Tool Holder Essentials - Every Machinist Needs to Watch This - Haas Automation Tip of the Day

hello and welcome to this ha step of the day now behind me is a mill and this is a tool but to get the most out of our Mills and our tools we have to use the right tool holder for the job now the problem is there are as many different kinds of of tool holders out there as there are vehicle types on Android so we'll ask the question that we know you want the answer to which of these holders is the best and we're going to answer that with a torch and using physics and we're gonna cut some stuff in half so you do not want to miss what comes next if someone asks what is the best vehicle you might say the sports car it's super fast and it costs a lot of money so it's got to be the best right but what if you have to pick up some two by fours at the hardware store perfect how about 500 to buy that's not gonna work how about going to the beach with a family of seven no you get the idea you got to match the task with the vehicle and the same can be said of our tool holders we judge these tool holders based on a bunch of different factors like price how much the entire tooling system is gonna cost us balance that's just how badly the tool assembly is going to shake at higher rpms and we've got grip how well the holder holds on to the tool when roughing and finishing and those sorts of things we've got clearance some tool holders are better at others at reaching our part without running into our fixture and among other things we've got run out which is just how much the tool will wobble in the holder now I just want to mention right now that I'm painting this entire topic with a very broad brush when I say this holder I'm talking about this style of holder this type of holder not a particular and now to reinforce this our legal department has written up this disclaimer ok did you catch all that perfect that's out all the way onto the holders let's start with our drill trucks as drilling is one of the most common operations in machining now they come in two basic styles we've got a keyed Chuck over here see because this is a key and you'll tighten the drill by inserting the key and rotating it tightly and then these are keyless chucks over here keyless you can tighten them by hand now these both have their place this style of Chuck was was invented by a fellow named AI Jacobs he patented it way back in 1902 and you'll find them on all kinds of drills like the drill press in your garage workshop I actually saw this this same style of Chuck at a blacksmith shop up in Northern California just last week now if you're a set up machinist you need to know the difference between these two style of chucks as soon as a setup machinist walks in the room he needs to look at this style of holder and this style of holder and realized that there is a fundamental difference in performance a keyed Chuck as great as they are typically has between three and four thousandths of an inch of run-out that is not what I would call precise as compared with a precision keyless chuck now this style of chuck and these are two different brands typically have about a thousand a half or 40 microns worth of run-out so my recommendation in general moving forward is to load up your machines with precision keyless Chuck's if you really want to hold tight tolerances with your drills now this style of holder the keyless chuck was invented by Albrecht right back in about 1908 and they've been popular ever since now I really like drill trucks I just love them especially for their their range and their ease of use especially with high speed steel twist drills now the thing to know about twist drills is that the shank is the same size as the cutting flutes as a cutting edge right so this guy is a thirteen thirty second now I had a calculator earlier I know that this is point four zero six to five inches in diameter so what are we going to hold this wonky size drill in it has to be some type of holder that's got a certain amount of range to it of all the holders that we've got no single tool holder has more range than these drill Chuck's this single Chuck right here can hold all of the drills on this table and it only takes a moment to change the drill it says right here that this chuck will hold from 1/32 to 1/2 inch so about one millimeter to 13 millimeters ooh did you see this guy over here when you were panning across this one's pretty cool this drill looks absolutely horrible this drill was not tightened well enough and it's spun in the Chuck probably operator air I would not trust this drill for great run out on important jobs and it probably scratched up the jaws on whatever holder it was used on now these newer styles of chucks are kind of hybrids yes they're keyless chucks I can tighten them by hand but they also come with wrenches that we can use if we just want to increase our grip a little bit now these things are designed to be used with drills but I would never use them with an anvil a lot of these chucks this one here in fact is actually two pieces the truck is separate from the holder and these things are held together with friction and a taper a Jacob's taper jt6 in this case we can actually separate the Chuck from the from the holder with the use of a wedge in the same way that we would a drill press now while drilling these two pieces are being forced together at all times the drill is pushing up axially and enforcing these together with an Mills the exact opposite is happening it's trying to pull that tool out because the helix on the end no and it's gonna want to separate these two and nothing good can happen you're not getting extra grip by any means now if we're running a carbide drill like this guy here we might run into problems I personally would not run a carbide drill in a standard style drill chuck the material is just so hard that it's more likely to spin in this style of Chuck not that I haven't done it I've done it a bunch of times but but I just know that there are better options out there although albrecht does make a set of jaws that's got diamond in it right so it really bites into the carbide or hardened steel drills I've got to tell you a quick story that I first heard in an article by Kip Hansen now he was talking about Carl a Bergstrom and how he was the person that invented the helical flute and mill with that 30 degree he looks on it way back in 1918 well it turns out that putting a helix on the end mil actually solved a whole bunch of problems so much better than the old straight flute end mills they were using at the time the tools cut much quieter and left a much smoother surface finish but they also immediately pulled out of the tool holder so Carl did what any brilliant machinist would do he took the tool he walked over to a grinder and he ground a big flat on it then he tapped the holder for a set screw [Music] so catch this Carl Bergstrom invents the helical end mill and five minutes later invents the Weldon shank side lock holder Weldon holder and mill holder all of those names refer to the same thing and because the the set screw style proves so effective we ended up with a holder that has a really incredible grip strength but because we've ground off a huge chunk of our tool and drilled holes in the side of our holders this assembly is not typically very well balanced so what does this mean for us well without a special tool that's been balanced as a matched set we don't want to run these things above ten thousand rpms they'll shake so balance is definitely not a strong suit for welding shank tools but the price is fantastic sometimes five times cheaper than other alternatives remember back with the keyed drill chuck we said that we might have as much as three or four thousandths of an inch of run out while the precision keyless chuck might have a foul and a half of run-out this style of holder the Weldon shank in might give as much as 1,000 of an inch of run-out that's that's a lot of run-out and the tooling companies tell us that if we have a sow of run-out our tool life might drop in half that's right it might drop by 50% the rule of thumb in the industry is that for every one tenth of a thousandth of an inch every two or three microns of run-out that we're gonna lose ten percent of our tool life and yet that's probably an exaggerated number but for the most part I believe it so when we're talking about price for this holder this is a very inexpensive holder you have to also kind of think about your tool life in that if you're burning through tools the holder might be costing you more than you think now what if I have a tap or a drill can we hold that in a side lock holder the short answer is no you don't want to be doing that and there's a good reason for it high speed steel tools are pretty soft and if you drive a set screw into the side of that tool while in a side lock holder it's gonna dent out or bulge that steel shank and when you go to pull the tool out it's gonna scratch the inside of your holder there is a reason why we call these end mill holders and not drill holders right we have drill chucks which are not meant to be used with n Mills and then we've got these end mill holders which typically aren't used with drills unless those drills were made for it and actually have a Weldon flat on them so if you need to grind a flat on a tool to be used in a side lock holder make sure that you're using the right kind of grinding wheel the green wheel for the car by typically and the other wheels for the high speed steel if you use a high speed steel tool on the green wheel you're going to load it up and you're just going to get yelled what if a car salesman told you that if you paid for the red paint your car could go 50 percent faster than the standard blue paint of what would you think well that's really what's happening with modern paint or modern coatings for our tools if you're machining on aluminum and you're running at EIC n coating you might be able to push the tool a forty percent faster with the RPM if you're cutting on steels you run a TI ll n coating you might be able to run 50 percent faster or maybe maybe double that rpm with that fancy coating so our tools are spinning faster than they ever have in the history of machining because these modern tool coatings and that creates a problem because our tools need to be balanced especially above 10 K so we want to show you our balancing machine the balancing process is pretty straightforward you open the lid we drop our tool in and we add in some numbers and the Machine balances things out it marks the tool with a laser showing us where we need to remove material in order to make this thing balance after it's been marked we take that holder over to our mill and we'll remove some material the amount we were told by the software will then go back put it in the machine and Rivera fie that the tool is better balanced we were able to remove just a little bit of metal radially from our holder to put it back into balance but some Weldon holders are so out of balance once they've got the tool in them that you just can't balance them because they really weren't designed to run at those higher rpms while we struggled with balance using a side lock holder a shrink fit holder has none of the drawbacks know the character floss of a Weldon this guy is perfectly round smooth all the way around because there's no a set screw it's holding the tool in a different way because there's no set screw the tool itself doesn't need a Weldon flat so it can be made completely around as well round is good it's easier to balance these things at the factory round tool round holder when you assemble them they're still round and they still remain balanced so this guy can run at the max rpm oh here a machine consistently without vibrating as much as a side lock holder for high speed machining tool pass which one are you gonna choose the shrink in this case now how do we actually hold the tool in the shrink fit holder well we've got a little physics experiment to show you how we have a brass ring and a spherical brass ball now at room temperature the ball does not fit inside the ring but if we were to heat up the ring the metal is going to expand and as the ring gets larger the spherical ball is going to be able to pass through with the ring heated the ball can fit through now if the Florida to go halfway through the ring and we let it cool like that it would create a press fit then we'd have a hard time getting them apart which is exactly how our shrink fit tooling works at room temperature the tool doesn't fit in the holder the holder is smaller than the tool so we take the holder we put it in the shrink fit machine and it's heated up immediately by an induction ring this happens very quickly we'll hold onto the tool making sure to wear Kevlar gloves so we don't print our fingers then we'll drop the tool into the holder after it's expanded at that point we let the entire system cool and this can take 10 minutes or more in fact if I'm looking at this ring on my table I'm not going to touch that ring until it's cooled down I'm gonna give that stuff for half an hour before I go anywhere near it with the shrink fit to holder that is one of the drawbacks that if you let it cool down and take a long time the particular shrink fit machine that we've got though is special after the tool holders been heated the tools been dropped in and the unit is cool immediately in just a few seconds when the tool comes back up we can remove and it's ready for use now when it comes to cost the price of a shrink that holder is actually pretty reasonable but there's more to it than that if we had a side lock holder all we need to run that system is a single allen wrench that's about as cheap as it gets for a tooling system for an ER college system we need the ER wrenches or maybe fancy torque wrenches for the shrink fit holder though we need the shrink fit machine and the prices of the machines just varies greatly so our price depends on the machine that we're getting run out excellent with the shrink fit holder maintenance maintenance is about as good as it gets for a holder there's no moving parts we might just run a bar brush down that bore every now and then to get rid of any carbon buildup but that's it and another factor is clearance some people will go with a shrink fit holder system based on the clearance alone especially if they're doing five axis because of that 9 degree included taper on the holder and the small diameter at the nose you can get really close to those parts especially with those you know tilted rotary parts without worrying about collisions with your holder the holder is out of the way now a drawback to shrink fit holders is that you need one for every size tool that you plan on running now if I have 10 tools with 10 different size tool shanks I'll need 10 shrink fit holders now compare that to an ER system where a single ER holder can accommodate any of those tools with a simple collet swap so the range on our shrink fit holders not great these are not one size fits all they're one size fits one now there are two final things you need to know when we're talking about shrink fit holders one has to do with the size one has to do with the material of the tools themselves now if you already have a shrink fit system you've got to know this and if you're thinking about buying a shrink fit system you need to know this the first thing we'll mention here is about the size of the tool the size of the shank of a tool really matters it affects the grip strength when using a shrink fit holder and we're going to demonstrate this with a bore gauge the question is how much press fit do we really have