WORKHOLDING SYSTEMS www.ptgworkholding.co.uk INSTALLATION & PRE-LOADING INSTRUCTIONS Pre-load Adjustment Screw Component Component End Locator Pre-load Flats Double Angles Machine Drawbar M/C Spindle Expander Pin Pre-load Flats Expanding Sleeve Mandrel Body • Ensure the machine drawbar is fully forward. • Screw expander pin clockwise into the drawbar until the sleeve grips the • Load mandrel body to machine spindle component. (using clock register or double-angle form to check concentricity) • Back-off expander pin anti-clockwise until first available pre-load flat is adjacent to pre- • Fit end-locator to mandrel body (if not load adjustment screw. already fitted). • Remove component and check loading • Ensure double-angles are clean on both the clearance to ensure easy loading. mandrel body and sleeve. • Tighten pre-load adjustment screw ensuring • Place expanding sleeve on mandrel body. expander pin has slight radial movement, to allow pin to slide freely. • Ensure pre-load adjustment screw is retracted, and place expander pin in • Finally, check by loading the component mandrel body. Screw the pin clockwise and operating the drawbar, ensuring the into the drawbar until the head of the pin component is satisfactorily held. Ensure that contracts with the sleeve, ensuring the pin the drawbar pressure is sufficient to prevent does not expand the sleeve. slippage. INSTALLATION & PRE-LOADING INSTRUCTIONS & PRE-LOADING INSTALLATION • Load component onto the mandrel • The mandrel is now ready for operation. assembly in its working position. 2 CONTENTS INSTALLATION & PRE-LOADING INSTRUCTIONS ................................2 CONTENTS ...........................................................................................3 INTRODUCTION ...................................................................................4 MODULAR MANDREL SYSTEMS .........................................................5 POWER OPERATED MANDRELS FACEPLATE DRAWBAR OPERATED MANDREL ........................ 6 SPIGOT DRAWBAR OPERATED MANDREL ...............................7 HAND OPERATED MANDRELS BETWEEN CENTRES MANDREL ................................................8 FACEPLATE NUT OPERATED MANDREL....................................9 STANDARD SLEEVES ........................................................................ 10 SPECIAL SLEEVES AND MANDRELS .................................................11 SPECIAL APPLICATIONS ....................................................................12 SPECIAL APPLICATION ENGINEERING ..............................................13 CHUCKING APPLICATIONS ................................................................14 FREQUENTLY ASKED QUESTIONS ....................................................15 CONTENTS The continuing advances in production methods in the metalworking industry has created a need for precision workholding devices capable of automatic clamping in component “bores. In addition, the equipment must transmit the high accuracy of the latest machine tools and develop sufficient holding power to resist the cutting forces imposed on the work-piece.” 3 INTRODUCTION PTG Workholding Ltd. is a leading supplier of workholding technology. We have the skills and expertise to meet the most exacting and demanding engineering tasks. As modern manufacturing advances, and in response to customer demand, we now offer a full and versatile range of workholding equipment. Complementing the core business of expanding mandrels and sleeves, design and manufacture of all styles of fixture, special collet chucks are now available. Our experienced CAD team will take account of all your particular requirements in preparing a proposal. Whilst most holding operations can be successfully obtained by using the modular system and good tool design, PTG are able to offer unmatched engineering knowledge that only years of experience can yield. We may have already solved the very problem you face for other manufacturers. PTG Workholding Ltd. works in many existing markets, including organisations within the following sectors: • Automotive • Aerospace • Machine tool manufacturing • Sub-contract operations • Electrical engineering • Medical INTRODUCTION 4 MODULAR MANDREL SYSTEM PTG produce and supply precision expanding mandrels capable of automatic clamping in component bores, achieving the highest accuracy and holding power to resist the cutting forces imposed on the work piece. PTG’s modular mandrel system provides the following benefits: Our unique double-angle principle allows for fast loading and unloading of components. A standard expansion range of 0.8mm (0.032”). Guaranteed accuracy of 0.013mm (0.0005”) T.I.R., or closer if desired. Greater holding power by