Precision Work Holding Systems Quick Change Collet Chucks NAVI 60 installed at KTA Spindle Toolings on 5 - Axis Makino IKRAN 60 installed at KTA Spindle Toolings Pune NAVI 60 installed at Seinumero Nirman Pvt Ltd NAVI 60 installed at CPC Precicomp Pvt. Ltd Company Overview Importance of Precision Work Holding Systems Inovic Engineering Solutions is part of Kaygee Engineering Group with more than four decades of experience in precision manufacturing. Over the years, the company has gone through mass production learning and has designed, developed and produced various precision components and assemblies for leading manufacturers in the Automobile and Aerospace Industries. Since 6 years, Inovic has also started manufacturing precision tooling systems, along with Jig & Fixtures for various industrial applications. The vast expertise garnered to design and manufacture products with a synergetic structure drove the development of Precision Work Holding Systems. Inovic has the expertise to custom design, develop and manufacture innovative work holding systems for your production and automation requirements. Our specialised know-how can help boost your production with higher precision quality and profitability. While selecting a work holding system, the method of holding a part is as crucial as the way in which it is cut. In other words, how a part will be cut often depends on how it is held. An e cient manufacturing process requires good machine selection, proper cutting tools and the right work holding. The first two areas typically receive substantial consideration but work holding is often overlooked. The right work holding selection can increase manufacturing process stability, e ciency and safety. Work holding requirement can be affected by many factors including the material being cut, critical tolerance requirement, workpiece shape and dimensions, and frequency of changeover. Quick change collet chucks is the solution for shorter runs. COMPANY OVERVIEW | 3 At Inovic, a team of experienced engineers ensure all factors are considered in finding the most suitable work holding system for a specific application thus optimising the manufacturing process. Replacing standard push type steel collet systems with special polymerised rubber collet systems, we offer you flexible and customised solutions Made in India. Inovic provides a wide spectrum of standard and customised solutions. Our NAVI,EVA Mandrel, IKRAN NAVI and IKRAN EVA range of sealed Pull-Back compact chucks with high accuracy can improve throughput and part quality in operations on CNC Turning Centers, Machining Centers, Turn Mill Centers and Indexing Table machines. The range is based on maximum work piece diameter and the size of the spindle nose. The NAVI,EVA Mandrel,IKRAN NAVI and IKRAN EVA work holding systems, along with precision clamping heads and bushings offers various advantages with distinct features in comparison over conventional collet chucks with spring steel colletsand Bushings. Product Range 4 | PRODUCT RANGE Features and Advantages Superior Geometric Tolerances with Concentric Precision < 0.015mm Quick Changeover of Clamping Heads Parallel Clamping Pull-Back Action Against Fixed End-Stop Superior Clamping Force Eliminates Repeated Jaw Boring in Conventional 3-Jaw Chucks Improved Cutting Parameters with Stability and Vibration Dampening Consistent Accuracy and Reliability The Clamping Head | Quick Change Collets The clamping heads from Inovic are based on the Rubber Flex principle, integrated by precision-hardened alloy steel segments held firmly by