UNIVERSITY OF MISKOLC

FACULTY OF MECHANICAL ENGINEERING DEPARTMENT OF MACHINE TOOLS

AND INFORMATICS

MASTER THESIS
Title:
Simulation of
Clamping device

Present By: directed by:

Azzeddine Saadi Dr Attila Szilgyi

June 2016
 ACKNOWLEDGEMENTS

I would like to extend thanks to the many people, who so generously contributed to the work
presented in this thesis.
Special mention goes to my enthusiastic supervisor, Dr Attila Szilagyi. My MSc has been an
amazing experience, not only for his tremendous academic support, but also for giving me so
many wonderful opportunities.
Similar, profound gratitude goes to Kiss Daniel, who has been a truly dedicated consultant. I am
particularly indebted to him for his constant faith in my lab work, and for his support. I have very
fond memories of my time there.
Finally, but by no means least, thanks go to mum, dad and all my family for almost unbelievable
support. They are the most important people in my world and I dedicate this thesis to them.
 ABSTRACT

This thesis represent the simulation of SMW autoblok 210 BB Chuck of CTX alpha 500 machine
by PTC program and analyzing the strength of gripping force during the holding of workpiece.

1) This thesis takes some generals and comparative approach to investigate the main kinds
of clamping devices and their Jaws, advantages and classification. Also it explains the
clamping principle in general.

2) This thesis also defines the Chuck of SMW autoblok 210 BB of CTX alpha machine with
the main dimensions, technical features and applications.

Since the disassembling of Chuck of CTX alpha machine that belongs to the workshop of
University is impossible, this thesis tries to simulate another hydraulic Chuck with the same
work principle and measure its gripping force during the motion by PTC program.
Contents
Chapter 1....................................................................................................................................................... 4
1. Introduction .............................................................................................................................................. 5
Chapter 2: Generals about clamping devices ............................................................................................... 5
2.1 History ................................................................................................................................................. 4
2.2 Self-centering ...................................................................................................................................... 6
2.3 The types of clamping ......................................................................................................................... 7
2.3.1 Three - jaw chuck ......................................................................................................................... 7
2.3.2 Four - jaw chuck ........................................................................................................................... 8
2.4 The types of jaws ................................................................................................................................ 9
2.5 General Clamping Principles ............................................................................................................. 10
2.6 The classification of chuck ................................................................................................................10
2.7 Advantages........................................................................................................................................10
Chapter 3: Chuck of SMW autoblok 210 BB of CTX machine ..................................................................... 11
3.1 CTX Machine (alpha 500) ..................................................................................................................11
3.2 Definition .........................................................................................................................................12
3.3 Technical features.............................................................................................................................13
3.4 Application/customers benefit ........................................................................................................13
3.5 Standard equipment .........................................................................................................................14
3.6 Technical data ................................................................................................................................... 15
3.7 Main dimensions and technical data ................................................................................................ 16
3.8 Actual gripping force diagram........................................................................................................... 19
Chapter 4: The hydraulic Chuck of the workshop.......................................................................................20
4.1 The hydraulic Chuck..........................................................................................................................20
4.2 Work principle of chuck ....................................................................................................................21
4.3 Drafting (2D modeling with the main dimensions)...........................................................................23
4.3.1 Chuck body................................................................................................................................. 23
4.3.2 Guide ring................................................................................................................................... 24
4.3.3 The Jaw....................................................................................................................................... 25
4.3.4 The Chuck Adapter..................................................................................................................... 26
4.3.5 The balanced actuator arm........................................................................................................27
4.3.6 The actuator ring........................................................................................................................ 28

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 4.4 3D Modeling......................................................................................................................................29
4.4.1 Definition ................................................................................................................................... 29
4.4.2 Benefits of PTC's 3D CAD Software............................................................................................29
4.4.3 3D Parametric Design Software ................................................................................................. 29
4.4.4 3D Direct Modeling Software..................................................................................................... 29
4.5 3D model of each part of the model................................................................................................. 30
4.5.1 Actuator ring ..............................................................................................................................30
4.5.2 The bolt ......................................................................................................................................30
4.5.3 The guide ring ............................................................................................................................31
4.5.4 Actuator pistons.........................................................................................................................31
4.5.5 3D Balanced actuator arms........................................................................................................32
4.5.6 Chuck adapter ............................................................................................................................33
4.5.7 The jaws .....................................................................................................................................33
4.5.8 The jaws Chuck body..................................................................................................................34
4.5.9 Guide Bushing ............................................................................................................................34
4.6 Assembling........................................................................................................................................35
4.7 Example of 3D modeling (the actuator arm) .................................................................................... 38
4.8 Example of assembling......................................................................................................................42
Chapter 5: Simulatuion ...............................................................................................................................45
5.1 Definition ..........................................................................................................................................45
5.2 PTC Creo: Simulation Capabilities .....................................................................................................45
5.3 The main steps of the real simulation on PTC ..................................................................................47
5.3.1 Simplifying the model (taking the third).................................................................................... 47
5.3.2 Create the Mesh.........................................................................................................................48
5.3.3 Applying a force .........................................................................................................................50
5.3.4 Setting up the constraints.......................................................................................................... 51
5.3.5 Create springs ............................................................................................................................51
5.3.6 Definition the interfaces ............................................................................................................ 52
5.3.7 Starting running the simulation (Static Analysis).......................................................................52
5.3.8 The results.................................................................................................................................. 53
5.3.9 Explanation ................................................................................................................................ 54
Chapter 6: Efficiency and maintenance ......................................................................................................57
6.1 What Affects Grip (Clamping) Force? ............................................................................................... 57