applying pressure evenly along the length of the sleeve. No need to hold the work to close bore tolerance. One mandrel can accommodate a wide range of MODULAR MANDREL SYSTEM sleeve sizes. Availability of multiple sleeves for work with greater length-to-diameter ratios, eliminating wobble and chatter. Pull-back of component onto end locator for positive location. PTG Workholding are generally able to recondition arbors by re-grinding the angles to return mandrels to their original accuracy. Order online at www.ptgworkholding.co.uk 5 FACEPLATE DRAWBAR OPERATED MANDREL The faceplate drawbar operated expanding mandrel can be used on any machine with drawbar facilities, for general turning and grinding operations. Adaptor plates made to suit the machine mounting can be manufactured by PTG Workholding, or the customer. Component end-locators, solid type or compensating (for out of square locating faces) can also be manufactured to your requirements. The natural pull-back action of the sleeve ensures the component is hard against the location face. There is an over-expansion stop built into the expander pin to avoid over- stressing the expanding sleeve. For maximum efficiency, expansion sleeves should be pre-loaded to maintain contact with mandrel double-angles at all times. G dimension End locator to be qualified Mounting screw fixing holes K holes to suit to suit N screw R screws over *M thread L expansion stop J H G -0.26(.010") -0.40(.015") +0.000(.0000") -0.015(.0006") C E D A F B Gripping diameter A. *8C has female thread Sleeves are ground in the expanded position to provide loading clearance for component. A. N R F Max B C D E F G H J K L M Tool # Min Max DP Ø DP Ø (daN) 3A 12.5 16.0 60 20.0 22.0 14.6 20 40 75 11.0 6 12.6 M4 58 M8 28 M4 700 90.800.210.1 2C 16.0 22.0 66 20.0 27.0 15.0 22 40 75 15.0 6 14.1 M8 58 M8 28 M4 1000 90.800.215.1 1C 22.0 28.5 72 20.0 32.0 15.5 30 40 75 20.0 6 20.7 M8 58 M8 58 M6 1200 90.800.221.1 A3 Part18C Notes28.5 41.0 79 20.0 38.0 15.3TOLERANCES31 40 75 26.5(UNLESS6 OTHERWISE26.3 M10 STATED)58 M8DRAWN58 M6 KJL1800 90.800.227.1 4C 41.0 63.5 84 20.0 43.0 14.8 36 40 75 37.5 6 37.0 M12 58 M8DATE58 M6 2300 90.800.234.1 X X.X X.XX X.XXX ANGULAR POWER OPERATED MANDRELS POWER OPERATED 5C 63.5 76.2 109 25.0 51.0 25.3 36 60 120 55.0 6 57.3 M20 94 M10ISSUE94 M8 2800 90.800.241.1 6C 76.2 89.0 118 25.0 57.0 24.7 37 60 120 74.5 6 71.1 M20 94 M10HEAT94 TREATMENT:M8 3200 90.800.248.1 0.4 0.10 0.05 0.013 0.5 7C 89.0 130.0 133 30.0 63.5 25.2 47 100 180 86.5 6 84.1 M24 150 M12None150 M10 2700 90.800.253.1 MATERIAL: REMOVE8C 130.0 ALL178.0 BURRS153 SHEET30.0 79.5 24.6 22 100 180 124.0 6 123.0 M36 150 M12 150 M10 5500 90.800.259.1 SCALE 1:1 K L DESIGN CUSTOMER: & SHARP EDGES LAST SAVED BY PLYMOUTH, DEVON 90.800.234.1 ken FINISH: WEIGHT g 06/10/2008 SHEET 1 OF 1 6 SPIGOT DRAWBAR OPERATED MANDREL The spigot drawbar operated expanding mandrel can be used on any machine with drawbar facilities, for general turning and grinding operations. Adaptor plates made to suit the machine mounting can be manufactured by PTG Workholding, or the customer. Component end-locators, solid type or compensating (for out of square locating faces) can also be manufactured to your requirements. The natural pull-back action of the sleeve ensures the component is hard against the location face. There is an over-expansion stop built into the expander pin to avoid over-stressing the expanding sleeve. For maximum efficiency, expansion sleeves should be pre-loaded to maintain contact with mandrel double-angles at all times. POWER OPERATED MANDRELS POWER OPERATED Over expansion L stop. H G J A -0.005(.0002") -0.013(.0005") F C E D K B Gripping diameter A. Sleeves are ground in the expanded position to provide loading clearance for components A. F B C D E F G H J K L M Max Tool # Min Max (daN) 3A 12.5 16.0 66 11.0 22.0 9.8 20 20 26 11.0 14 9.5 M4 700 90.810.210.1 2C 16.0 22.0 70 11.0 27.0 8.0 20 20 26 15.0 18 14.1 M8 1000 90.810.215.1 1C 22.0 28.5 85 11.0 32.0 10.0 27 30 40 20.0 17 20.7 M8 1200 90.820.221.1 18C 28.5 41.0 92 11.0 38.0 10.5 27 30 40 26.5 18 26.3 M10 1800 90.820.227.1 4C 41.0 63.5 99 13.0 43.0 9.5 27 30 50 37.5 21 37.0 M12 2300 90.820.234.1 A3 Part Notes TOLERANCES (UNLESS OTHERWISE STATED) DRAWN KJL DATE X X.X X.XX X.XXX ANGULAR ISSUE HEAT TREATMENT: 0.4 0.10 0.05 0.013 Order0.5 online at www.ptgworkholding.co.uk None MATERIAL: REMOVE ALL BURRS SHEET K L DESIGN SCALE 1:1 CUSTOMER: 7 & SHARP EDGES LAST SAVED BY PLYMOUTH, DEVON 90.820.234.1 ken FINISH: WEIGHT g 06/10/2008 SHEET 1 OF 1 BETWEEN CENTRES MANDREL The nut operated between-centres expanding mandrel is generally mounted between 60 degree centres, and can be driven from the drive flat with a carrier or drive plate.