When it comes to increasingly complex machining processes and workpiece clamping technology, more is often required than just the right product or standard solutions. Sometimes, even providers of quite good clamping technology reach their limits. Those who bring experience, know-how, and understanding of the processes along with a comprehensive range of various solutions for workpiece clamping technology can also shine with consulting. This usually results in custom-made solutions with devices for projects and processes. This is becoming increasingly important as batch sizes decrease and part diversity increases.
"We have been receiving more and more inquiries for extensive solutions that go far beyond a single clamping product," reports Chris Vogel, Head of Key Account International Projects at Andreas Maier GmbH & Co. KG (AMF). "Especially due to constantly decreasing batch sizes and simultaneously greater part diversity, more flexibility is required than a single clamping element can provide," adds project manager Thomas Kirchner from the traditional company in Fellbach. Here, listening, process understanding, and consulting competence are required. The most important prerequisite is that a consulting provider thinks technology-open and advises.
One might grant providers honest intentions. However, truly technology-open consulting can probably only be offered by a company that also has the entire range of clamping technology. Therefore, mechanical, pneumatic, and hydraulic clamping elements should be part of the portfolio, as well as zero-point clamping technology, magnetic and vacuum technology, and quick clamping devices. And precisely when standard goods cannot solve the problem, the time for individual project solutions comes. However, the number of providers who can do this is small, and the industry is often very discreet.
Solution-oriented providers think technology-open
As such a technology-open thinking provider with a comprehensive view, AMF, founded in 1890, has crystallized over the years. The company from Fellbach is known worldwide as a complete provider in clamping technology and is among the market leaders. We are all the more pleased that such a significant provider gives us insight. Because, "when it comes to individual solutions with fixture construction, we can stand out due to great expertise and consulting competence," promises Vogel. "But every project that leads to an individual solution begins first with listening – personally and without a preconceived questionnaire."
Ultimately, it is always about the bottleneck factor of time. So, how can I reduce setup times in production and increase machine spindle running times with shorter call-off times as batch sizes decrease and part diversity increases? The topic of "saving time" actually begins much earlier – namely at the start of the fixture construction project. Kirchner explains why: "At the beginning of such a project, we assemble a cross-functional team with members from design, manufacturing, and purchasing, as well as a project manager. They communicate hierarchically free and at eye level and can then make decisions in two hours, where it may take others two weeks."
Internally and externally fast, hierarchically free and at eye level
This is not only lived internally at AMF for such projects but also externally. The customer's designer speaks directly with AMF's designer. "Our customers repeatedly highlight this as an extraordinary feature that makes life easier," assures Vogel. This agility and transparency ensure short paths and are the basic prerequisite for a successful and rapid project process.
However, AMF initially goes into advance. After initial discussions and identifying all aspects, the team develops one or sometimes several solution proposals. After that, the customer can determine for themselves where they want to start and how far they want to go. So, what can the customer contribute themselves? Once again, Vogel: "This is an important part of our partnership. Because, of course, many customers can manufacture certain elements for fixtures themselves."
Example 1: Less complexity in favor of higher precision
To make it more illustrative, Vogel tells us about a project for a manufacturer of high-performance pumps for super sports cars. For this, four complex parts made of aluminum casting are manufactured fully automatically and without human intervention. AMF has added a 5-axis machining center with automation, including four new fixtures that can be switched into the machine in a few minutes when mounted on machine pallets and are immediately positioned thanks to zero-point clamping technology. The challenge here is the fixation of the raw parts made of aluminum sand casting.
In an earlier concept from another provider, two components were clamped and processed per fixture. However, several disturbing contours limited the processing. "Our fixture only clamps one raw part. This has reduced complexity and significantly increased process reliability." Now the machining center with horizontal spindle orientation and swivel table can position the workpiece tolerance-accurately for every necessary processing after measuring the position. The customer praised AMF as a partner that understands the processes very well, has responded to them, and where a contact person from the project team was always directly reachable.
Example 2: Highest complexity made manageable
Another example shows how the highest complexity can be achieved with utmost machining precision for large cast parts for printing machines on flexible fixtures. For parallel setup on a total of three pallets, AMF manufactured modular clamping fixtures and drew on its extensive standard portfolio for hydraulic clamping elements and zero-point clamping technology. Since the machine does not have its own clamping hydraulics, AMF also provided the hydraulic unit from its large assortment.
The fixation of the massive cast parts in the first and second clamping stages realizes a combination of hydraulic pull-down clamps and floating support elements to ensure the parts are perfectly flat.
Once clamped, the casting skin is removed, the contour is pre-milled, holes and threads are introduced, including those for the zero-point clamping bolts needed for the direct clamping of the workpiece for the next processing step. Rotated by 180°, zero-point clamping modules take up the screwed clamping bolts and fix the components directly, without distortion and fully accessible for five-sided machining. To expand the capacities of the pallet changer and maximize flexibility, AMF zero-point clamping stations are located on machine pallets, allowing for quick and precise fixture changes.
Clever fixture creates maximum flexibility for four parts
A highlight is the flexibility of the clamping fixtures. Two movable mounting plates are mounted on a base plate. Hydraulic support elements, which are only plugged in, can be easily repositioned. This allows the fixtures to not only accommodate two pairs of corresponding side parts that can be machined on five sides after turning, but also all four variants of the components in their respective processing states.
To help workers keep track amidst this unimaginable complexity, the suitable positions for each component are color-coded. This creates safety and ensures speed during main time-parallel setup. Additionally, there is a clamping plan and a setup plan available for each component at the machine.
'Even here, the customer was full of praise in the end. He couldn't imagine this solution beforehand. That he was able to manufacture the clamping plates himself caused both astonishment and satisfaction. Such involvement in a provider's projects had not been known before at the printing press manufacturer.'
Positive conclusion when projects are implemented together
Machinists benefit from clamping device providers who not only want to sell their products but also provide genuine process support because they can offer open ears, understanding, and expertise in fixture construction. And when the challenges are discussed and solved together, quickly and on an equal footing, nothing stands in the way of a real increase in productivity and speed.
Contact:
