Groove jointing, internal and external splines manufactured completely and position-oriented
The EWS-Slot grooving unit is driven by the machine's tool turret, converting the rotary motion introduced into translation with a superimposed lift-off function. This makes programming extremely simple. The grooving unit is positioned in the prepared hole in such a way that the extended ram is at the end position in the Z axis. The groove depth is realized by a constant X feed, which varies between 0.04-0.15mm/stroke depending on the version.
The spindle speed ranges between 400 rpm - 1,200 rpm, with one revolution corresponding to one complete stroke. Thus, for example, a keyway with a width of 6mm and a depth of 5mm is produced within 7.5 sec. (800 rpm and 0.05mm feed/rotation) It is important in this operation that the chip can break at the end of the slot, i.e. that there is a recess or hole. But not only grooves, internal and external splines are also possible. This is particularly interesting for workpieces with partial splines.
High-speed thread cutting with reversing kinematics. The new EWS Tapmatic thread cutting head for driven tools enables thread cutting processes without having to reverse the direction of rotation thanks to its reversing kinematics. This saves time and energy and protects the motor ? all this with a defined depth of thread. The units are available for M3-M12 threads.
Advantages
Reduction of processing time up to 50%
Increase in production capacity
Increase of the service life of the threading tool by 3 times
The triad of front labyrinth, special sealing elastomer and preload ring forms the heart of this technology
The labyrinth technology protects against direct contact with cooling emulsion and dirt particles
The speed-related lift-off function of the sealing element reduces mold heating by up to 50 percent
Due to the contraction effect of the sealing elastomer, the sealing lip closes the path to the mold interior and ensures maximum safety against the suction of emulsion during the cooling phase
No friction-induced running-in at the mold spindle (50 percent of all service cases)
In case of service: Inexpensive seal replacement instead of expensive spindle replacement
The EWS.Varia VXT quick-change system is the latest addition to the successful Varia series, specially developed for static turning applications. This system offers the highest precision, stability and flexibility, based on the proven EWS.Varia VX system. The VXT line enables extremely compact tool clamping, which is particularly advantageous when machining in the direction of the turret box, as every millimeter of the clamping length counts.
Optimized stability and damping - The double-cone flex system offers maximum rigidity thanks to widely spaced support points; - The elastic second cone in the rear part of the adapter and additional clamping screws improve damping, resulting in a longer service life and higher surface quality. - The dual surface fit ensures reliable torque transmission and precise position orientation.
Tool change, flexibility and modularity The one-handed operation allows tools to be changed safely and quickly directly in the machine - EWS.Varia VXT combines the most frequently changed machining operations and enables the use of standard and overhead tools.
Highest precision and performance - Maximum clamping depths of VXT3 = 50 mm and VXT4 = 58 mm - Repeat accuracy of +/- 0.002 mm - Transmittable torque of VXT3 = 160 Nm and VXT4 = 200 Nm - Medium cooling pressure: maximum 80 bar
For loyal customers and users of the EWS.Varia VX system, there is a special EWS.Varia VXT interchangeable insert that enables a cost-efficient conversion of existing tool holders to the EWS.Varia VXT system and offers a seamless introduction to the newly developed technology. The benefits include maximum cost efficiency and an uncomplicated changeover, as existing VX tool holders can be easily converted to the VXT system, saving time and money. Translated with DeepL
Mit CyberCon4 von EWS erhält der Anwender einen digitalen Einblick in die kinematischen Abläufe seines Werkzeugs. Ein mit CyberCon4 ausgerüsteter Werkzeughalter erfasst umfängliche Daten zur Überprüfung und Kontrolle des eingesetzten Werkzeugs. Diese Datenerfassung erleichtert sowohl das Vorbeugen von Schäden an der Maschine als auch die Erfassung von Daten für das Shopfloor-Management.
Der digitale Blick zur Erfassung kinematischer Abläufe EWS entwickelt eigene Sensorik als Teil des Industrie 4.0 Konzeptes. Mit EWS.CyberCon4 steigt EWS in das Zeitalter der digitalen Transformation ein. Das digitale Konzept ist offen auch für Kooperationspartner, um den Anwendern möglichst viel Standard zu bieten. Über eine App können die Daten am Tablet oder Smartphone abgelesen werden. Allerdings ist das nur ein Teil der Möglichkeiten. EWS.CyberCon4 ist im Gesamtbild ein Baustein des gesamten IoT Konzeptes von EWS. Neben der Sensorik kommen neue Technologie-Features, wie das neue Dichtungskonzept „HPC-Line“ zum Einsatz Zunächst ist die Sensorik nur in Deutschland und Österreich lieferbar.
