Protection Systems – The Safe-Lock pull out protection system from Igenhausen-based Haimer, close to Augsburg in Germany, is said to ensure safe cutting in tool clamping.
According to Haimer, special drive keys in the Safe-Lock tool holder perfectly match the spiral shaped grooves on the cutting tool shank, creating frictional clamping forces and a positive locking form-fit. This prevents the cutting tool from getting pulled out of the tool holder. Also, it increases the productivity through faster permissible speeds and increased tool life, the company notes.
Safe-Lock is becoming a standard in tool holding for milling operations, the company claims. Superior to conventional milling chucks and Weldon shanked tool holders, since its introduction, ten years ago, it has been winning numerous license partners. These rank amongst leading cutting tool and tool-holder manufactures, like, Walter, Widia, Sandvik Coromant, Seco Tools, Sumitomo, Kennametal, Helical, Emuge Franken, Data Flute, Niagara, OSG, and Mapal, with Iscar and Ingersoll now offering Safe-Lock shanks since 2017. Moreover, the shrink, collet and hydraulic chuck Safe-Lock tool-holder portfolio has largely increased the last few years. Kennametal now offers Safe-Lock hydraulic chucks, while Mapal is in the process of introducing the company's hydraulic chuck with Safe-Lock to the market.
Andreas Haimer, Haimer's managing director notes: “We are proud that our Safe-Lock pull out protection system has established itself as the new standard in the heavy duty and rough milling industry, and is also becoming more and more important in other areas such as trochoidal milling.”
Safe-Lock has also taken its place in heavy-duty machining, which is a daily challenge in the aerospace and energy producing industries. Various titanium alloys are not only light, but also very rigid, corrosion-resistant and difficult to machine. All this does not only affect machine concepts and processes, but also the cutting tools and tool holders that are being used.
During the milling process of workpieces made from a solid block, up to 90% of the material is removed. To optimise the process economically and qualitatively, as well as to achieve a high metal removal rate, high torques and feed rates with low rpms are chosen. And during this High Performance Cutting operation (HPC), high pulling forces occur. In combination with high cutting forces and aggressive feed rates, a flexing movement of the tool in the tool holder is created, which increases the risk of tool getting pulled out. This especially affects all tool holder designs that provide accurate clamping and a high run-out accuracy, like for example shrink, hydraulic or milling chucks.
The Safe-Lock system is also widely used in the rather competitive automotive industry, where the difference between profit and loss is dependent on process efficiency and quality without compromise is a must as well. Daniel Rautenbach,managing director of CNC-Machining Specialists at Glätzer knows how fiercely competitive and thorough the automotive industry must be. He notes: “Perfect quality and delivery reliability are the basic requirements for quotes in our industry. Pricing is highly competitive.”
Safe-Lock is also becoming increasingly popular in other industries and during HSC machining with high-helix end mills as well as in trochoidal milling. During trochoidal milling operations, where the cutting speed and axial depth of cut can be increased through software support, the productivity is also improved. Thus milling operations are carried out three times faster with deeper depths pf cut, even when it comes to hard and difficult to machine materials.