Consider not just enough movement to squeeze the stack, but you need say 0.030 either end of the stack for clearance plus some extra to pop the collet.
This extra movement means considerably more force than the holding force on the stack is required to pop and eject a typical TTS tool.
Doing it manually, you undo a turn or two, and have to give a firm rap on the drawbar to release.
You also end up with some lost travel from the drawbar elastic elongation under tension. Quite measurable!!
A single 2" cylinder at 80 PSI needs close to 2" travel convert to about 0.25" travel at the stack to release AND eject.
1" travel at the cylinder just won't give the extra pressure required to release and overcome the extra bits of 'lost travel', practical clearances, etc.
If the pressure on the stack was constant as the travel changed all would be fine, but the pressure must increase considerably past the required holding tension in practice.
At this point consideration must be given to ensure the fatigue life of the belleville washers are not exceeded.
If you squash past about 75% they will fail during cycling, as many have found, and how many of the 'real professional' packs need their broken washers replaced?
Fatigue life should be taken into account if you want to keep the maintenance low.
Looking at washer data, much over 75% compressed from the free state is asking for problems, and you probably need them at 65% to get the required holding force.
Any comments?
Super X3. 3600rpm. Sheridan 6"x24" Lathe + more. Three ways to fix things: The right way, the other way, and maybe your way, which is possibly a faster wrong way.