Die Vorteile
Vermeiden von kostspieligen Maschinenstillständen dank intelligentem Werkzeugsystem
Dynamische Ermittlung von belastungsabhängigen Wartungszyklen
Sensorik ist offen für die Kommunikation mit externen Schnittstellen
Datenverwaltung, intern und extern
Sensor basiert auf BLE 4.1-Technik (Bluetooth Low Energy)
Erkennen von Dichtungsversagen durch „FCS (Fluid Control Sensor)“, bevor Maschinenschäden entstehen
The new HPC-Line (High pressure ceramic) from EWS sets new standards for driven tools with axial and radial rotary unions.
The time when you had to decide between using high speed in conjunction with low coolant pressure or high pressure at low speed is over. The newly developed EWS.HPC-Line sealing technology now represents a further quantum leap. The seal set, which is based on technical ceramics, is capable of covering 70 bar at up to 12,000 1/min. Added to this is unrestricted dry-running capability.
The running-in process in particular meant the technical knockout for many sealing systems after only a short time, because the previous seals burned out after only seconds or they hardened, which then led to failure within a very short time. The technical ceramic used in the HPC-Line has excellent dry-running properties, which was a key criterion in the developers' specifications.
Even in terms of heat generation, there is something positive to report, because the high-precision face seal causes far less heat than was the case with lip seals due to the optimized friction factor µ. In addition, the frictional force FR= µ x FN was reduced to a minimum through geometry optimization and intelligent load balancing at the sealing elements.
For centuries, the keyway or spline connection was considered a set for the transmission of torque. The new possibilities in the field of manufacturing technologies, open up new dimensions for the developers of transmission units.
EWS relies on the polygonal shaft-hub connection in its new series and thus exploits significant technological advantages:
The balanced geometry reduces the imbalance of the driveline towards zero, a positive effect on the vibration of the work spindle and thus on the surface of the component. Added to this is the improved service life of the cutting edge and the increase in the service life of the entire tool system.
Due to the homogeneous force distribution over the entire circumference, up to 30 percent more power can be transmitted with the same dimensions, and the resistance of the connection to impact and breakage increases many times over.
EWS.Highspeed – these are special high-precision spindle bearings from EWS that enable particularly high speeds and are used in high-speed applications. The Highspeed tool series from EWS has lower heat generation, resulting in longer tool life. Not suitable for rough machining!
Adjustable up to +/- 115° with collet holder and support The latest swivel head generation from EWS is equipped with a Cylkro gearbox, which brings great advantages in terms of stability and size. Thus, it is possible to reduce the overall length of the swivel heads by up to 17 mm compared to the standard mountings. This offers significantly more flexibility in the cutting tool length, especially in the swivel range of +/-45°, and also enables use on machines with very compact swivel spaces.
The swivel unit covers an angle of +/- 92°. During the swiveling process, the coolant supply is directly carried along. The distance from the contact surface to the swivel axis can be offered from 48 mm. Even a high-pressure internal cooling system up to 70 bar can be integrated into the module without changing the external dimensions.
The limiting speed is 6,000 rpm, the maximum transmittable torque is 16 Nm, the max. cutting tool diameter is limited to max. 10 mm.
The swivel head is mainly suitable for drilling or light milling applications. For higher demands on torque and power, EWS offers its TKW series. These are fixed-angle tools that are specially made for each angle range. The standard angles from 15° to 75° - stepped in 15° increments - are part of the Uhingen-based company's standard and are usually available from stock.
EWS.tcJet brings the cooling directly to the cutter through the insert and ensures optimum chip removal. At the same time, cutting edge life is significantly increased. The internal cooling version of EWS is available for normal and high-pressure applications for different tool holders and cutting edge carrier manufacturers.
Features
EWS.tcJet brings the cooling directly to the cutting edge through the insert and ensures optimum chip removal
Longer tool life and higher productivity due to optimum cooling
For normal and high pressure applications for different tool holders and cutting tool manufacturers
Kennametal and the EWS Group have raised their partnership to a global cooperation, offering a wide KM system range for turning and milling operations, both static and live.
The tool systems offer extremely high cutting performance and enable guaranteed high productivity, ensuring optimized machine utilization through higher repeatability and shorter setup times. The range includes tool systems with KM interface for various machine models from leading machine tool manufacturers such as DOOSAN™, HAAS™, HWACHEON™, HYUNDIA WIA, Mazak™, DMG Mori, and OKUMA™.