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 6.1.1 Speed (RPM) Of Chuck: ..............................................................................................................57
6.1.2 Jaw Height.................................................................................................................................. 57
6.1.3 Jaw Mass ....................................................................................................................................58
6.1.4 Chuck Condition .........................................................................................................................58
6.2 How to major the clamping force .....................................................................................................58
6.2.1 Gripping force tester GFT........................................................................................................... 59
6.2.2 Some real experiments in workshop of our department on CTX alpha machine......................61
6.3 GENERAL MAINTENANCE..................................................................................................................63
6.3.1 Grease gun ................................................................................................................................. 63
6.3.2 Electronic safety control unit.....................................................................................................65
6.3.3 Dress and cleaning plate RPS .....................................................................................................66
6.3.4 Boring rings ADS.........................................................................................................................67
CHAPTER 7: conclusion and references ..68

7.1 CONCLUSION..68
7.2 REFERNCES..69

3
Chapter 1
Introduction

A chuck is a specialized type of clamp used to hold an object, usually an object with radial
symmetry, especially a cylindrical object. It is most commonly used to hold a rotating tool (such
as the drill bit in a power tool) or a rotating workpiece (such as the bar or blank in the
headstock spindle of a lathe). Some chucks can also hold irregularly shaped objects (ones that
lack radial symmetry). In some applications, the tool or workpiece being held by the chuck
remains stationary while another tool or workpiece rotates (for example, a drill bit in the tailstock
spindle of a lathe, or a round workpiece being milled by a milling cutter [3]
Many chucks have jaws, which are dogs that are arranged in a radially symmetrical pattern (like
the points of a star) to hold the tool or workpiece. Often the jaws will be tightened or loosened
with the help of a chuck key, which is a wrench-like tool made for the purpose. Many jawed
chucks, however, are of the keyless variety, and their tightening and loosening is by hand force
alone. Keyless designs offer the convenience of quicker and easier chucking and unchucking, but
have lower gripping force to hold the tool or workpiece, which is potentially more of a problem
with cylindrical than, say, hexagonal shanks. Collet chucks, rather than having jaws,
have collets, which are flexible collars or sleeves that fit closely around the tool or workpiece
and grip it when squeezed. [3]

A few chuck designs are more complex yet, and they involve specially shaped jaws, higher
numbers of jaws, quick-release mechanisms, or other special features.
To chuck a tool or workpiece is to hold it with a chuck, in which case it has
been chucked. Lathe work whose work holding involves chucking individual slugs or blanks is
often called chucking work, in contrast to bar work (bar feed work), which is parted off from bar
stock. Automatic lathes that specialize in chucking work are often called chuckers. [1]

4
Chapter 2: Generals about clamping devices

1. History
The original forms of work holding on lathes were between-centers holding and ad
hoc fastenings to the headstock spindle. The spike-style centers still used on wood lathes
represent an ancient method. Ad hoc fastening methods in centuries past included anything from
pinning with clenching or wedging; nailing; lashing with cords of leather or fiber; dogging down
(again involving pinning/wedging/clenching); or other types. Faceplates have probably been
around at least since the era of medieval clock-makers.
Tooling similar to today's chucks seems likely to have evolved from faceplate work, as workers
using faceplates for repetitive work began to envision types of clamps or
Dogs for the faceplate that could be opened and closed in more convenient ways than repeated
total disassembly and reassembly.

Names known to figure in the history of chuck development include those of Simon
Fairman (17921857) and Austin F. Cushman (1830-1914) - the two may have been
uncle/nephew or father-in-law/son-in-law) - and Arthur Irving Jacobs. Apparently, Fairman
invented the first piece of tooling that we today would call a lathe chuck, and Cushman invented
the first self-centering lathe chuck. Cushman's name lived on via an eponymous company.
Judging from a historical sketch given by the Jacobs Chuck Manufacturing Company (a well-
known brand in the drill chuck field), Arthur I. (A.I.) Jacobs was apparently the person who
further developed Cushman's self-centering scroll-gear idea into the type of drill chuck known
today (for which his company would later become famous). A.I. Jacobs's patent of 1902 (U.S.
Patent 709,014) appears] to be the principal patent. The term "drill chuck" clearly did not
originate with him, but his new type of drill chuck evidently long ago displaced any earlier types
that lacked the angled jaw movement and outer sleeve now found on all common drill chucks.
[1]