a polymer. This results in minimal wear and tear during machining. The development of the clamping head is derived from a combination of steel & polymer in conjunction with polymerisation, perfected over numerous trials and experience. The clamping heads have a changeover time of under a minute using our Collet Changing Fixture (CCF). PRODUCT RANGE | 5 Smooth bore collets are typically suited for second operation work to protect finished machining. Serrated bore collets are typically suited for first operation work and heavy duty machining. Collets are precision ground to size with total system accuracy < 0.015 mm. Polymer between collet segments provide excellent sealing as well as vibration dampening. Collets are available in various configurations for all types of applications: Types Shapes Sizes Smooth Serrated Round Hex Square Custom TCT-50 TCT-60 TCT-100 with gripping range between ±0.5 mm Standard pull-back chucks The Navi work holding system is designed for OD clamping on CNC Turning Machines, Turn Mill Centers and Grinding machines with power chucking system. The two variants are Standard pull-back & Combi pull-back. Description Advantages Description NAVI Series 6 | NAVI SERIES Bar Clamping Standard end-stop Pull-back effect Through-bore chuck suitable for bar & pipe machining Work piece is rested on the standard end-stop located inside the chuck. Additional end-stop extensions are mounted on standard end-stop suitable for the workpiece. Rigid and sturdy clamping of the workpiece due to pull-back effect. The axial tension against the work piece end-stop ensures stability & vibration dampening Depth end-stop The End-Stop is designed for clamping long shafts where work piece resting is inside the chuck behind the clamping head. Front end-stop The End-Stop is mounted on the top of the chuck and the work piece is clamped behind or inside the clamping device. NAVI Series Applications Combi pull-back chucks Power actuated Through bore chucks suitable for bar & pipe machining Power actuated Optional bar machining can be done by removing the workpiece end-stop The workpiece end-stop is clamped with three radially placed screws Quick change over Rigid clamping due to Pull-Back effect Improved cutting parameters along with vibration dampening Higher RPM Advantages Maximum flexibility Rigid & sturdy clamping of the workpiece due to axial tension against the workpiece end-stop Ideal for internal workpiece end-stop & front end-stop Total length accuracy is < 0.01 mm Collet Main Body Adaptor Drive Bolt Spindle Flange (Base Plate) Collet Main Body Adaptor Standard End-Stop Drive Bolt Spindle Flange (Base Plate) NAVI Series Specifications NAVI SERIES | 7 Size Chuck Type Clamping Range Tolerance Minimum Clamping ø(mm) Maximum Clamping ø(mm) Max. Bar Capacity ø(mm) Concentricity Accuracy (mm) Spindle Nose Options Max. RPM Collet Head ø(mm) Main Body ø(mm) Base Plate ø(mm) Depth of End-Stop (mm) Chuck Total Length (mm) Collet Protrusion Length (mm) End Stop Thread Size Front End-Stop Bolt Hole Position ø(mm) Main Body Length (mm) Draw Tube Adaptor Threading Size Base Plate Bolt Hole Position ø(mm) Radial Clamping Stroke (mm) Axial Clamping Stroke (mm) Collet Smooth Series Collet Serrated Series NAVI 50 combi draw-in ± 0.5 mm 14 50 52 0.01 mm A25 | A26 6000 80 130 145 | 165 60.5 127.5 4 M8 107 (M8 x 3) 57 M58 x1.5 | M73 x1.5 104.8 | 133.4 1 2 TCT 50 CS TCT 50 CSE NAVI 60 combi draw-in ± 0.5 mm 14 62 66 0.01 mm A25 | A26 | A28 6000 100 150 165 | 165 | 210 63.5 134 4 M10 126 (M8 x 3) 64.5 M70 x1.5 | M88 x1.5 | M88 x1.5 104.8 | 133.4 | 171.4 1 2 TCT 60 CS TCT 60 CSE NAVI 100 combi draw-in ± 1.0 mm 30 100 100 0.02 mm A26 | A28 | A211 3000 145 220 235 | 235 | 280 73 155.5 | 159.5 | 165.5 0 M10 192 (M8 x 3) 77 M135 x1.5 133.4 | 171.4 | 235 2.5 5 TCT 100 CS TCT 100 CSE A B N C BD FD K TL I D J AT BH The EVA Mandrel work holding system is designed for ID Clamping on CNC Turning Machines, Turn-mill Center and Grinding machines with power chucking system. The segmented bushings from Inovic consists of a combination of case-hardened steel and a high-tech polymer. Each element is tailor made and precisely machined to your exact specifications, demands and can be easily adapted. This results in high precision, increased workspace flexibility and reduced lead time. All contact surfaces are completely ground in one operation thus guaranteeing optimum concentricity. EVA Mandrel Series 8 | EVA MANDREL SERIES The Segmented Bushings Description Advantages Power Actuated Mandrel suitable for all standard spindle Flange sizes Maximum flexibility Rigid and sturdy clamping of the workpiece due to axial tension against the workpiece endstop Ideal for blind bores Concentricity accuracy <0.01 mm Short Clamping lengths Clamping range Ø15 to Ø130 Vibration dampening due to polymer EVA Mandrel Series Specifications EVA MANDREL SERIES | 9 Size Chuck Type Clamping Range Tolerance Minimum Clamping Ø(mm) Maximum Clamping Ø(mm) Concentricity Accuracy Ø(mm) Spindle Nose Options Max. RPM Collet Head Ø(mm) Main Body Ø(mm) Base Plate Ø(mm) Depth of End - Stop (mm) Chuck Total Length (mm) Front End -Stop Bolt Hole Position Ø(mm) Main Body Length (mm) Draw Tube Adaptor Threading Size Base Plate Hole Position Ø(mm) Reserve Stroke Radial (mm) Release Stroke Radial (mm) Collet Weight EVA 15 ID Clamping ± 0.5 mm 15 29 0.01 A25 I A26 3000 29 130 145 I 165 41 117 72 110 M45 x 1.5 104.8 I 133.4 1 2 ID Sleeve 9 KG 94 Grm EVA 25 ID Clamping ± 0.5 mm 25 40 0.01 A25 I A26 3000 40 130 145 I 165 44 130 77 124 M45 x 1.5 104.8 I 133.4 1 2 ID Sleeve 10 KG 92 Grm EVA 35 ID Clamping ± 0.5 mm 35 54 0.01 A25 I A26 3000 54 150 165 I 165 I 210 44 150.5 77 139.5 M45 x 1.5 104.8 I 133.4 I 171.4 1 2 ID Sleeve 13 KG 20 Grm EVA 50 ID Clamping ± 0.5 mm 50 80 0.01 A25 I A26 3000 80 150 165 I 165 I 210 45 153 100 146.5 M58 x 1.5 104.8 I 133.4 I171.4 1.5 2.5 ID Sleeve 16 KG 63 Grm EVA 70 ID Clamping ± 0.5 mm 70 100 0.01 A25 I A26 3000 100 150 165 I 165 I 210 45.6 161.5 115 155 M73 x 1.5 104.8 I 133.4 I 171.4 1.5 2.5 ID Sleeve 20 KG 84 Grm EVA 100 ID Clamping ± 0.5 mm 100 130 0.01 A25 I A26 3000 130 220 235 I 235 I 280 48 191 192 179 M74 x 1.5 133.4 I 171.4 I 235 1.5 3 ID Sleeve 53 KG N C BD FD K TL D J AT BH The Ikran Navi manual work holding system is suitable for use in drilling and milling operations on machining centers. The chuck can be mounted vertically as well as horizontally. IKRAN NAVI Series 10 | IKRAN NAVI SERIES Base end-stop Front end-stop Pull-down effect Through-bore chuck in which the work piece is rested on end-stop extensions mounted on the the base of the machine located inside the clamping device. The End-Stop is mounted on the top of the clamping device and the work piece is clamped behind the clamping device. Rigid and sturdy clamping of the workpiece due to pull-down effect. The axial tension against the work piece end-stop ensures stability & vibration dampening. Profiles Specially designed clamping heads can be used for different profiles & moulded parts. 