EWS.CyberCon4

Driven tools form a further core area of EWS. More than 8,000 different tools are available at short notice.

In addition to standard products like axial and angular heads, EWS offers swivel units, slot broaching tools, multiform tools and multi-spindle machines. There is just no limit.

The tool clamping systems range from the classic collet chuck holder to Weldon and hydro extension to Capto, KM, ABS and HSK.

The applications range from classic CNC lathes to highly complex turning milling centers.

The EWS CAPTO-series offer standard solutions as well as a great number of machine optimized toolholders. Moreover we provide toolholders with plate fit.

The EWS CAPTO-series imply size C4-C8.

Restraint is the key

Thanks to its short design, the new HSK-63AT collet holder for multi-tasking machines means that you can be flexible even in the smallest of areas!

Our sales department will be happy to advise you in selecting the right HSK or EWS Capto version.

Gear hobbing on CNC lathes without B-axis

Years ago, EWS was the first tool manufacturer to offer gear hobbing heads in its standard range, and has continued to develop the holders for gearing technology ever since then.

With this technology, it became possible for the first time to produce external gearing on machines without a Y/B-axis. In contrast to a standard milling wheel holder, the tool head of the EWS modular cutter can be swivelled about the axis of the shank.

This offers users the advantage of substituting a B-axis with a comparatively small investment.

In the meantime, module 3 has become commonplace on VDI40/BMT65/BMT75 machines. The tool heads have become more stable at the same time as being more user-friendly.

The alignment system using a sinusoidal profile has come into widespread use and saves considerable alignment and setup times.

Reaching concentricity 0 using a simple collet chuck and this within one minute: this is Zero-Zero.

The specifically designed clamping nut with 6 symmetrically arranged screws at the circumference makes this step possible. The clamping nut is split, so that the inner ring can be minimally shifted. This simple technical finesse allows to eliminate tolerance additions.

The machine operator only has to replace the previous clamping nut, which step opens up a new concentricity dimension – and this for a price starting at € 90.00. Zero-Zero is available for DIN 6499 collet chuck holders from ER 16-ER40.

„Give me a long enough lever and a place to stand, and I will move the Earth…

(Archimedes' Law of Levers, 250 BCE)“


It is not quite so spectacular, but nevertheless closely related. „Give me a point on the turret disc that I can rely on, and aligning radial tools on the tool changer is a thing of the past.“

These were the fundamental requirements on EWS engineers… and they came up with the EWS-Adjust.

The trick is to position the line of symmetry for the insertion hole in the turret congruent with that of the alignment pin. Time-consuming angle of rotation calibration is no longer required if this is guaranteed and implemented on all tool stations.

This is precisely what EWS has achieved with its Adjust system. Incidentally, this solution can be retrofitted to many tool turrets at any time.


Mode of function in detail:

Aligning using 2 screws on a pin in the turret is a widely used method. However, this time-consuming calibration, especially when it comes to machines with 2 turrets (up to 28 tool stations) degrades the high fast motion speeds, rendering them insignificant. The gains in travel speeds are eliminated by the enormously long setup times.

Irrespective of how the alignment on the pin is designed, it always takes time to achieve the setting, because the DIN pins that are generally used are never located exactly in position in the turret bore. If you consider that a PIN–position is 10μm offset in the Y-axis at a distance of 56 mm (in relation to the VDI bore), this amounts to as much as 0.03 mm on a normal drilling rod holder with an extension length of 100 mm. This consideration does not take account of the installation inaccuracies in the machine-tool.

EWS has tackled this problem with its new EWS-Adjust system. The goal was to eradicate the problem.

There is only one way of doing this; the pin on the turret must be aligned, and this must be done on the machine, preferably in the machining position. For this purpose, EWS has developed an eccentric pin that is fitted into the same bore when the standard– pin is removed.

Together with an EWS setting pin, the pin can be aligned precisely with the machining position. The lower part of the eccentric is an expanding pin which is acted on by a threaded pin, thus securing the angle of rotation position.

This task must be done once for all turret stations. The tool that is used on the turret can be set using an external fixture. This is also only necessary once, providing there are no collisions.

The EWS-Adjust bar is provided with a fixed part with a counter screw opposite to eliminate the last play between the bar and pin. The system can be retrofitted to almost all tools supplied by EWS.

Measuring device for setting tool change systems.

Precise setting of tool change systems always used to be a complex procedure.

Thanks to the new EWS-Calibrit, the offset can be easily determined in both the X- and Y-positions, and also in the corresponding Z-position.

EWS Calibrit is ideal for service technicians and in-house maintenance departments.

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

Area of application:
- Lathes without tailstock and with a turret
- To support long tools
- Top changeable short taper 12
- The top kit can be integrated in simple combination holders

Prerequisite:
- Counter spindle with tailstock function
- Taper shank adjusted to GSP

Machining process:
- Milling on the main spindle
- Switch to tip in GSP
- Use tip rotating
- Execute machining
- Remove tip from GSP
- Pass work piece to GSP, work second side

The solution for multiple

The new EWS Drillstar offers an intelligent tool arrangement a tremendous use of the cutting tool length, in spite of a limited total tool diameter. This can be realized by using the controlled CNC-axis Y-B together with the tool spindle axis of the multi tasking machine efficiently.

Overview of features:
- Execute 3 drill or boring operations without a tool change.
- Hole diameter 16 mm, clamping depth 3xD
- Tool orientation 3x120o at an angle of pressure 35o, crown-shaped and Y-axis offset.
- Usable tool length 60 mm interference at 120 mm internal or external coolant supply, individually selectable

Make any centric or eccentric form desired

4, 6, or 8 edged, polygonal or free form with the EWS Multiform on the CNC turning/milling machines

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.

