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KAIZEN TOOLS CORPORATION

FAQs:ABOUT KAIZEN HYDROGRIP TOOLINGS


Mandrels & chucks:
1..what are hydrogrip toolings either it is mandrel/chuck or toolholders & fixtures?
a. They are work holding and toolholding devices.they can be a single solid mandrel adopted with miniature
power pack consisting pistons,cylinder ,pressure control valves,actuation & refill devices or a clusture of
fixture.
This technology is more popular world wide for precision mfg & inspection areas .where as becoming more
familiar in India now a days for all possible areas.

2.How Do they work ?


The component to be clamped is placed in the clamping zone of the mandrel or chuck
if it is manually operated mandrel:
a.You turn the actuator screw to the specified graduation (it is marked to turn with the allenkey clock wise or
anti clock wise for clamping and declamping ) to clamp or declamp.
b.While clamping the metal expands to the entire surface and grips the component.the clamping force and
expansion ratios are specific to component type and type of operation performed and working conditions like
process temp .(mentioned in printed brouchere)
IF it is auto clamped it can be interfaced with CNC thr pushrod / drawbar or available powerpacks:
a.It is like any other clamping fixture .

3. How the hydrogrip toolings are classified ?


a.on the basis of fluid / pressurizing mediums
like OIL based & jelly based .
b.on the basis of method of component production
like CNC m/cing, grinding , EDM spark erosion & wirecut ,adopting process automation ,inspection &
assembly lines and so on.
c.on the basis of general type of organizations:
Like conventional mfg industries & toolrooms ,press shops &forging industries,powder Metallurgy
industries,foundries,CNC m/cing industries,MIM companies and so on.

4.can you name specific industrial applications ?


Auto component industry,automotive assembly units,toolrooms ,manufacturing industries like textiles
m/cs,CNC m/c tools mfg,conventional m/c tool builders,printing m/c mfg industries,m/c tools maintenance
industries,gears manufacturing companies,inspection & instruments calibration companies,air craft & aero
space mfg industries,defence & ammunitions mfg organizations,educational institutions,agro equpts & irrigation
equpts mfg companies,Oil & gas transportation & handling companies,railways engine,transmissions &braking
systems mfg cos, R&D institutions & gauges mfg companies.

5.How repeatability is ensured ?


a.Hydrogrip mandrels are designed & manufactured to the finest quality & geometrical tolerances as close as
with in 2 microns.irrespective of the component tolerances the mandrels behave the same pattern & ensures
repeatability & reproduceability.

6..why conventional tapermandrels are ineffective compared to hydrogrip mandrels ?


Incase of precision grinding & cnc mc/ing applications & inspection conventional taper mandrel has
limitations in following areas
a.Taper mandrels take care only point contact area and reveal the other geometries using pointing dials placed
on various locations.the point in contact may be a high point or an imperfect point which is not adequate to
function as reference surface.you will be ending by accepting a bad quality product and rejecting a good quality
product.
Otherway,expansion toolings expand / contract there by taking entire surface as true reference.
b.Taper mandrels won’t work on partial or bling holes as ref :
where as expansions toolings will do.
c.while using expansion toolings the targeted quality is inbuilt in process itself.
d.On thinwall/intricate profiled components ,al.or brass alloyied m/cined or ground and honed or lapped
components ,die cast components , MIM components or PM components for indigenous or exports
requirements NO DAMAGE or DENT MARKS ALLOWED.where as you can’t avoid it using tapermandrels.
Such cases expansion mandrels come as only rescuer.

7.what about the case in ID clamping compared to conventional screw type holders or taper holders ?
a.what ever listed for taper mandrels applicable here also.added to that below
b.any component inserted in to housing for any mfg process or inspection goes in only with a clearance to get
inside the housing.there it self the true revealing fails.

8.How hydrogrip chucks / ID clamping fixtures are more superior compared to diapharm chucks &
mechanical 3 jaw & 4 jaw chucks ?
a.The above clamping system consists of wear parts which results in inconsistency and ineffective over
prolonged useage..hydrogrip toolings avoid such failures.
b.hydrogrip toolings are most of the cases directly mounted to spindle taper (to become integral part of spindle )
which is of greater advantage to overcome cumulative error on chucking systems.