5-axis machining The clamping device is suitable for machining on a 5-axis machining center. IKRAN NAVI Series Applications Stationary chucks Description Advantages Manually operated The chuck is operated with a flat wrench which has to be half turned. Short set-up time Pull-down effect on end-stop stabilizes the workpieces. Ideal for 5-axis machining Chuck can be equipped with front & internal end-stop Accuracy < 0.015mm Serrated Collet Drive Bolt Adaptor Main Body Base Body Drive Bolt Size Chuck Type Clamping Range Tolerance Minimum Clamping ø(mm) Maximum Clamping ø(mm) Max. Bar Capacity ø(mm) Concentricity Accuracy (mm) Collet Head ø(mm) Main Body ø(mm) Total Height (mm) Length (mm) Width (mm) Clamping slot width (mm) Clamping bolt distance (mm) Wrench size (mm) Collet Protrusion Length (mm) End-Stop Thread Size Front End-Stop Bolt Hole Pos ø(mm) Main Body Length (mm) Radial Clamping Stroke (mm) Axial Clamping Stroke (mm) Clamping Device Weight (kg) Collet Smooth Series Collet Serrated Series IKRAN 50 Stationary ±0.5 mm 14 50 52 0.015 mm 80 130 122 200 200 16 182 17 4 M8 107 (M8 x 3) 57 1 2 TCT 50 CS TCT 50 CSE IKRAN 60 Stationary ±0.5 mm 14 62 66 0.015 mm 100 150 130.5 250 250 18 200 23 4 M10 126 (M8 x 3) 64.5 1 2 TCT 60 CS TCT 60 CSE IKRAN 100 Stationary ±1 mm 14 100 100 0.015 mm 144.7 220 163.5 300 300 12 268 23 4 M12 192 (M10 x 3) 81.5 1 2 TCT 100 CS TCT 100 CSE A B C BD TL L W P BP / CB WS D J IKRAN NAVI Series Specifications IKRAN NAVI SERIES | 11 The IKRAN EVA manual work holding system is suitable for OD turning and milling operations on machining centers. The chuck can be mounted vertically as well as horizontally. IKRAN EVA Series 12 | IKRAN EVA SERIES Stationary chucks Description Advantages Manually Operated The chuck is operated with a flat wrench which has to be half turned Short setup time Pull down effect on end stop stabilizes the workpieces Ideal for 5-axis machining Chuck can be equipped with front end-stop Short Clamping lengths Accuracy<0.015mm Vibration dampening due to polymer. IKRAN EVA Series Specifications IKRAN EVA SERIES | 13 Size Chuck Type Clamping Range Tolerance Minimum Clamping Ø(mm) Maximum Clamping Ø(mm) Concentricity Accuracy Ø(mm) Collet Head Ø(mm) Main Body Ø(mm) Length (mm) Width (mm) Depth of End - Stop (mm) Clamping Slot Width (mm) Clamping Bolt Distance (mm) Wrench size (mm) Chuck Total Length (mm) Front End -Stop Bolt Hole Position Ø(mm) Main Body Length (mm) Draw Tube Adaptor Threading Size Base Plate Hole Position Ø(mm) Reserve Stroke Radial (mm) Release Stroke Radial (mm) Collet I-EVA 15 ID Clamping ± 0.5 mm 15 29 0.015 mm 29 130 200 200 41 16 182 17 174 72 103.5 M45 x 1.5 104.8 I 133.4 1 2 ID Sleeve I-EVA 25 ID Clamping ± 0.5 mm 25 40 0.015 mm 40 130 200 200 44 16 182 17 188 77 117.5 M45 x 1.5 104.8 I 133.4 1 2 ID Sleeve I-EVA 35 ID Clamping ± 0.5 mm 35 54 0.015 mm 54 150 200 200 44 16 182 17 198 77 127.5 M45 x 1.5 104.8 I 133.4 I 171.4 1 2 ID Sleeve I-EVA 50 ID Clamping ± 0.5 mm 50 80 0.015 mm 80 150 250 250 45 18 200 23 210 100 138.5 M58 x 1.5 104.8 I 133.4 I171.4 1.5 2.5 ID Sleeve I-EVA 70 ID Clamping ± 0.5 mm 70 100 0.015 mm 100 150 250 250 45.6 18 200 23 220 115 143.5 M73 x 1.5 104.8 I 133.4 I 171.4 1.5 2.5 ID Sleeve I-EVA 100 ID Clamping ± 0.5 mm 100 130 0.015 mm 130 220 300 300 48 12 268 23 265 192 168 M74 x 1.5 133.4 I 171.4 I 235 1.5 3 ID Sleeve C BD L W P BP/CB WS TL D J Collet changing fixture is a manual and easy to use tool which enables collets to be changed in less than a minute. Insert the steel pins into the collet face and rotate the wheel clockwise to collapse the collet. Once the collet is positioned within the chuck body, rotate the wheel anti-clockwise to expand and release the