5
2.2 Self-centering
A self-centering chuck, also known as a scroll chuck, uses dogs (usually called jaws),
interconnected via a scroll gear (scroll plate), to hold onto a tool or workpiece. Because they
most often have three jaws, the term three-jaw chuck without other qualification is understood by
machinists to mean a self-centering three-jaw chuck. The term universal chuck also refers to this
type. These chucks are best suited to grip circular or hexagonal cross-sections when very fast,
reasonably accurate (0.005 inch [0.125 mm] TIR) centering is desired [3]
Sometimes this type of chuck has 4 or 6 jaws instead of 3. More jaws grip the workpiece more
securely if it is truly cylindrical, and thin-walled work will deform less. Four jaws are also useful
for square bar work. [3]
There are also independent-jaw (non-self-centering) chucks with three jaws.
There are hybrid self-centering chucks that have adjustment screws that can be used to further
improve the concentricity after the workpiece has been gripped by the scroll jaws. This feature is
meant to combine the speed and ease of the scroll plate's self-centering with the run-
out eliminating controllability of an independent-jaw chuck. The most commonly used name for
this type is a brand name, Set-Tru. To avoid undue genericization of that brand name,
suggestions for a generic name have included "exact-adjust".[3]
Three-jaw chucks are often used on lathes and indexing heads
The four jaw chucks, available in varying sizes, are generally used for essentially more strongly
holding non-circular bars like square, rectangular, hexagonal and even more odd sectional jobs in
addition to cylindrical bars, both with and without premachining at the gripping portion. The
jaws are moved radially independently by rotating the corresponding screws which push the rack
provided on the back side of each jaw. [3]

6
2.3 The types of clamping
There are several types of holding devices used on the engine lathe.
2.3.1 Three - jaw chuck
Traditional 3-point clamping
Strong deformation by only 3 clamping points and high tension pressure.
As a consequence the component runs out of true (polygon forming).

Figure 2 : Traditional 3-point clamping [4] Figure 1 : Traditional 3 Jaws Chuck [5]

The most common is the three-jaw chuck (see figure). This chuck permits all three jaws to work
simultaneously, automatically centering round or hexagonal shaped pieces. Each jaw only fits
with the particular groove in the exact chuck it was made for, so the jaws are not interchangeable
between chucks. The advantages of this type of chuck are that it is very versatile, quick set-up,
large range of sizes, and uniform holding pressure on the workpiece. The disadvantage is that is
the least accurate of the holding devices in the Student Shop. The three-jaw chuck only has an
accuracy of between +0.005 to +0.010, depending upon its condition. [6]

7
2.3.2 Four - jaw chuck
The second type of chuck is the four-jaw chuck, (see figure). This is also called the independent
chuck because each of its jaws operates independent of the other three.
This permits odd shaped work to be held and centered about a feature. The advantages are that it
is versatile, provides a secure hold the workpiece, large range of sizes, and has extremely
accurate centering method. The four-jaw chuck is accurate to +0.0005.
The main disadvantage is the long process necessary to center the workpiece, requiring a high
level of in the use of a dial indicator. [6]

Figure3 : 4 jaws chuck [ 5 ]

8
2.4 The types of jaws
Soft jaw

This kind of Jaw is used for gripping the workpieces with soft material like Aluminum.

Figure 4: soft Jaw[8 ]

External hard jaw

This kind of Jaw is used for gripping the workpieces with hard material like from intern like
Steel.

Figure 5: External hard jaw [8]

Internal hard jaw

This kind of Jaw is used for gripping the workpieces with hard material like from extern like
Steel.

Figure 6: Internal hard jaw [8]

9
2.5 General Clamping Principles
Lamp should firmly hold the workpiece without distorting it.
Should overcome the maximum possible force exerted on workpiece by using
minimum clamping force
Easy to operate
Vibrations should tighten the cams and wedges in the clamp design (if any) and not
loosen them. [7 ]

2.6 The classification of chuck

We can classify the clamping tool according to:
number of jaws
material of body (cast iron or steel)
type of mounting
type of jaws
the diameter of chuck [9 ]

2.7 Advantages
High loading clearances
Reduced tooling set-up expense,
high productivity (high workpiece flexibility)
Short clamping lengths
High workpiece tolerances possible
Run-out accuracies up to 0,003 mm attainable
High lateral rigidity due to
flat-face contact of the workpiece
High torque transmission
Symmetrical expansion of clamping collet
Quick change-over to other clamping diameters possible
Manual actuation with chuck wrench
Circumferential clamping
Pull-back effect against the end-stop
Very good concentricity of 0.01 mm after clamping head change
Optimal holding power plus additional accumulator
Increased tool life and cutting speeds when using an end-stop
Gentle or powerful clamping whatever is needed [9 ]

10
Chapter 3: Chuck of SMW autoblok 210 BB of CTX machine
3.1 CTX Machine (alpha 500)
The latest CTX series of the 5th Generation provides additional performance in power,
torque and precision, along with a larger work area, more flexibility and improved ergonomics.
Especially unique in this class are the numerous high-tech components. In addition to the
extensive standard equipment, an optional Y-axis and counter spindle are available for increased
flexibility and complete machining.
The new universal Turning Machine of CTX series by GILDMEISTER, with up 25 percent
increased performance ranging from intelligent expansion options of driven tools to complex
Milling / Turning Centers with mill / turn spindles and tool magazines , this series stands out
among the competition . [19]

Figure 7 : CTX Machine [19]

11
3.2 Definition
The chuck SMW autoblok 210 BB (Big Bore) is a specialized type of clamp used to hold
an object, usually an object with radial symmetry, especially a cylindrical object. It is most
commonly used to hold a rotating tool (such as the drill bit in a power tool) or a rotating
workpiece (such as the bar or blank in the headstock spindle of a lathe). Some other chucks can
also hold irregularly shaped objects (ones that lack radial symmetry). In some applications, the
tool or workpiece being held by the chuck remains stationary while another tool or workpiece
rotates (for example, a drill bit in the tailstock spindle of a lathe, or a round workpiece being
milled by a milling cutter).

