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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 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. Importance of Precision Work Holding Systems 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 efficient 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, efficiency 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 Product Range 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. Features and Advantages Superior Geometric Tolerances Quick Changeover of Parallel Clamping Pull-Back Action Against with Concentric Precision Clamping Heads Fixed End-Stop < 0.015mm Superior Clamping Force Eliminates Repeated Jaw Improved Cutting Parameters Consistent Accuracy Boring in Conventional with Stability and Vibration and Reliability 3-Jaw Chucks Dampening 4 | PRODUCT RANGE 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). Collets are available in various configurations for all types of applications: Types Shapes Sizes Smooth Round TCT-50 Serrated Hex TCT-60 Square TCT-100 with gripping range Custom between ±0.5 mm 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. PRODUCT RANGE | 5 NAVI Series 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. Standard pull-back chucks Combi pull-back chucks Spindle Flange Spindle Flange Main Body (Base Plate) Main Body (Base Plate) Collet Collet Adaptor Adaptor Standard End-Stop Drive Bolt Drive Bolt Description Advantages Description Advantages Power actuated Quick change over Power actuated Maximum flexibility Through bore chucks Rigid clamping due to Optional bar machining Rigid & sturdy clamping of suitable for bar & pipe Pull-Back effect can be done by removing the workpiece due to axial machining the workpiece end-stop tension against the workpiece Improved cutting parameters end-stop along with vibration dampening The workpiece end-stop is clamped with three Ideal for internal workpiece Higher RPM radially placed screws end-stop & front end-stop Total length accuracy is < 0.01 mm NAVI Series Applications Bar Clamping Standard end-stop Pull-back effect Depth end-stop Front end-stop Through-bore chuck suitable for bar Work piece is rested on the Rigid and sturdy clamping of the The End-Stop is designed for The End-Stop is mounted on & pipe machining standard end-stop located workpiece due to pull-back effect. clamping long shafts where the top of the chuck and the inside the chuck. Additional The axial tension against the work piece resting is inside work piece is clamped behind end-stop extensions are work piece end-stop ensures the chuck behind the clamping or inside the clamping device. mounted on standard end-stop stability & vibration dampening head. suitable for the workpiece. 6 | NAVI SERIES NAVI Series Specifications Size NAVI 50 NAVI 60 NAVI 100 Chuck Type combi draw-in combi draw-in combi draw-in Clamping Range Tolerance ± 0.5 mm ± 0.5 mm ± 1.0 mm Minimum Clamping ø(mm) A 14 14 30 Maximum Clamping ø(mm) B 50 62 100 Max. Bar Capacity ø(mm) 52 66 100 Concentricity Accuracy (mm) 0.01 mm 0.01 mm 0.02 mm Spindle Nose Options A25 | A26 A25 | A26 | A28 A26 | A28 | A211 Max. RPM N 6000 6000 3000 Collet Head ø(mm) C 80 100 145 Main Body ø(mm) BD 130 150 220 Base Plate ø(mm) FD 145 | 165 165 | 165 | 210 235 | 235 | 280 Depth of End-Stop (mm) K 60.5 63.5 73 Chuck Total Length (mm) TL 127.5 134 155.5 | 159.5 | 165.5 Collet Protrusion Length (mm) I 4 4 0 End Stop Thread Size M8 M10 M10 Front End-Stop Bolt Hole Position ø(mm) D 107 (M8 x 3) 126 (M8 x 3) 192 (M8 x 3) Main Body Length (mm) J 57 64.5 77 Draw Tube Adaptor Threading Size AT M58 x1.5 | M73 x1.5 M70 x1.5 | M88 