when we use a shrink fit holder this holder is 5/8 of an inch point six to five around 16 millimeters so we're going to measure this board and we're going to measure the shank on that tool this is 0.625 ring gauge I've got my my bore gauge here we're gonna drop this guy in we are at zero on the bore gauge and with my holder that we've got right around a foul and three-tenths under so under nominal of 0.625 so if the tool was exactly point 65 inches we'd have about a thousand three tenths press fit or 33 micron press fit now why is this important to know because when you're grinding the tool they grind them to different tolerances when you make a part for somebody you have a plus or minus tolerance the tool guys have plus or minus tolerances as well those are called fit tolerances we're gonna make an entire tip of the day on this but just know this that the tolerance is so loose with an h8 grind that you'd have no precipitate all you patiently be dropping the tool in and out you cannot use tools that have h8 shanks with a strengthened holder so h7 much better and perfect would be an h6 tool if you ever have a tool pull out of a shrink fit holder look at the shank fit tolerance on the tool that's most likely the culprit now on to this high speed steel tool now years ago I would just avoid high speed steel tools altogether with the shrink fit machine that that we had at our shop the machine he had things very slowly and it was heating the tool at the same time it was heating the holder essentially they'd grow and shrink at the same time because you've got a tool steel tool and a tool steel holder they'd be stuck together forever nowadays machines are designed different they can they can heat up the holder without heating up the tool and you can get away with running a high speed steel shank tool but make sure you understand this before buying a machine some machines can't be run with high speed steel tools other ones can get away with [Music] here are the ER holders that we keep talking about these are the real workhorses of many if not most machine shops they're kind of the utility player of the holder world and there's a reason for this they've got good run out they've got good grip and as far as versatility and price go they're fantastic er systems can be really cost effective performers but I do think that they require a lot more training and care then some of the other holders were looking at today depending on the tool being used and the quality of the holder they can have really good balance and of course if we use the machine we can get the balance just perfect so if I had just a couple of tips for you on a are holders they'd be to make sure that you're using the right size call it for the tool and that usually means using the smallest collet available for the tool shank if I'm using a 12 millimeter shank tool I'm going to use an 11 to 12 millimeter collet not a 12 to 13 then make sure that that collet is torqued properly really affects everything even the run-out and finally and most importantly make sure everything is clean and dry when you're assembling these tools now we've talked about grip strength and when it comes to ER call it's your choice of what nut you're gonna use plays a big part in our grip strength some of these nuts like a low friction nut or a bearing nut they can increase our holding power by 50% right 50% just by using the right nut which can give all the clamping force right to the taper of the collet now because there is so much to know about er kaulitz and there are holders and running coolant with them and torquing them we made an entire video on that one subject and we'll link to it in the description of this video it is really worth seeing especially if you're actually a setup machine of some place now if you're just looking for a more grip I gotta say this a second time if you're using an ER college system and your end will start to pull out it's it's almost definitely within reason operator error right I had this happens to me quite a bit when I first started machining decades ago and then all of a sudden I just stopped having problems with er holders why is this because I started using the right collet for the holder I started using the right nuts right the bearing nuts low friction nuts which is gonna bump up your grip strength and really make sure that everything is clean and dry so I know I just said that again like two minutes ago but all those setup tips really make a difference in here will prove it to you watch this example in this example the holder was not torque the proper spec and it's using just a standard collet nut now after heavy slot milling the tool has pulled out of a holder and ruined our part in this example we used a low friction nut that is cleaned and torqued properly with the same program speeds and feeds and the end mill is held securely throughout the entire job and if that isn't good enough for you then we can move on to some of the other holders that have way more gripping strength than an ER system now as your need for better gripping power clearance and run-out increase we might find ourselves looking at some of the other high-end holders that were on the table earlier one of which was the milling chuck and