Hydraulic clamping devices are devices where the clamping movement is generated by the
hydraulic actuation of the cylinder. Numerous methods of clamping are available, for example,
jaw chucks, chucks with swivel clamps, sleeve expansion mandrels and other clamping methods.

Their main advantage is that they offer an automated process with high reliability. As a result,
hydraulic clamping equipment is usually employed for manufacturing parts on tooling machines,
machining centers and manufacturing lines. Hydraulic clamping systems also offer uniform
clamping forces at all clamping points which adds to their machining precision. [20]

Figure 5: BB 210 Chuck [ 10]

12
 3.3 Technical features
Steel design, all parts hardened and polished
Manual lubrication via lubricating nipples
Jaw stroke 25 mm at a size of 500 mm
Extra-large through-hole
Gripping force transmission via wedge hook
Case hardened body to assure greatest precision and long chuck life [20]

3.4 Application/customers benefit

End machining of long tubes
Rapid and clamping stroke for short clamping cycles
Full spindle bore can be used
For open center or partial open center clamping
High loading clearances
Reduced tooling set-up expense, high productivity (high workpiece flexibility)
Short clamping lengths
High workpiece tolerances possible
Run-out accuracies up to 0,003 mm attainable
High lateral rigidity due to flat-face contact of the workpiece
High torque transmission
Symmetrical expansion of clamping collet
Quick change-over to other clamping diameters possible
Circumferential clamping
Pull-back effect against the end-stop
Very good concentricity of 0.01 mm after clamping head change
Optimal holding power plus additional accumulator
Increased tool life and cutting speeds when using an end-stop
Gentle or powerful clamping whatever is needed

13
3.5 Standard equipment
3 jaw chuck
1 set T-nuts with bolts
1 set soft top jaws
Mounting bolts
Grease gun

Figure 6: BB 210 Chuck with all the equipments [ 21 ]

14
3.6 Technical data

we can see in the table below the most important data of Chuck SMW autoblok 210 BB with
details such as the weight , the maximum speed , the maximum gripping force , the diameter of
the hole , the moment of inertia, the axial piston stroke, the radial jaw stroke , the number of jaws
and the maximum draw pull

Figure 7: the technical data of SMW autoblok 210 BB jaw [9]

15
3.7 Main dimensions and technical data

Figure 8 : Main dimensions of BB 210 [9]

16
Here we have a lot og types with detailed dimensions of SMW autoblok BB 210 Chuck like BB-
D 210 and BB-M 210

Figure 9: Main dimensions [9]

Top jaw

17
 Figure 10: Top jaw [9]

T-nuts

Figure 11: T-nuts [9]

18
3.8 Actual gripping force diagram

Figure 12: gripping force diagram of BB 210 [9]

The data in the diagrams refer to 3-jaw-chucks, newly maintained according to their service
manuals using SMW-AUTOBLOK K67 grease. The static and dynamic gripping forces have
been measured using standard soft top jaws, placed in a position not exceeding the outer
diameter of the chuck.

19
Chapter 4: The hydraulic Chuck of the workshop
4.1 The hydraulic Chuck
Since the disassembling of the SMW autoblok Chuck of CTX machine in the workshop is
impossible regarding to the daily use, we decided to disassemble another hydraulic chuck with
same principle of work.
This chuck was made by Hungarian professor with steel material as we can see in the figures
below

Figure13 : the hydraulic chuck

Figure14: the hydraulic chuck

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4.2 Work principle of chuck
When we want to open or close the grip of chuck we should push or pull the hydraulic spindle.
When the hydraulic spindle move radially the actuator ring will move according to that also in or
out.
when the actuator ring get in or get out into the back plate , the bolt will move according to that
also , and after that the bolt will push or pull the actuator piston inside or outside as we can see
the red arrows in the figure below.

Figure 15:the movement of bolts and pistons

21
The motion of the piston makes the actuator arms move radially by getting out or inside every
piston is responsible to move one arm.
Since the actuator arms and the jaws have the same serration so they have the same kind and
direction of displacement (radially) during getting out or inside, every arm is responsible to
move one jaw
This movement makes the jaws able to hold or release the workpiece as we can see the red
arrows in the figure below.

Figure 16: the mouvement of arms

Figure 17: the mouvement of jaws

22
4.3 Drafting (2D modeling with the main dimensions)
These are the main steps for creating a drafting of any part of the model
Step 1: Prepare the drawing
Step 2: Create main views
Step 3: Use the Wizard to generate views
Step 4: Create a Detail view
Step 5: Create a Section view S
Step 6: Create Dimensions
Step 7: Create a Breakout view
Step 8: Finish the drawing
Step 9: Finishing [11]

4.3.1 Chuck body

Figure 18: the Chuck body

23
4.3.2 Guide ring
These are the main dimensions of guide ring which has the same internal diameter with the
chuck body and the actuator arm as we can from the upper view below and it is the part of chuck
which is responsible to hold the actuators arms and keep their motion.

Figure 19:guide ring

We can see that it has 160 mm of outer diameter, 122 mm of inner diameter and 30 mm of
height.

