The use of electro permanent magnetic chucks for holding and machining has grown in prominence recently as a substitute for mechanical work holding equipment. Magnets shorten setup times and improve access to all sides of the workpiece in typical machine shops. When it comes to work holding in surface grinding operations, they are an invaluable tool. If you are interested to have a better insight of the electro magnetic permanent chuck, keep reading this blog till the end.
Surface Grinding Magnetic Chuck
The end user can operate faster feeds and speeds without chatter by using magnetic chucks. The machine must be adjusted to meet scenarios when a workpiece is held unevenly or is secured to the machining bed using mechanical clamps or vises. This usually necessitates several pauses and starts. We at Great Magtech Electric provide the best magnetic chuck to ensure smooth functioning.
How Does Electro Permanent Magnetic Chuck Works?
When performing machining operations, ferrous objects are held securely using an electro-permanent magnetic chuck. It combines the benefits of electromagnetic and permanent chucks. The two-step system works as follows: first, an electric pulse is used to activate the chuck, changing its magnetic state and enabling the material to be held firmly. It consequently maintains its magnetism even after the electricity is switched off. By doing this, the workpiece is guaranteed to stay in place without requiring an ongoing power source. It is a flexible and effective tool in industrial processes due to its reversible magnetic field and abilit y to run on continuous power.
This is a detailed procedure that explains the operation of an electro-permanent magnetic chuck:
1. Activation: Align the material's internal magnetic domains by passing an electric current through the chuck.
2. Clamping: The chuck firmly holds the ferrous material in place while the magnetic fields align, enabling accurate machining operations.
3. Deactivation: The power supply is switched off after the task is finished, but the chuck keeps its magnetic condition, guaranteeing that the material is held firmly in place.
4. Release: A quick pulse of current in the opposite direction demagnetizes the chuck, making it simple and safe to remove the workpiece when it's time to remove the material.
5. Repeat: The electro-permanent magnetic chuck, which offers a dependable and effective clamping solution for a variety of machining operations, is now prepared for the following cycle.
How Can an Electro Magnetic Magnetic Chuck Control Be Troubleshooted?
Make direct contact with the provider or manufacturer of your electro permanent magnetic chuck. Various magnetic technologies, such as permanent, electro-permanent, or electro-magnetic, are used in different types of mag chucks.
How is the Electro Permanent Magnetic Chuck Mounted On A Machine Table
There are numerous ways to install a chuck in the machine table but you can use these guidelines to insert the magnet chuck into the machine:
· Verify that the machine table is spotless and free of burrs and scratches.
· Make sure the chuck has not been damaged during transit by giving its base a thorough cleaning.
· In the work area, place the chuck on the machine table. Verify that everything is in between the table and the chuck's base and that it is securely seated.
· Using the clamps that are provided, secure the chuck in position on the ledges at both ends.
· Prior to beginning work, the chuck that is attached on a grinding machine needs to be ground.
· There is no need for extra grinding when a chuck is fitted on top of a larger magnetic chuck that has already been ground and is precisely flat.
To stop oxidation, lightly coat the EPMagnet chuck's surface with grease or oil while it's not in use.
What Elements Affect Electro Permanent Magnetic Chuck's Holding Force?
The chuck's magnetic flux determines the holding force. however, there are a few things to consider that can restrict or obstruct the flux's ability to reach the piece and lower the holding capacity:
1. The region of touch
The holding force and the piece's contact area with the chuck are intimately correlated. While small components with small contact surfaces cannot tolerate some forms of milling, large pieces with large contact surfaces provide adequate resistance to the cutting forces. The component needs to be positioned on the chuck so that it covers as many poles as feasible.
2. The thickness
For the magnetic flux to function, a minimum thickness of material (iron) is required. The gripping force will decrease if the parts are extremely thin and fall short of this minimum thickness since they won't be able to absorb the magnetic flux produced by the chuck.
3. Surface conditions in contact
The piece's and the chuck's contact surfaces need to be in ideal shape in order to produce strong magnetic holding. The holding capacity of pieces with a ground surface is higher than that of pieces that are partially flat or have a rough finish. It is crucial to keep the chuck's surface smooth and to grind it down as needed.
4. Material
A piece's substance is crucial for ensuring optimal magnetic holding. 100% of the best holding is presented by soft steels with low carbon content. Others, on the other hand, lose their ability to grip due to excessive concentrations of carbon alloys or other elements. Additionally, various heat treatments lessen the steels' ability to be held in magnetic chucks. Steels that are tougher to work with generally behave worse and tend to hold onto its magnetism after being taken out of the chuck. At times, extracting the component from the chuck may even provide a challenge.