Advantages
Large standard product portfolio of static and driven tools
Machine optimized tool systems
Sizes: KM32, KM40, KM50 and KM63
Special solutions with KM shank
Driven tool systems with up to 12,000 rpm; transmission ratio 1:1
Fit into different interfaces of machine tool dependent turret designs
VDI units for easy handling
Bolted units (BMT) for increased rigidity
Available with internal and external coolant supply
The EWS.PSC program includes a wide range of standard tools with PSC shank for milling spindles as well as tool systems with PSC spindle for lathes. Furthermore, tool holders with plate seat are available. The interface allows you to reduce the time spent measuring, setting up and changing tools. In addition, improved machine utilization can be achieved.
Increase your machine utilization
Increase in productivity
Reduction of set-up times
High flexibility
High stability and accuracy
Transmission of high torques
Wide product range The EWS.PSC program includes the sizes PSC 32, PSC 40, PSC 50, PSC 63 and PSC 80. Furthermore, the static and driven tools are optimized for specific turret interfaces and thus make the best possible use of the space available on your machine.
EWS.PSC - Inserts without gripper groove
Significantly reduced length of adapters
More available cutting tool length
Higher accuracy due to reduced overhang
Higher stability due to reduced overhang
Longer service life due to reduced load on bearings
The changeable centring tip for counter spindles Would you like to use your counter spindle temporarily as a tailstock, and then once again as a normal chuck? You can with the EWS.CenterPoint. For machines with one turret and two spindles for flexible insertion into the counter spindle.
Area of application
Lathes without tailstock and with a turret
For supporting long tools
Top changeable short taper 12
The top kit can be integrated into simple combination holders
Module milling on CNC lathes without B axis Years ago, EWS was the first tool manufacturer to offer module cutter heads in its standard program and has continuously developed the holders for the gear cutting technology. With this technology, it became possible for the first time to produce external gears on machines that do not have a Y- B-axis. In contrast to a standard disc cutter holder, the tool head of the EWS module cutter can be swiveled around the shank axis.
The advantage for the user is that a B-axis can be substituted with a comparatively small investment. In the meantime, even module 3 is common practice on VDI40/BMT65/BMT75 machines. The tool heads have become more stable and at the same time more user-friendly. The alignment system via sinus ruler has become established and saves enormous alignment and setup time.
Create any desired shape centrically or eccentrically 4-, 6- or 8-edge, polygon or free-form shapes with EWS.Multiform on CNC turning/milling centers
Free forms that used to be impossible can now be made with EWS Multiform on turning/milling or machining centres. For a six-edge outside the centre or a four-edge in the centre, additional processing steps such as reaming or eroding were necessary up until now. If a position change was also needed, complicated devices were needed for processing. This is now all possible with one chuck.
What is behind this? EWS Multiform uses a custom internal cam disc unit to produce the required form. For conventional geometry like squares or hexagons, there are standard cam discs available. The cam forces the cutting tool to follow a path in order to get the desired geometric shape. Of course you can’t defy the laws of physics which means that there will be a small radius on the edges.
The multiple new possibilities however will allow engineers to come up with new processes for manufacturing. ID and OD slots, offset squares and straight polygons are examples of an endless list of opportunities. To see what shapes are possible all that needs to be done is verify with EWS application engineering.
The best of both worlds! Lack of stability, the VDI system has been increasingly associated with this fact in recent years, resulting in block tools being favored more and more, although VDI tools still offer greater variety and flexibility. So the next step seemed obvious, to combine the best of both systems, and in cooperation with DMG, the EWS.ProLine system was developed to take full advantage of the potential of new turning machines.
EWS.ProLine has a conventional VDI shank, but can optionally be fixed to the turret via four screws, allowing the flexibility of the VDI system to be used for light machining, and the stable block-tool properties for heavy machining. The angular position of the radial tools is ensured via the Trifix® alignment system.
Cutting data similar to HSK63 machining centres? On a Gildemeister CTX Beta 1250 4A, two surfaces were milled in parallel with two cutter heads Ø 80 in 16MnCr5 steel. The infeed was 3 mm/head, at a 180 cutting speed. Without chattering or whistling, a surface was produced that was previously only known from HSK63 machining centers. The two axial tools from the EWS.ProLine were equipped with 4:1 planetary gears and had the VDI40 shank mount.
EWS takes a stand against vibrations in deep wells Machining deep holes with long projecting boring bars is one of the most demanding tasks in machining technologies. What influences vibrations, what amplitudes do they generate, what is the effect of their superpositions, when do you encounter uncontrollable resonances? These are all questions that are difficult to address from theory.