collet. Available in three sizes ( TCT – 50 , TCT – 60 , TCT – 100 ). A standard end-stop is used for accurate z-axis positioning of short work pieces. Additional end-stop extensions are mounted on standard end-stops suitable for the workpiece. A depth end-stop has a greater throat depth enabling longer shafts to be inserted resulting in minimal protrusion beyond the collet face. A front end-stop is mounted on top of the chuck face where resting face is ahead of the clamping area. All end-stops are located against a shoulder within the chuck body and are held in place with radially located screws. Base plates (Spindle flanges) offer the flexibility to mount collet chucks to a wider range of spindles – Larger chuck with a smaller spindle nose or a smaller chuck with a larger spindle nose. All base plates are hardened to 60-61 HRC and precision ground with overall accuracy < 0.005mm Base plates are available for all chuck sizes and suitable for different spindle nose sizes from A25, A26, A28 and A211. Accessories 14 | ACCESSORIES Collet Changing Fixtures End-Stops Base Plates Toughened collets are designed to be machined in by the customer to accommodate special sizes, shapes & counter bores. Boring fixture is basically a retaining ring with pins, which holds the collet segments firmly in place and puts the collet under slight compression to ensure accuracy and roundness during machining. Available for collet sizes TCT - 50 & TCT - 60. Collet Boring Fixtures Testimonials TESTIMONIALS | 15 Tool Holding Systems - Mr. Vipul Chopda, KTA Spindle Toolings “We are into manufacturing of BT40, BT50, HSK precision tool holders. The operations performed on our 5 – Axis ‘MAKINO’ are milling, drilling, tapping & boring. We changed from conventional collet chucks to NAVI 60 combi- pull back chuck & IKRAN 60 chuck in March 2020. We have experienced quicker change over time, increased accuracy and decreased burr clogging with INOVIC chucks.” Defense & Automotive - Mr. Tushar Mengale, Seinumero Nirman Pvt. Ltd. “We do CNC turning for various precision components like Stub Axles, Knuckles, Wheel Hubs & Defence parts. We shifted from Three Jaw Hydraulic Chuck to INOVIC NAVI - 60 combi Pull-Back chucks with customised special front End-Stop in January, 2020 & have been experiencing greater accuracy & consistency. Since then, the changeover time is much quicker & no boring of jaws is required. Also the rejection rate has been reduced drastically and no skilled labour is required anymore. ” Aerospace - Mr. Jitendra Mundke & Mr. Sandeep Raut, CPC Precicomp Pvt. Ltd. “We have been using INOVIC NAVI- 50 Standard Chuck since November 2018 on our MAZAK Turn Mill for precision aluminium components used in the aerospace industry. Our rejection rate has been reduced drastically & we are getting much higher consistency compared to our previous collet chucks. ” Automotive - Mr. Rajesh Kothari, Vardhaman Auto Comp Pvt. Ltd. “We are into the mass production of gear blanks & shafts for the two – wheeler industry. We shifted to the INOVIC NAVI – 60 Combi pull- back chucks in February 2018 for our turn milling, drilling, tapping & boring operations. Since then, we have been getting higher accuracy consistently. The quick change over time & reduced burr clogging has increased our e ciency and profitability. Also no skilled labour is required to do the task.” Inovic Engineering Solutions Pvt Ltd 201, Chitrakoot Apartments, 1065 Gokhale Cross Road, Next to Symbiosis Distance Learning Centre, Shivajinagar, Pune – 411016 +91 99224 18208 | sales@inovicengineering.com