that's what we're gonna look at now if we were to pull apart a million chuck we would find row after row of tiny needle bearings loosely held in a cage to keep him in place with a special graphite based grease the needle bearings right in between a tapered nut and the tapered holder body well after seeing a holder up close you might be wondering what's keeping the nut from just spinning around and around and around like a wheel bearing well check this out this is cool there is nothing special about the needle bearings themselves they aren't even tapered but the cage that they are loosely held in it's unique it holds the bearings at an angle changing their inclination when the pins are rotated at an angle shown here by these lines the pins as an assembly now function like the threads on a cap now as we turn the nut clockwise the bearings that are trapped in between the nut and the body they start to climb the taper being pinched between the nut in the body and compressing the body tightly against the tool this mechanical action gives us incredible gripping strength maybe five times more gripping strength than a standard ER collet I'll mention this now that you don't want to tighten up this holder without a tool in it it could damage the holder and that's especially true if you have a sleeve or a collet and that goes across the board with just about any tool holder on that shelf with our side lock and our shrink fit holders we can only hold one size one exact size tool but with a million chuck we do have a certain amount of range to them these sleeves are unlike our ER collets these sleeves are straight which means if we drop them in and then put our end mills in they've got nowhere to go which gives us an even stronger hold when doing heavy milling radially now I'll tend to use million chucks more often on my 50 taper machines where I need more gripping strength more torque for bigger cutters and I think part of the reason I don't use them as much my 40 taper machines is the tool length most million chucks stick out pretty far from the face of the spindle from gage line here and we know in general broad terms that the farther the animal is sticking out from the gauge line from the face the spindle here the more likely it is to chatter and we've talked more about that in our chatter video and we'll link to that in the description here's a final thought on milling chucks and it's how we tighten things up how we tighten up this milling Chuck actually affects the run-out of our tools it matters watch this a good tip to remember when using a million chuck is how tighten the tool can affect your tool run out if just doing heavy milling tighten up the nut until it stops if using the milling Chuck for finished milling precision drilling or another operation we're good run-out is critical then we'll want to one tighten the nut fully and then to back off the nut by just a little bit some holder manuals say to back off the nut by two or three degrees others by five or ten degrees now the reason they asked us to do this is because when fully tightened the tiny little roller bearings tend to climb on top of each other just a bit by backing off the nut just a little it relieves a strain between the roller bearings and keeps the tool nice and straight we've looked at holders that hold the tool in place with the use of tiny little jaws or nuts and mechanical rollers that climb up a steep taper even holders that make use of heat and thermal expansion but the holders on this table right now work in a completely different way they make use of this and no it's not Kentucky Bourbon it's actually hydraulic fluid the same kind of fluid that you would find in the braking system of your car these have just fantastic run out maybe a tenth of a thousandth of an inch less than three micron they've got great grip but they are high-end holders and their price reflects that if a salesman's got a tool for you to test let's say a drill they don't want you to run it in a holder that has lots of run-out so they might lend you a hydraulic holder to test the tool with because after it's punched ten thousand holes in unobtainium I'm gonna buy a box of his drill now good tool absolutely but remember we're testing the tool assembly and not just the tool now one of the benefits of using hydraulic fluid to compress a sleeve that holds a tool is we end up with a holder with really good vibration damping properties by tightening a single set screw against a plunger hydraulic fluid is forced through a channel into the sealed chamber around the tool the high pressure compresses the holder around the locking it in place now like our million Chuck's there are sleeves available that allow us to use different size tools with a hydraulic holder there are a couple of holders that have made it onto the scene recently that are worth mentioning one of them is the power grip by rego fix now rego fix has been around forever they invented the ER college system but that is completely different than what we have here this system uses a a steep sleeve that is pressed into this solid holder now to make this whole thing work you need a very special hydraulic press but we've got one now this is an incredibly easy process we just make