clamping element.

The clamping tolerance for diameters up to 65 mm =+ 0,5 above 65 mm + 1,0 mm. The
concentricity is less than 0.01 mm.

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Picture "a" shows a standard collet with a serated clamping surface. This collet can also be
used for raw material?

Picture "b" shows a collet for precision clamping with internal ground diameter, Picture "c+d"
shows a machinable collet (c) and how it can be machined (d).

On this collet only the outer diameter and the coupling part are hardened, while the inner
diameter and the face remain soft. With a loading ring the collet can be machined to the
required size.

Picture "e" shows a specially designed clamping device. By using it, the transfer of the axial
clamping force to radial clamping force is very efficient. This results in a very rigid clamping
system.

Even milling operations can be incorporated into the turning process.

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Clamping on mandrels

Workpieces may be mounted on mandrels. The mandrel is located between lathe centers
and the component is gripped by the surface of the bore diameter.

Basically two types of mandrels are used.

1. The fixed mandrel

2. The expanding mandrel

Fixed Mandrel

This mandrel is made of hardened steel and is ground slightly tapered (taper = 1 : 2000, i.e ;
over 100 mm the mandrel tapers by 0.05 mm)

Since the mandrel is located between the lathe centers, one end of the mandrel (the thicker
end) has a flattened area. This ensures that the lathe carrier will drive the mandrel. The
drive is transmitted from the 2 mandrel to the component by the friction between the mandrel
and the surface of the bore.

When fitting the workpiece onto the mandrel, neither the mandrel nor the workpiece should
be damaged. Frequently a mandrel press is used for pressing the mandrel in and out.

Disadvantages of a fixed mandrel

1. The clamping range for each mandrel is very small. The diameter of the thinner end is
the nominal size. The thicker end for 100 mm in length is 0.05 mm thicker in diameter.
A fixed mandrel 20 for example has a clamping length of 125 mm. That means the
thicker end has a maximum diameter of 20.0625 mm.

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2. The clamping force between the mandrel and the workpiece must be much higher
than the cutting forces which act on the bigger outer diameter of the workpiece. To
provide such a big radial clamping force, the axial force to press the mandrel into the
workpiece must be very high.

Result: The hole may become bigger (on one side, where the bigger end of the
mandrel provides the clamping force).

Result: The diameter of the hole is out of tolerance. (workpiece is spoilt). If you do not
press the mandrel hard enough into the hole of the workpiece, the cutting force may
loosen the workpiece.

Result: The bore diameter of the workpiece may become bigger and out of tolerance
(workpiece is spoilt).

3. If more workpieces with same dimensions have to be machined, the measurement in

x - axis must be readjusted for each workpiece.

4. When facing the workpiece, the workpiece may move in x- axis on the mandrel (no
stopper). Result: Measurement may be incorrect.

5. It is very time consuming to clamp and unclamp the workpiece. Why? Explain the
clamping process.
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Expansion Mandrels

Beside the self-centering 3 jaws chuck, one of the most often used clamping devices in the
industry is the expansion mandrel. For anY'7machine, workpiece or machine operation a
broad range of standard expansion mandrels are available. For special purposes expansion
mandrels can also be custom made. The function of an basic expansion mandrel is simple. A
slotted bush is pressed on to a tapered mandrel (as shown below).

The bush expands and transfers the axial force into a radial force which clamps the
workpiece.

The functions of expansion mandrels which are fixed directly into the taper of the main
spindle or onto the tapered and of the spindle head are comparable with collets.

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Advantages of expansion mandrels compared to fixed mandrels and basic expansion

mandrels are:

1. The clamping time is very short.

The clamping - or loosening process can also be power activated. That means, by
using this mandrel, the clamping process can be integrated in an automated production
process.

2. The clamping accuracy is very high and adjustable.

3. On an expansion mandrel, the accurate, cylindrical hole of the workpiece is not pushed
onto a tapered mandrel and is therefore not widened.

4. The hole length of the bore is in contact with the cylindrical expansion bush. That
results in a high concentricity from up to 0.01 mm.

5. Expansion mandrels fixed directly into or onto the spindle head are normally provided
with a stopper (important for mass production).

6. Expansion mandrels may have a clamping range from 0.5 to 5.0 mm. This depends on
the type and the diameter of the bush.