24
4.3.3 The Jaw
We can see in the figure below this is an internal hard jaw which is the real responsible of
holding or gripping the workpiece by the inside or outside face during or without the motion.

Figure 20: Chuck Jaw

This jaw has 85 mm of long and 22 mm of width 58 mm of height and lot of detailed dimensions
which are shown in the figure above.

25
4.3.4 The Chuck Adapter
The chuck adapter is an important part of chuck and is the responsible of keeping the transition
of force from the pistons to the arms, and link the chuck body with the other parts of chuck like
the actuator ring, the guide ring, the arms and the pistons.

Figure 21 : the adpter of chuck

We can see in the figure above the chuck adapter has 200 mm of out diameter, 114 mm of inner diameter,
and lot of other detailed dimensions.

26
4.3.5 The balanced actuator arm
The actuator arm is one the most important parts in the chuck which transmits the force or
vertical displacement of the piston to a radial displacement in the jaw directly, we have three
arms in this chuck and every one of them has a radial displacement.

Figure 22: the balanced actuator arm

27
4.3.6 The actuator ring
The actuator ring is the first part of chuck who receive the pulling or pushing force from the
hydraulic shaft and transmit it to the pistons then the arms and after to the jaws, it has three bolts
connected to the pistons, the main characteristic in this ring that has vertical displacement or
movement according to the hydraulic shaft.

Figure 23 : The actuator ring

We can see in the figure above the actuator ring has 114 mm of outer mm and 32 mm of inner
diameter and lot of detailed dimensions.

28
4.4 3D Modeling
4.4.1 Definition
In 3D computer graphics, 3D modeling (or modeling ) is the process of developing a
mathematical representation of any three-dimensional surface of an object (either inanimate or
living) via specialized software. The product is called a 3D model. It can be displayed as a two-
dimensional image through a process called 3D rendering or used in a computer simulation of
physical phenomena. The model can also be physically created using 3D printing devices. [12]
4.4.2 Benefits of PTC's 3D CAD Software
In today's engineering world, a variety of 3D design software exists to create digital prototypes,
but only PTC Creo 3D CAD software offers a unique blend of parametric and direct modeling
with product design apps that are truly interoperable. This seamless integration of technology
fosters greater productivity and innovation, helping to accommodate the diverse needs of product
development professionals across varied disciplines, levels of expertise, and degrees of
specialization.
4.4.3 3D Parametric Design Software
A 3D parametric design approach is a powerful mechanical CAD (MCAD) modeling approach
that uses parameters to define a design's features and relationships between features. Parametric
modeling provides an accurate and complete design definition; making it easy for you to capture
design intent and build models that change as the parameters of their features are changed.
4.4.4 3D Direct Modeling Software
Direct modeling software enables you to freely create and interact with 3D CAD geometry,
quickly seeing the results of engineering decisions. An intuitive and flexible editing environment
is well-suited for beginners: providing a solid introduction to 3D CAD modeling. [13]

29
4.5 3D model of each part of the model
4.5.1 Actuator ring
The actuator ring is the first part of chuck who receive the pulling or pushing force from the
hydraulic shaft and transmit it to the pistons then the arms and after to the jaws, it has three bolts
connected to the pistons, the main characteristic in this ring that has vertical displacement or
movement according to the hydraulic shaft.

Figure 24: Actuator ring

4.5.2 The bolt

Figure 25: the bolt

30
4.5.3 The guide ring
The guide ring is fixed part of chuck which is responsible to hold the actuators arms and keep
their radial motion or displacement to transmit the force directly to the jaws, as we can see in the
figure below.

Figure 26: The guide ring

4.5.4 Actuator pistons

The actuator piston is the part of chuck which is responsible of transmission the force or vertical
displacement of the actuator ring or the bolts to radial displacement of actuator arms, we have
three pistons in this model.

Figure 27: Actuator pistons

31
4.5.5 Balanced actuator arms
The actuator arm is one the most important parts in the chuck which transmits the force or
vertical displacement of the piston to a radial displacement in the jaw directly, we have three
arms in this chuck and every one of them has a radial displacement.

Figure 28: Balanced actuator arms

As we can see in the figure above every arm has two main holes to allow the displacement of the
pistons.

32
4.5.6 Chuck adapter
The chuck adapter is an important part of chuck and is the responsible of keeping the
transmission of force from the pistons to the arms, and link the chuck body with the other parts
of chuck like the actuator ring, the guide ring, the arms and the pistons.

Figure 29: Chuck adapter

4.5.7 The jaws

We can see in the figure below this is an internal hard jaw which is the real responsible of
holding or gripping the workpiece by the inside or outside face during or without the motion
according to the force or radial displacements of actuator arms.

Figure 30: the jaw

33
4.5.8 Chuck body
Chuck body is the bigest , heaviest and the most important part in the model wich is responsible
the save all the parts of chuck inside during or without motion like the actuator arms , the pistons
,and the jaws .
It has the same outer diameter of chuck adapter .

Figure 31: Chuck body

4.5.9 Guide Bushing

Guide bushing is a small part of the model which safe the upper part of piston during the pulling
or pushing.