This insight was the basis for the new development of EWS Rigid. The aim was to create a drill holder that counteracts vibrations by means of a passive damping system. Variable vibration dampers with linear degrees of freedom act on the dampers, which are mounted floating in the interior of the cutter carrier.
The position of the absorber is adjusted by means of a radially mounted adjusting screw, which can be used to create optimum vibration conditions. The improvement of the surface finish of bores, as well as the increase of the cutting edge life are significant.
Emulsion can do more than just cool... At least when using EWS.Spinjet, the coolant is used to drive a turbine that rotates the tools at up to 55,000 rpm, depending on the type. The tool drive of the turret is at a standstill during this machining operation!
Advantages of the GreenLine
Saves up to 70% of machining time (20,000 to 55,000 rpm)
High-speed machining
Less tool and machine wear
Features
Coolant-driven high-speed spindle uses the existing coolant supply of the machine spindle
Wireless real-time speed display enables permanent measurement and monitoring during machining on the machine
Machine requirement
Min. 20 Bar Coolant pressure
12l/min Volume flow
High Pressure Line Power / Speed / Efficiency The high pressure high speed spindle is the optimal solution for small diameter machining; milling, drilling, deburring, fine grinding and more ...
EWS quality now also available for sliding headstock lathes: With this new development of driven tools, EWS responds to multiple customer demand. The tool systems EWS.Swiss Tools, which look simple at first glance, have it all!
EWS.Swiss Tools - for STAR and CITIZEN machines In the design of EWS.Swiss Tools, the main focus was on the bearing arrangement and spindle runout. The requirements profile was developed together with an American medical technology company that uses very small drills and needs extreme runout characteristics. The spindle bearing technology used with labyrinth sealing sets new standards in this area, combined with a long service life.
Service is also already taken care of. The service centers in Germany, China, Korea and the USA are trained in the systems and can respond immediately. Third-party products can also be serviced there at any time.
Alignment system for Glidemeister turning-milling centers EWS Trifix® is the alignment system for Gildemeister turning-milling centers. the alignment bars, which are mounted on both sides, each engage via a bevel in high-precision manufactured recesses in the turret surface. the bars are preset with preload. the spring effect of the alignment system eliminates static overdetermination. this ensures the twisted position of the tool holder without additional adjustment effort and thus significantly reduces machine set-up times. due to the high precision requirement, application for double-toothed tools is not possible. the tools are delivered pre-aligned and can be used directly.
EWS is a system partner of DMG MORI for this tool generation.
EWS Trifix® advantages
Repeatability on one station below 6 µm with 200 mm throat depth
high positioning accuracy from one station to another (0.01mm)
completely aligned driven tools and static holders
static holders can be used with additional mounting hole pattern
heavy duty spindle heads with additional mounting hole pattern can be used
Achieve 0 runout within one minute with a simple collet – that's Zero-Zero!
The specially developed clamping nut with 6 symmetrically arranged screws on the circumference make this possible. The clamping nut is split in two, so that the inner ring can be moved minimally. Thus, tolerance additions can be eliminated via this simple technical finesse.
It is only necessary to replace the previous clamping nut and the user is already moving in a new concentricity dimension and that from 90.- €. Zero-Zero is available for collet chucks according to DIN 6499 from ER 16-ER40.
The area of driven tools is one of the core competencies of EWS. More than 15,000 different driven tools can leave the Uhingen plant at short notice.
In addition to the standard program such as straight tool holders (axial drilling and milling heads) and angled tool holders (radial drilling and milling heads), angular heads, swivel units, grooving units, multi-form units, multi-spindle units and individual special solutions for BMT and VDI turrets are offered. The variety of driven tool systems knows no limits here.
The tool clamping systems range from the classic collet chuck through Weldon and Hydrodehn to PSC, KM, ABS and HSK. The field of application extends from the classic CNC lathes to highly complex turning-milling centers. Thus, driven tools can be offered for all common machine manufacturers such as DMG MORI, EMAG, Index, Haas, Mazak, Mori Seiki, Nakamura, Okuma and many more. A complete listing of all manufacturers can be found in the online catalog. Experience over several decades in the development, design and production of driven tools makes EWS the specialist on the market.
With the quick change system EWS-Varia a benchmark for flexible modular systems was set. EWS-Varia with its safe handling and short change times is one of the most successful systems on the market. This was impressively underlined by the award of the Innovation Prize of the State of Baden-Württemberg in 2006.
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