9.How do hydrogrip mandrels & chucks increases productivity ?


a.multiple component loading is a greater advantage can be never thought in any other system of mfg.
b.clamping & declamp hydraulic either manual or automated reduces down time
c.foolproof.
d.Very high cycle time improvement for cnc m/cing and cylindrical grinding areas.

10.How do hydrogrip toolings ensures repeatblity & reproducibility inturn achieve process capability ?
a.over useage of tolerance is brought in control as against limits given so as to achieve that the resultant
components fall in controlled sigma bands.
b.The components may have enjoyed ID or OD tolerances permitted during previous operations (some may be
in max,others in mean or min zone ).while clamping ,because of the expansion property the hydrogrip toolings
centralizes all the components so that the geometry & size control on current operation is achieved as desired.
c.Resultant parameters achieved on all the components of a particular batch are identical with in sigma limits.
d.With all this your process becomes capable.

11.What care to be exercised to achieve longer useage life on hydrogrip toolings ?


a.Don’t clamp or declamp in the absence of coverage dummy or actual components.
b.Don’t tamper / dismantle hydraulic ports/ power packs.
c.There are different hydrogrip toolings by design meant for different applications interms of holding pressure
& operating temperature.hence follow the instructions adviced.

12.How do I decide the kind of hydrogrip mandrel or chucks reqd for me ?


a.you need to send the detailed component drgs & parameters reqd to be clamped rest we will take care of it ?
b.pl.send what was the previous operation done ?
c.what is the ref dimension /area for doing current operation ?
d.what kind of operation?how much is the depth of cut per feed.? What can be process temp.generated ?
e.wt.of the component ?
f.single component or multiple component ?
g.specify whether the mandrels is meant for inspection,grinding or cnc m/c etc.if it is cnc m/c the kind of
clamping you want.either manual or auto clamping is needed? Spindly taper or face plate or chuck mounting is
reqd.
h.IF you are unable to decide on above you may simply send the drgs we shall guide the entire process & work
for you.if possible you may also kindly send the component sample.

13.any Case studies of successful productionised areas using hydrogrip mandrels:for mfg & inspection ?.
1.most of powder metallurgy & MIM components m/cing,grinding & inspection conventional & CNC.
2.Thin wall components Brass,Al alloys,diecast components.
3.Gears,gear blanks & guide rings ,bushes for automotive,textile m/s,printing m/cs for gears hobbing,gear
shapping , gear shaving & gear grinding.
4.precision bearings,cones,cone top & bottom,cup top & cup bottom.
5.M/c tool mfg industries for spindles ,guide rings ,longer ball cage & screwrods ..
6.Automotive valve guides , valve seats & tappets and flow control valves mfg.
7. CNC tooling systems , tool holders & shanks.
8.mfg of endmills , gear hobbing cutters ,form cutters & all types of multipoint cutting tools.
9.master ring gauges, plug gauges & thin wall rings.
10.In case of CNC or conventional gun drilling,deep hole drilling / reaming to guide the cutters.
11.while performing CNC operations on heavy jobs (like cylinders heads or bodys) the cutting action may be at
one end and ref: surface may be at an other end or far away to reach.such cases hydrogrip mandrels & chucks
plays a vital role to ensure results with out setting change.
12.cylinder liners ,pistons & piston rings mfg & inspection.
13.they function as attribute type of inspection arrangement on special cases.
14.All jigs & fixtures.
15.collets,drill & tapp heads mfg.
16.Drive pinions & pulleys ,bushes & shafts,oil pump gears ,shift gears & timing belt pulleys.
17.clutches & clutch plates mfg.
18.oil pump inner rotors & outer rotors.
19.All types of Cams, cam shafts mfg & cam grinding operations.
20.Double disc grinding & Rotary table surface grinding of components with ID or OD as ref:(alex types).
21.For achievements of high level of geometrical accuracies like concentricities ,runouts & cylindricity
22.majority of engine & transmission parts mfg.
23.Induction motors & micro motors shafts & rotors mfg & assy.
24.computers , printers hardwares & pheripherals mfg.
25.most cases of aircraft ,sattelite ,launch vehicles parts mfg & fabrication of body.
26.Wide range of defence mfg applications Riffle parts,bullet shells , shells & missiles body mfg.
27.turbine blades inlet/ exhaust & rotors mfg.
28.dynamic balancing of shafts,spindles & equipts etc.
29.shock absorber parts mfg & assy.
30.hydraulic / pneumatic pistons,cylinders mfg & assy.
31.Process automation systems / special purpose machines.
32.Robotics.
33.compressors , parts mfg & assy for refrigeration & air conditioning.