Figure 32: the guide bushing

34
4.6 Assembling
PTC Creo Advanced Assembly Extension (AAX) helps users simplify complex designs and
allows for the development of advanced content with better control, design intent propagation,
and system integration. With its advanced tools for top-down assembly design, PTC Creo AAX
streamlines the flow of information from design to manufacturing, helping you reach the optimal
design, including customized designs, in far less time. [14]
At the beginning of the assembling we create the first part for assembling the whole model, we
put the actuator ring free without any kind of placements or constraints after that we add the
bolts and make the placements and the constraints as insert, as we can see in the figure below.

Figure 33:actuator ring assembled with the bolts

35
In the second part of assembling we put the guide ring free and after we assemble the arms and
make the placements and the constraints as mate with offset, after that we add the pistons and
make the placements and the constraints as insert with offset, as we can see in the figure below.

Figure 37:the guide ring assembled with arms and pistons

In the third part of assembling we put the chuck body free and after we assemble the jaws and
make the placements and the constraints as mate with offset, we have to make special placement
for every jaw, as we can see in the figure below.

Figure 34: chuck body assembled with jaws

36
The whole chuck
At the end of assembling we collect the previous three assembled parts together in one model
using all the possible kinds of placements and constraints such insert, mate and align between
the parts of model.
We can see the whole model assembled in the figure below.

Figure 35: the whole model assembled

37
4.7 Example of 3D modeling (the actuator arm)
Create a sketch
Create a sketch of actuator arm with exact dimensions and angels as we can see in the figure
below.

Figure 40: sketch 2D

Extrude
To make the model 3D we should extrude the sketch with thickness that we need as we can see
in the figure below.

Figure 41:the part after extruding

38
Make another sketch
To add or modify the model we should create another sketches with new dimensions as we can
see in the figure below.

Figure 36 : the part with new sketch

Extrude
We should extrude the sketch with thickness that we need as we can see in the figure below.

Figure 37: the part after extruding

39
Make hole
After that we have to make a hole in the bottom part of the arm with special diameter as we can
see in the figure below.

Figure 38: part with hole

Create new plane with 15

Make new sketch with 15 to create another hole as we can see in the figure below.

Figure 39: the model with new plane

40
Make sketch (circle)
After that we create a sketch of circle with special diameter 28 mm on the new plane as we can
see in the figure below.

Figure 46: the part with new sketch

Extrude it to get hole

We should extrude the previous sketch to make a hole throughout the upper part, at the end we
get the final part as we can see in the figure below.

Figure 40: the final part

41
4.8 Example of assembling
Create new file with assembling type

Figure 41: new file with assembling type

Choose the basic part

At the beginning of the assembling we create the first part for assembling the whole model, we
put the actuator ring free without any kind of placements or constraints after that we add the
bolts and make the placements and the constraints as insert, as we can see in the figure below.

Figure 42:the first part of assembling

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Choose the other part
We add the bolts and decide the exact place that we are going to assemble in, after we make the
placements and the constraints as insert.

Figure 50:actuator ring with bolt

Precise the placement

After adding the bolt we should choose the kind of constraint placement between the bolt and
the actuator ring as we can see in the figure below.

Figure 51: chosing the constraints

43
After doing all the previous steps during the assembling and making all the possible kinds of
constraints and placements. Here we get the new assembled part as we can see in the figure
below.

Figure 52: the final assembled part

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Chapter 5: Simulatuion
5.1 Definition
Simulation is the virtual, mathematical process by which a computer processes input data
intended to represent certain real world conditions. Ideally you describe the stresses and loads
under which your product will operate and then, based on simulation results, either fix design
flaws or forestall them.

But simulation isn't just a tool to perfect a design you've already settled on.
Simulation allows you to optimize your design, as opposed to iterating and then testing each of
the iterations you come up with. You can create feasibility and optimization studies to achieve
goals. For example, you may want to optimize part thickness to not exceed the maximum
allowable stress. If you can measure it, you can optimize it.

Basic simulation is well within the capabilities of any engineer. Imagine how much faster your
product will get to market if analysts can focus on five upper-level problems instead of 20
smaller ones.

5.2 PTC Creo: Simulation Capabilities

PTC Creo Simulate is a structural, thermal and vibration analysis solution with a comprehensive
set of finite elements analysis (FEA) capabilities that allow you to analyze and validate the
performance of your 3D virtual prototypes before you make the first part.

The PTC Creo product suite offers a range of interoperable simulation solutions, all with a
simplified user interface and an intuitive workflow. With a few clicks, simulation can fit easily
and conveniently into your design life without requiring data translation, eye-popping math, or
the sudden acquisition of mysterious skills. [15]

PTC Creo Simulate, integrated closely with PTC Creo Parametric, has comprehensive FEA (finite
element analysis) capabilities to handle thermal and structural analysis. Simply apply your constraints,
loads and forces, and the software gives you the results. Change inputs as you wish and continue
on the road to your best product.

For those with specialized requirements, simulation also saves money, time, rework, and
frustration.

45
PTC Creo Simulators capabilities include:

Structural analysis
Linear steady state thermal analysis
Material libraries
Meshing
Optimization
Post processing [15]

46
5.3 The main steps of the real simulation on PTC
5.3.1 Simplifying the model (taking the third)
Since the model volume is big and its mesh has a big number of elements that is
what will make the simulation take a long time, it was necessary to simplify the
model as much as possible by taking the third part of each piece of the model since
it is symmetry.