x1.5 | M88 x1.5 M135 x1.5 Base Plate Bolt Hole Position ø(mm) BH 104.8 | 133.4 104.8 | 133.4 | 171.4 133.4 | 171.4 | 235 Radial Clamping Stroke (mm) 1 1 2.5 Axial Clamping Stroke (mm) 2 2 5 Collet Smooth Series TCT 50 CS TCT 60 CS TCT 100 CS Collet Serrated Series TCT 50 CSE TCT 60 CSE TCT 100 CSE NAVI SERIES | 7 EVA Mandrel Series 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. Description Advantages Maximum flexibility Power Actuated Rigid and sturdy clamping of the workpiece due to axial Mandrel suitable for all standard spindle tension against the workpiece endstop Flange sizes Ideal for blind bores Concentricity accuracy <0.01 mm Short Clamping lengths Clamping range Ø15 to Ø130 Vibration dampening due to polymer The Segmented Bushings 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. 8 | EVA MANDREL SERIES EVA Mandrel Series Specifications Size EVA 15 EVA 25 EVA 35 EVA 50 EVA 70 EVA 100 Chuck Type ID Clamping ID Clamping ID Clamping ID Clamping ID Clamping ID Clamping Clamping Range Tolerance ± 0.5 mm ± 0.5 mm ± 0.5 mm ± 0.5 mm ± 0.5 mm ± 0.5 mm Minimum Clamping Ø(mm) 15 25 35 50 70 100 Maximum Clamping Ø(mm) 29 40 54 80 100 130 Concentricity Accuracy Ø(mm) 0.01 0.01 0.01 0.01 0.01 0.01 Spindle Nose Options A25 I A26 A25 I A26 A25 I A26 A25 I A26 A25 I A26 A25 I A26 Max. RPM N 3000 3000 3000 3000 3000 3000 Collet Head Ø(mm) C 29 40 54 80 100 130 Main Body Ø(mm) BD 130 130 150 150 150 220 Base Plate Ø(mm) FD 145 I 165 145 I 165 165 I 165 I 210 165 I 165 I 210 165 I 165 I 210 235 I 235 I 280 Depth of End - Stop (mm) K 41 44 44 45 45.6 48 Chuck Total Length (mm) TL 117 130 150.5 153 161.5 191 Front End -Stop Bolt Hole D 72 77 77 100 115 192 Position Ø(mm) Main Body Length (mm) J 110 124 139.5 146.5 155 179 Draw Tube Adaptor Threading Size AT M45 x 1.5 M45 x 1.5 M45 x 1.5 M58 x 1.5 M73 x 1.5 M74 x 1.5 Base Plate Hole Position Ø(mm) BH 104.8 I 133.4 104.8 I 133.4 104.8 I 133.4 I 171.4 104.8 I 133.4 I171.4 104.8 I 133.4 I 171.4 133.4 I 171.4 I 235 Reserve Stroke Radial (mm) 1 1 1 1.5 1.5 1.5 Release Stroke Radial (mm) 2 2 2 2.5 2.5 3 Collet ID Sleeve ID Sleeve ID Sleeve ID Sleeve ID Sleeve ID Sleeve Weight 9 KG 94 Grm 10 KG 92 Grm 13 KG 20 Grm 16 KG 63 Grm 20 KG 84 Grm 53 KG EVA MANDREL SERIES | 9 IKRAN NAVI Series 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. Stationary chucks Main Body Serrated Collet Drive Bolt Adaptor Base Body Drive Bolt Description Advantages Short set-up time Manually operated Pull-down effect on end-stop stabilizes the workpieces. The chuck is operated with a flat wrench which has to be half turned. Ideal for 5-axis machining Chuck can be equipped with front & internal end-stop Accuracy < 0.015mm IKRAN NAVI Series Applications Base end-stop Front end-stop Pull-down effect Profiles 5-axis machining Through-bore chuck in which the work The End-Stop is mounted on Rigid and sturdy clamping of the Specially designed clamping The clamping device is suitable piece is rested on end-stop extensions the top of the clamping device workpiece due to pull-down effect. heads can be used for different for machining on a 5-axis mounted on the the base of the and the work piece is clamped The axial tension against the profiles & moulded parts. machining center. machine located inside the behind the clamping device. work piece end-stop ensures clamping device. stability & vibration dampening. 