sure that everything is clean and dry like always like every tool will drop in our sleeve then we'll drop in our tool we'll drop in the holder close the door and press in that is it we are ready to run this tool now this thing has incredible gripping strength it's got fantastic run out maybe a tenth of a foul or three micron and it's got a really nice form factor four or five axis machining and of course they make these with different extensions for longer reaches but it does require a hydraulic press and special tool holders this press is an automatic one while they do have some manual ones available the final holder on my table is actually a relatively new style of holder but it's made by a company that's been making holders for a very long time Albrecht now this style of holder is called an Albrecht APC but it's been licensed to a mugie as anna Moogie FPC and green as a green hpc and that's the model i've got here now this is a brand new holder and I'm not going to cut it in half for you even though you'd like me to but that's okay because they've done it for us in their catalogues nice cross-section view there for you and everybody likes a nice cross-section this holder requires nothing but an Allen wrench to use like our side lock holder but at the same time this is nothing like a Weldon the Allen drives a worm gear mechanism inside the unit and the use of this steep angled tapered sleeve give this small unit really high gripping forces precision-made components give us excellent or run out less than three microns or a tenth of a fowl on par with our hydraulic now these holders are pricey but like a lot of the other high-end holders mixing in a few of these with the rest of your holders might make sense if you've got higher grip strength you might be able to increase your feed rate decrease cycle time make some of that money back by having better run out your tools are going to last longer so you can make some of your money back that way as well so all this has to be kept in mind when choosing a holder at the beginning of the video we told you that we would show you the best to a holder and I'm telling you it's here on this table but after watching this video you realize that it really depends on your application what you intend to do with that tool now if I'm open up a garage shop putting a mill of my garage this week I tell you right off the bat I'm gonna be getting a couple of these high precision drill chucks awesome or even a key drill chuck if you got the jobs that can that can make use of that so I'm buying a couple of these I'm absolutely buying a bunch of these er collet holders these things are kind of like the SUVs of the tool holder world you got to buy those and you're gonna have some side lock holders you might have a a Weldon shank rougher that you need to use on some mild steel so you've got your drill chucks you've got your er Kaulitz you've got your side lock holders you're buying those for sure you're gonna start with these basic tools and then add these high-performance tool holders as needed you might fly this hydraulic tool holder that takes almost no tooling a simple allen wrench holds it in place and you'll run that it's going to work fantastic for you then you've got some of these albrecht chucks like the APC that you can walk into one holder at a time you're gonna cross a line at some point if you do a lot of 5-axis work you're gonna need better tool clearance right so if you're using that that tapered spherical ball nose end mill porting cylinder heads you're probably gonna buy yourself a shrink fit machine so you're gonna walk into a rego fix power grip system or a shrink fit holder system at some point if you're doing that kind of work but it all depends on how many parts you're running and your particular needs so there are way too many applications to discuss in a single video but that's what the comments section is for have you tried rough milling with a drilling truck how did that work out for you we'd love to read about that I really would in the comments section so tell us about it have you fallen in love with one of the holders on this table a certain brand or style that works really well for you tell us about it in the comment section have I said something totally off the mark and just really misspoken and said something ridiculous in this video well then keep it to yourself no okay go ahead and tell us about it in the comment section what kind of crowd source two correct answers in those cases but that is it for this video thanks for letting all of us here at hospice mall part of your success and for watching this hosta for the day [Music]

Channel: Haas Automation, Inc.

Views: 633,274

Rating: 4.9065819 out of 5

Keywords: CNC machine tools, CNC machining, Gene Haas, Haas Automation, Haas CNC, CNC, Haas, haascnc, machining, manufacturing, cnc machines, cnc mill, milling machine, cnc machine, cnc milling machine, machine tools, lathes, cnc machining, rotary table, cnc machinery, cnc machine tool, boring bar, cnc machining center, cnc cutting machine, mark terryberry tip of the day, tool holder essentials tip of the day, haas tip of the day, haas tod

Id: -xH06bgpcIY

Length: 34min 58sec (2098 seconds)

Published: Thu Dec 19 2019