Function:
- The needed profile is created by using a cam disc. Both standard and customs versions are available.
- The drive runs in the turret just like a driven tool.
- Note: Constraint for turrets with permanently running driven tools as the rotation speed is limited to max. 1,000 RPMs.

Requirements:
- Turret for driven tools
- For machines VDI20 - VDI50 and BMT55 - BMT75

The best of both worlds!

Insufficient stability was a fact increasingly associated with the VDI system in recent years. As a result, block tools were preferred more often, although the VDI tools still offer greater diversity and flexibility.

So the next step appeared obvious: combining the best of both systems. In cooperation with DMG, we developed the EWS ProLine system in order to fully utilize the potential of new lathes. While EWS ProLine features a conventional VDI shank, it can be optionally mounted to the turret using four screws.

For instance, the flexibility of the VDI system can be utilised for lighter machining, and the stability properties of block tools can be utilised for heavy cutting. The angular position of the radial tools is ensured through the Trifix®, the alignment system.


Cutting data similar to HSK63 machining centres?

The professional audience at the EMO 2011 watched an impressive live demonstration:

on a Gildemeister CTX Beta 1250 4A, two surfaces were milled at the same time in 16MnCr5 steel using two 80 mm-diameter cutter heads, with 3 mm feeding per head at a cutting speed of 180. One surface was produced without whistling or clattering; previously this could only be achieved with HSK63 machining centres.

The two axial tools from the EWS ProLine were equipped with 4:1 planetary gear sets and featured the VDI40 shank holder.

EWS takes measures against vibrations in deep drilling procedures

Deep drilling procedures with drilling rods with a long overhang are one of the most demanding tasks in cutting technologies.

What influences vibration, what amplitudes does it create, what is the effect of superimposed vibration and when are uncontrollable resonances encountered? All these are questions that are difficult to answer using theory alone.

These findings formed the basis for the new development of EWS Rigid. The objective was to create a drilling holder with a passive damping system to counteract the vibrations that are created. This involves using variable vibration dampers with linear degrees of freedom in a floating mounting inside the cutter carrier.

The damper position is set using a radially mounted setscrew, which allows optimum vibration conditions to be created.

The improvement in surface qualities of bores is significant, as is the increase in the service life of cutter tools.

EWS is presenting the new drilling rod system for the first time at the EMO 2013, equipped with an HSK63 base holder and an adapter for the EWS Capto C3.

Emulsion can do more than just cool...

At least when using EWS Spinjet, the coolant is used to drive a turbine which allows the tool to rotate to up to 60,000 rpm, depending on the type.

The turret's tool drive stops moving during this process!

EWS quality now available for Swiss-type lathes.

This new development in driven tools is EWS's response to many customers' requests. The tool systems may appear straightforward at first sight, but their simplicity belies their performance.

The design concentrates on the mounting and the spindle concentricity. The requirement profile was developed jointly with an American medical technology company which uses very small drill bits and requires extreme concentricity properties. The spindle bearing technology used with labyrinth seals sets new standards in this field, and is associated with a long service life.

Provision has already been made for service. The service centres in Germany, China, Korea and the USA have already been trained in the system and are ready to respond without delay. Third-party brands can also be serviced there at any time.

The HSK series from EWS offers standard solutions as well as a large range of machine optimised tool holder fixtures. Tool holder fixtures with insert seats are also available.

The HSK series includes sizes HSK40-HSK100.

Static tools form one of the EWS core areas. There is no other manufacturer in the world offering such a variety of products: More than 20,000 different tool holders are available for machine operators.

Our portfolio includes VDI tool holders with shaft diameters of 16-80 as well as block tool holders of BMT55-BMT85 to machine-specific holders for MAZAK, Okuma or Mori Seiki, to name just a few.

We also offer prism holders according to DIN 69881 (VDI3425 Bl.3) in all nominal sizes.

Our standard portfolio includes Capto, HSK, KM and ABS adaptations in addition to the standard holders.

Moreover, our scope of supply includes special holding fixtures made according to customer drawings or innovative solutions of the EWS engineers designed to master production engineering challenges.

Trifix® is the new adjusting system for Gildemeister multi tasking machines. The double sided adjusting system is guided by a very precise key way at the surface of the turret. 


The plates are preloaded, and the resiliency in the adjusting system eliminates static redundancy.

This allow the exact position of the tool to be secured and significantly reduces the setup time of the machine.

Because this is a highly sophisticated precision instrument it is not possible to use double serrated tool shafts.

The tool is supplied fully adjusted and can be used right away.

Trifix® advantages:
- Repeat accuracy below 6 µm at radius of 200 mm
- High positioning accuracy from one station to another (0.01 mm)
- Driven tools and static tool holders are completely aligned
- Static tool holders can be used together with additional drill pattern for mounting
- Heavy duty spindle noses can be used together with additional drill pattern for mounting
- Tool disc / functional areas are easy to clean

The rapid change system EWS-Varia allows to set-up a modern CNC lathe or a turning milling center – and this flexibly.

A tool change will just take 20 seconds, which is an unbeatable argument especially in small batch productions whenever it is about reducing the set-up time and thus increasing the productivity.

The advantages, however, are also evident in large batch productions. Preset twin tools lie at the machine, thus significantly reducing the down-times.

A further advantage is provided by the variety of adaptations; so the optimal tool clamping can be selected for each operation. The inserts available include:

• Collet chuck holders
• Weldon/Whistle Notch
• Milling arbors
• Morse tapers
• Hydro extension
• Shrink adaptations