10 | IKRAN NAVI SERIES IKRAN NAVI Series Specifications Size IKRAN 50 IKRAN 60 IKRAN 100 Chuck Type Stationary Stationary Stationary Clamping Range Tolerance ±0.5 mm ±0.5 mm ±1 mm Minimum Clamping ø(mm) A 14 14 14 Maximum Clamping ø(mm) B 50 62 100 Max. Bar Capacity ø(mm) 52 66 100 Concentricity Accuracy (mm) 0.015 mm 0.015 mm 0.015 mm Collet Head ø(mm) C 80 100 144.7 Main Body ø(mm) BD 130 150 220 Total Height (mm) TL 122 130.5 163.5 Length (mm) L 200 250 300 Width (mm) W 200 250 300 Clamping slot width (mm) P 16 18 12 Clamping bolt distance (mm) BP / CB 182 200 268 Wrench size (mm) WS 17 23 23 Collet Protrusion Length (mm) 4 4 4 End-Stop Thread Size M8 M10 M12 Front End-Stop Bolt Hole Pos ø(mm) D 107 (M8 x 3) 126 (M8 x 3) 192 (M10 x 3) Main Body Length (mm) J 57 64.5 81.5 Radial Clamping Stroke (mm) 1 1 1 Axial Clamping Stroke (mm) 2 2 2 Clamping Device Weight (kg) Collet Smooth Series TCT 50 CS TCT 60 CS TCT 100 CS Collet Serrated Series TCT 50 CSE TCT 60 CSE TCT 100 CSE IKRAN NAVI SERIES | 11 IKRAN EVA Series 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. Stationary chucks Description Advantages Short setup time Manually Operated Pull down effect on end stop stabilizes the workpieces The chuck is operated with a flat wrench which has to be half turned Ideal for 5-axis machining Chuck can be equipped with front end-stop Short Clamping lengths Accuracy<0.015mm Vibration dampening due to polymer. 12 | IKRAN EVA SERIES IKRAN EVA Series Specifications Size I-EVA 15 I-EVA 25 I-EVA 35 I-EVA 50 I-EVA 70 I-EVA 100 Chuck Type ID Clamping ID Clamping ID Clamping ID Clamping ID Clamping ID Clamping Clamping Range Tolerance ± 0.5 mm ± 0.5 mm ± 0.5 mm ± 0.5 mm ± 0.5 mm ± 0.5 mm Minimum Clamping Ø(mm) 15 25 35 50 70 100 Maximum Clamping Ø(mm) 29 40 54 80 100 130 Concentricity Accuracy Ø(mm) 0.015 mm 0.015 mm 0.015 mm 0.015 mm 0.015 mm 0.015 mm Collet Head Ø(mm) C 29 40 54 80 100 130 Main Body Ø(mm) BD 130 130 150 150 150 220 Length (mm) L 200 200 200 250 250 300 Width (mm) W 200 200 200 250 250 300 Depth of End - Stop (mm) 41 44 44 45 45.6 48 Clamping Slot Width (mm) P 16 16 16 18 18 12 Clamping Bolt Distance (mm) BP/CB 182 182 182 200 200 268 Wrench size (mm) WS 17 17 17 23 23 23 Chuck Total Length (mm) TL 174 188 198 210 220 265 Front End -Stop Bolt Hole D 72 77 77 100 115 192 Position Ø(mm) Main Body Length (mm) J 103.5 117.5 127.5 138.5 143.5 168 Draw Tube Adaptor Threading Size M45 x 1.5 M45 x 1.5 M45 x 1.5 M58 x 1.5 M73 x 1.5 M74 x 1.5 Base Plate Hole Position Ø(mm) 104.8 I 133.4 104.8 I 133.4 104.8 I 133.4 I 171.4 104.8 I 133.4 I171.4 104.8 I 133.4 I 171.4 133.4 I 171.4 I 235 Reserve Stroke Radial (mm) 1 1 1 1.5 1.5 1.5 Release Stroke Radial (mm) 2 2 2 2.5 2.5 3 Collet ID Sleeve ID Sleeve ID Sleeve ID Sleeve ID Sleeve ID Sleeve IKRAN EVA SERIES | 13 Accessories Collet Changing Fixtures 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 ). End-Stops 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 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. Collet Boring Fixtures 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. 14 | ACCESSORIES Testimonials Automotive “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 efficiency and profitability. Also no skilled labour is required to do the task.” - Mr. Rajesh Kothari, Vardhaman Auto Comp Pvt. Ltd. Aerospace “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. ” - Mr. Jitendra Mundke & Mr. Sandeep Raut, CPC Precicomp Pvt. Ltd. Tool Holding Systems “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.” - Mr. Vipul Chopda, KTA Spindle Toolings Defense & Automotive “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. ” - Mr. Tushar Mengale, Seinumero Nirman Pvt. Ltd. TESTIMONIALS | 15 Inovic Engineering Solutions Pvt Ltd 201, Chitrakoot Apartments, 1065 Gokhale Cross Road, Next to Symbiosis Distance Learning Centre, Shivajinagar, Pune – 411016 +91 99224 18208 | [email protected]