Special power activated clamping mandrel

This type of expansion mandrel has a big clamping range. Otherwise it is used like the other
expansion mandrels for turning grinding, gear cutting or control purposes. Spring mechanism
prevents the jaws from falling out.

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The latest developed clamping technology offers a hydraulic activated membrane expansion
mandrel. It is used for tools as well as workpieces.

Advantages:

 Enclosed chamber system: Insensitive to dirt.

 Clamping force can be metered precisely.

 Tremendous clamping force thanks to high internal pressure.

 Requires little maintenance.

 Maximum long-term true accuracy 1-3! -l (up till _ 50 mm).

 0.3% expansion rate off, relevant damping diameter. For example: mandrel _ 50 has

a clamping tolerance from 0.15 mm.

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Question sheet For Clamping Devices For Workpieces on Lathes

1. What is the disadvantage of the independent 4-jaw chuck?

.………………………………………………………………...……………………………
.…………………………………………………………………………………...…………

2. List the procedure for centering the workpiece on the independent 4-jaw chuck:

………………………………………………………………...……………………………
.…………………………………………………………………………………...…………

3. What happens if the workpiece cannot be accommodated in the chuck jaws?

………………………………………………………………...……………………………
.…………………………………………………………………………………...…………

4. Name the 3 types of collets commonly used in turning operation:

a.………………………………………………………………...……………………………
b..…………………………………………………………………………………...…………
c..…………………………………………………………………………………...…………

5. What are the 2 main differences between a3-jaw chuck and a collet chuck?

a.………………………………………………………………...……………………………
b..…………………………………………………………………………………...…………

6. Why must the collet chuck have gaps and what are its function?

.……..…………………………………………………………...……………………………
....…………………………………………………………………………………...…………
....…………………………………………………………………………………...…………

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7. There is a keyway on collet chucks. What will happen if no keyway is provided?

.……..…………………………………………………………...……………………………
....…………………………………………………………………………………...…………
....…………………………………………………………………………………...…………

8. Why do we check the squaresness of faceplates?

.……..…………………………………………………………...……………………………
....…………………………………………………………………………………...…………
....…………………………………………………………………………………...…………

9. Describe clearly how to mount the faceplate onto the spindle:

a...…………………………………………………………………………………...…………
b...…………………………………………………………………………………...…………
c...…………………………………………………………………………………...…………
d...…………………………………………………………………………………...…………
e...…………………………………………………………………………………...…………

10. Describe how to check off the balance on a faceplate:

a...…………………………………………………………………………………...…………
b...…………………………………………………………………………………...…………
c..…………………………………………………………………………………....………
d.…………………………………………………………………………………...…………

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Answer Seet For Clamping Devices For Workpieces on Lathers

1. What is the disadvantage of the independent 4-jaw chuck?

The clamping procedure is time consuming

2. List the procedure for centering the work piece on the independent 4-jaw chuck:

a Align the vertical axis or the work piece with the face on the chuck
b. Align the horizontal axis using fixed point adjustment or dial test indicator
reading

3. What happens if the workpiece cannot be accommodated in the chuck jaws?

The jaws are removed and the work piece is clamped to the faceplate.

4. Name the three types of collets commonly used the interning operation

a. Dead length types

b. Draw back types
c. Push out types

5. What are the two main differences between a 3-jaw chuck and a collet chuck?

a. Collet chuck must be tightened by draw bar to hold it in position

b. Only certain diameters of the work piece can be pushed into the collet chuck
as compared to the 3-jaw chuck.

6. Why must the collect chuck have gaps and what are its functions?

To secure work piece strongly and firmly during operation.

7. There is a keyway on collet chucks. What will happen if no keyway is provided?

The collet chuck will rotate or turn free in the spindle hole even though tightened.

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8. Why do we check the squareness of faceplates?

To avoid an uneven surface and the tendency of oversizing the work piece during
the cutting operation.

9. Describe clearly how to mount the faceplate onto the spindle

a. Clean spindle nose
b. Clear bore and location faces of faceplate
c. Place protective board a cross sideways under the spindle nose

10. Describe how to check off the balance on a faceplate

a. Place speed selection gear in neutral

b. Turn faceplate using hands until wokrpiece is halfway between top and bottom
of swing and release faceplate.
c. If the faceplate turn and the work piece swings back to the bottom, then out of
balance exists

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