14.what are the advantages?


1.cost reduction on unit price of component produced.either increased bottom line or win the competition.
2.start from minimizing downtime ,increase of productivity and goes upto achieving capable process.
3.Brings down human involvement there by minimizes errors.foolproof systems.
4.simple to operate and easy maintenance.fix it &forget type.
5.hydrogrip fixtures can be handled directly by operator if installed in front /near of every producing m/c to
ascertain quality inprocess .(need not wait & create down time until feed back from quality dept arrives)
6.Frequent useage of CMM and gear test & pcd runout testing equipments can be limited to only for final
inspection and sampling inspection.while hydrogrip fixtures take care of line inspection or process control
area.hence life of such heavy invested equipments saved.(imagine the inspection cost/component)
7.continuous improvement possible with best of the savings in cycle time.zero down setting time.
8.Handling damages on finished components avoided.
9.now a days ,when ever bottle neck arises from a particular m/c the first focus is given oh clamping systems
by way of converting them to hydrogrip.
10.stands first choice in all FMEA activities as a preferred choice to eliminate errors due to clamping.

15.what is the limitations & where we can not apply this technology ?
a.No limitations.can be applicable in every precision mfg area.we continuously explore new areas.
b.clamping need not be only on cylindrical surface alone ,can be extended to any profiles, contours & gears.

16.Can we adopt the hydrogrip component holding system for various fixtures?
a.Every jig or fixture needs component / tools several location & clamping arrangement.jigs & fixtures are used
in conventional as well as CNC turning,milling,surface grinding ,cyl.grinding,broaching,drill & reaming
etc ..etc.. operations.nowadays such cases adopting hydrogrip clamping ensures positive clamping and makes
the system simple .
b.Speciality inspection fixtures demands hydrogrip clamping .
c.Incase of gear testing equipments , instruments & fixtures presence of hydrogrip clamping eliminates the need
for sophisticated measuring equipments .it makes it possible to arrive at cost effective inspection fixtures build
to meet the specific tasks.
d.For low volumes & trail production Instead of going for std.gear test equpts/roll test m/cs at heavy costs
,custom built low cost inspection solutions are possible.

17.what are rotary hydrogrip fixtures ?


a.They are speciality inspection fixtures used for final inspection of gears ,gear blanks & similar rotating parts.
b.most components need to fulfill the geometrical requirements like OD run out ,concentricity & face run out
etc at large surface area .for inspecting such components instead of keeping the component stationary and
moving the dials allover the surface ,here with rotary arrangement ,we ensure rotating the component keeping
the dials at fixed points .by this way vibrational errors and manual movement errors are avoided.
c.Rotational play is controlled based on application .ranging from .02mm to .003 microns by the use of high
precision class P4 bearings etc.

18.What are hydronuts & why it is essential ?


a.CNC & conventional milling/hobbing applications while performing gears hobbing or gang / horizontal
milling ,conventional locknuts fail due to play on cutters .it can be by clearance/backclash errors .where as
hydronuts takes care of such errors and offers a positive clamping solutions.

19.What are hydrogrip toolholders for CNC ? advantages ?


a.Positive clamping is ensured with a clamping force much higher than resultant cutting force.
There are standard & special varities available based on applications.
b.High T.I.R accuracy & repeatability ensured depending on applications as close as < 3 microns.
c..Higher accuracy & greater feed rates are advantages than cutting tool clamping .
d.As close as 0.003mm roundness achievable on 2.5 *D (L/D) ratios.
e.with a single shank varities of dia of cutters can be clamped using collets.
f.longer tool life.
g.The clamping dia is meant for “h6” cutting tool tolerance.
h.balanced at G=6.3 @ 15,000 RPM.

20.What is the safe operating temp ? and what to do for elevated temp application ?
1.the safe operating temp is between 20 to 40 deg C.consult us for elevated temp applications for specialized
solutions.

21.How do I clamp on PCD of gears for processing or inspection ?


a.Gear PCD clamping is made effective only with hydrogrip mandrels & chucks .
b.In case of High precision gears clamping ,the entire gear profile is clamped using complete profile wirecut &
fine lapped with micron accuracies.where as other cases precision ball cages are used .optional to customers
accuracy needs.
c.excepting this method ,by all other methods PCD clamping shall continue to be a half hearted method.