Figure 53: The simple model

47
After going to Mechanical Application we should:

5.3.2 Create the Mesh

Meshing: The process of breaking the geometric model into small pieces in order to create nodes
and elements is called meshing. In other words meshing is the process of converting the
geometric model to a FEA model.
Pro-mechanica is a very user friendly software, one of the reasons is because of its auto meshing
capability. AutoGEM in pro-mechanica controls the meshing. Lean how this works here. [16]

Figure 54 the model after creating the mesh

48
After choosing the convenient material for each part of the model (steel) and
clicking on the upper button in the figure below where the red arrow we get 4474
elements which is good number for running a simulation without long time.

Figure 43: creating the mesh

49
5.3.3 Applying a force
Setting up a force on the cylindrical surface of the Actuator ring which it represent the force of
Hydraulic shaft during the pulling or pushing.
After clicking the button where the red arrow we can precise the direction, the load, the
reference, and the properties as we can see in the figure below.

Figure 44: creating a force for the model

After clicking on ok we can see that force has already applied on the surface of the actuator ring

Figure 45 : the applied force

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5.3.4 Setting up the constraints

When you apply a force then you want to see the results of the applied force in the body in terms
of stress, displacements etc. The main aim of any FEA is to arrest displacement completely or
partially in a predetermined way.
By determining the translation degrees of freedom of every part of the model

Figure 46: the main constraints of the model parts

5.3.5 Create springs

Figure 47: the main springs of the model parts

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5.3.6 Definition the interfaces
Kind of connection between the model parts to see the transmission of force
between them.

Figure 60: the interfaces of the model

5.3.7 Starting running the simulation (Static Analysis)

Figure 61:the static analysis

52
5.3.8 The results
The gripping force without motion
After applying a force of 3KN we get gripping force of 11.17 KN
The change of gripping force during the motion

Table 1 : some values of gripping force according to the some values of speed

The
speed 0 500 1000 1500 2000 2500 3000 3500 4000 5000
(r.p.m)
The
gripping 11.17 11.13 11.02 10.83 10.54 10.21 9.78 9.28 8.7 7.31
force(KN)

Figure 62: curbe of the change of gripping force according to the change of speed

Observation: we can see that the gripping force is decreasing when the speed of rotation is
increasing

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5.3.9 Explanation
centrifugal force makes the gripping force decrease during the motion because the Jaws will get
out , but since the mass of the actuator arm is bigger than the Chuck's the decreasing will not
be big.

Figure 63: centrifugal force [17]

F2

F1

Figure 48: centrifugal forces of jaw and arm

F1: centrifugal forces of the arm

F2: centrifugal forces of the jaw

54
The Mathematical relation between the applied force Fa and the gripping force Fg

Fg

Fr

Fa
Figure 65 the main forces in the chuck

Fa: the applied force

Fr: the reaction force
Fg: the gripping force
When we push or pull the spindle by the force Fa, the transmitted force of the piston through the
actuator ring makes a reaction force on the actuator arm Fr, and the force of jaws makes reaction
force on the workpiece.
Since the model is static that means the reaction force from the workpiece equal to the gripping
force Fg, as we can see in the figure above.

55
The forces triangle
According to the forces in the previous model we can make the triangle of forces

Fr

15
15

15

Fa

Fr

Fa
15
Fr = Fa / sin15 Fg
Fg = Fr / cos15
By some replacements we get the equation:
Fg = Fa (cos15/sin15) = Fa / tag (15)

56
Chapter 6: Efficiency and maintenance
6.1 What Affects Grip (Clamping) Force?
6.1.1 Speed (RPM) Of Chuck:
As speed increases grip force decreases.

Figure 49: the change of gripping force according to the change of speed [18]

6.1.2 Jaw Height:

Figure 67: the effect of height[18]

57
6.1.3 Jaw Mass:
As the mass of the top jaw increases the grip force decreases.
6.1.4 Chuck Condition:
If the chuck has damage or excessive wear grip force can be impacted.
6.1.5 Lubrication (greasing):
Proper chuck lubrication can increase grip force up to 50%. [18]

Figure 68 the effect of lubrication[18]

58
6.2 How to major the clamping force
6.2.1 Gripping force tester GFT
Gripping force and speed measurement of jaw chucks and collet chucks in dynamic or static measuring
mode

Figure 69: Gripping force tester GFT [9]

Measuring heads
The main heads of Gripping force tester

Figure 70: Measuring heads [9]

59
Unique features
Wireless data transfer from measuring Head to reading unit (Radio433.92MHz,
upto4mdistance)
Measuring in safety only with closed doors
Capacitors are used instead of batteries
Driven Menu
Display kN or lbf
Languages: German, English, Italian, Spanish
Software CD for displaying a gripping Force curve on the PC
Measuring heads for jaw chucks and Collet chucks

Figure 71: Gripping force tester GFT [9]

60
6.2.2 Some real experiments in workshop of our department on CTX alpha machine

Majoring the

Figure 50: CTX alpha machine 500 Figure 51: majoring the gripping force
clamping force with variations of speed

61

Figure 52: Gripping force tester GFT

Table 2: some values of gripping force according to the some values of speed

Speed(rot/ 0 500 1000 1500 2000 2500 3000 3500 4000

min)
Force (KN) 44 44 43 42 40 37 34 29 24

By Excel

Figure 75: curbe of the change of gripping force according to the change of speed
6.3 GENERAL MAINTENANCE

62
 Before the chuck is mounted on the lathe, make sure that all the threads are thoroughly
clean and free of debris. This will ensure the chuck will run true.
The chuck is engineered to very close tolerances and may initially be stiff to operate.
With use movement will become easier.
To maintain easy jaw action, regularly spray oil onto the scroll and work lever through
full range of movement.
Inspect chuck regularly for buildup of dust in the scroll and jaws. Clean as required.
Disassemble chuck periodically to clean & inspect to increase chuck life
to maintain the chuck for a long period of time, it is necessary to lubricate the

Chuck on a regular basis. Inadequate lubrication causes malfunction at low Hydraulic pressure,
reduces gripping force, affects gripping accuracy and Causes wear and seizure. Consequently,
securely lubricate the chuck.

6.3.1
Figure 53: kind of grease [18]

Grease gun
K05
High adhesion
High resistance against coolant = long lubrication intervals
Low friction coefficient =high gripping force
Avoids tribocorrosion

K67
For sealed chucks with constant grease lubrication
Basic components: mineral oil sand lithium
Without solvents[9]

63
 Special grease for manual and power chucks

Greasing set
Id. No. 083726
Grease gun (DIN1283) for cartridges 14Oz. (DIN1284).
Also refillable from grease can 1000g

Figure 54: Greasing set [9]

Supply range:
Grease gun
1adapter flexible for high pressure grease fitting
1adapterforconegrease

6.3.2 Electronic safety control unit

Electro pneumatic control unit for Big Bore chucks
1/2 or 3/4 design for SP and Big Bore chucks
Actuation via foot pedal or push button (not included in the supply range)
Clamping control via air flow sensors
Quick chuck actuation via diaphragm valves with quick exhaust

64
 Airflow control with LED for ready and air flow. Adjustable air flow sensor sensitivity. [9]

Figure 55: Electronic safety control unit [9]

65
6.3.3 Dress and cleaning plate RPS
With 2 different fine serrations to clean and dress top jaws with fine serration inch/metric

Figure 79: Dress and cleaning plate RPS [9]

Dress and cleaning plate, hardened, precision ground serrations,

2 different serrations, on the upper and lower side of the plate. Just turn it!
Rapid cleaning of the top jaws serration. Swarf and dirt is accumulated in the diagonal
groove
Dressing of light damage on the serration by using the grinding compound

Dressing and cleaning of

serration

Figure 80: cleaning of serration [9]

66
6.3.4 Boring rings ADS
To bore jaws on the clamping chuck
The

Figure 81: Boring rings ADS [9]

advantages of the SMW-AUTOBLOK boring rings for jaws:

Complete set to bore all dia. From 20 to 150 mm.
Set consisting of 36 rings 20 -50 mm each stepped 2mm. From50-
150mmsteppedin5mm increments.
Clearly organized on base plate.
Rings from 105 mm and up have 3 tapped holes for Clamping bolts to machine jaws for
internal gripping.
Rigid design. Ringsare10mmthick, quenched for greater durability.
Mounting handle is used for the safe insertion of the smaller rings without danger of
injuries.

67
Conclusion
As a conclusion we can say that the Hydraulic Chuck is one of the best clamping devices, and
inspite of the high speed of rotation it does not lose a lot of its gripping force.

68
References

[1] http://en.academic.ru/dic.nsf/enwiki/800067#History

[3] https://en.wikipedia.org/wiki/Chuck_(engineering)

[4] http://www.ladner.fr/InoZet-Compensating-6-Jaw-add-on-bridge-system.html

[5] http://atondd-bg.com/assets/userfiles/file/Bison/01.pdf

[7] Nidhin, CLAMPING 2010

[6] Aliotsy Andrianarivo ,Microsoft Word - LATHE.doc, 2008 [8]

http://www.grupotdg.com/index.php/tdg_en/tdeg/productos/informaci_n_t_cnica1/tipos_de_garra
s/
[8]
http://www.grupotdg.com/index.php/tdg_en/tdeg/productos/informaci_n_t_cnica1/tipos_de_garras/

[9] http://www.precisetooling.com.sg/catalog/smw-autoblok/Katalog_9E.pdf
[10] http://www.smwautoblok.com/index.php/sliding-jaw-chucks/hydraulic-front-end-
chucks/hynd-s.html
[11] [http://www.catia.com.pl/tutorial/generative_drafting.pdf]

[12] [https://en.wikipedia.org/wiki/3D_modeling]

[13] [http://www.ptc.com/cad/3d-cad-software]

[14]
[https://www.ptc.com/~/media/Files/PDFs/CAD/Creo_Advanced_Assembly_Ext_DS.ashx?la=en
]
[15] http://www.ptc.com/cad/creo/simulate#sthash.eLqPXkAC.dpuf

[16] ( http://www.brighthubengineering.com/cad-autocad-reviews-tips/19614-pro-
mechanica-tutorial-part-2/#imgn_0 )

[17] http://keisan.casio.com/exec/system/1271292951

[18] http://kitagawa.com/wp-content/uploads/chucks-101_-web-blue.pdf

[19] http://en.dmgmori.com/)

[20] http://www.geiger-haag.com/hydraulicchucks.html

[21] http://www.smwautoblok.com/media//KNCSN_main.jpg

69