Magnet Chucks for Workholding in CNC Vertical Machining Centers
The maximum magnetic force that a magnetic chuck may theoretically produce is 16 kg/cm2. Our magnetic workholding chuck can accommodate 5-side machining if additional magnetic blocks are added. Visit our website to find out more about our magnetic workholding device, or get in touch with us with any questions or concerns.
Using Electro Permanent Magnetic Chucks Safely
Even though electro permanent magnetic chucks provide a lot of advantages, there could be risks involved in using them. Here are a few such hazards along with advice on how to stay clear of them.
Unintentional Disactivation
The magnetic chuck may suddenly stop working, which could cause the workpiece to move accidentally. To prevent this:
1. Make use of fail-safe measures to avoid unintentional deactivation.
2. Put in place safety precautions such magnetic field monitoring devices, which may identify any decrease in magnetic force and cause an automated shutdown or alarm.
Workpiece Accordance
Risks can arise from employing workpieces with particular features or from improper material choices. Observe the following safety measures:
1. Determine whether the workpiece's material and the magnetic chuck are compatible. Magnetic clamping might not be appropriate for all materials.
2. To guarantee appropriate and secure clamping, take into account the workpiece's size, shape, and weight distribution. Workpieces with irregular shapes or imbalances can cause instability or slippage.
Control and Strength of the Magnetic Field
1. Strong magnetic fields are produced by electro permanent magnetic chucks, which need to be handled and controlled carefully. To reduce dangers, make sure the magnetic field strength is appropriate for the needs of the workpiece. An excessive magnetic force may make it difficult to remove the workpiece or even cause damage.
2. Give operators explicit instructions on how to activate and deactivate the magnetic field and familiarize them with the control mechanisms.
3. Install safety features to notify operators when the magnetic field is active, such as warning systems or magnetic field indicators.
Observer Security
Strong magnetic fields produced by electro permanent magnetic chucks can be dangerous for anyone using electrical gadgets or for those with specific medical conditions. Think about the following:
1. To avoid any negative consequences, operators with pacemakers, metallic implants, or sensitive electrical devices should stay away from the magnetic chuck when it's close to them.
2. Restrictions should be made obvious, and any possible hazards should be communicated with suitable signage.
Maintenance and Training for Operators
For electro permanent magnetic chucks to operate safely, adequate training and upkeep are necessary:
1. Teach operators how to use the magnetic chuck safely and how to activate, deactivate, and maintain it.
2. Make routine checks to spot any indications of wear, damage, or broken parts. Deal with any problems right away.
3. For maintenance procedures including cleaning, lubrication, and component replacement, according to the manufacturer's instructions.
Round Magnetic Chuck Types
There are three varieties of round chucks, similar to magnetic chucks of any shape:
permanent circular chucks, electropermanent circular chucks, and electromagnetic circular chucks.
1. You should weigh the advantages and disadvantages of each type before selecting a round chuck.
Permanent Round Magnetic Chucks
Energy is not necessary for them. Not at all. The most valued benefit is that permanent magnetic chucks don't require a plug and are easy to install and move to another machine. They also provide complete safety (and functionality) in the event of a power loss.
No electrical power
Permanent chucks are available in lower sizes and at a fair price. Their low magnetic force is a weakness. Although a permanent magnet with the same level of strength as an electromagnet could be created, no human could ever turn it on or off since stronger magnets require greater physical power. At Great Magtech we offer numerous chucks but these 2 types of chucks are the most Famous ones:
Super Chuck: For securing workpieces with the metal cutting. Ideal for rigid devices as its magnetic force is uncontrollable.
General Rectangular: Perfect for securing workpieces with strong molding. It is a suitable fit for machines that can be loaded with heavier equipment because of its strong body. A better switch lever enables the clamping force to be manually adjusted.
Types Of Electro Magnetic Permanent Chucks
Electropermanent magnetic chucks are stronger than normal magnetic chucks. Larger workpieces with diameters ranging from 400 mm to several meters are clamped using them. The operator can handle all clamping and machining processes on a single screen, which makes it ideal for complex machining activities that need to be connected to the CNC machine control unit.
Electricity is only required by electropermanent magnetic chucks to activate and deactivate their magnetic field at the start and finish of the clamping process. Unlike electromagnetic chucks, which must always be plugged in and cannot function without electricity, they require very little power and are completely safe even in the event of a power loss.
Since all of our chucks have a connector on the side, installing an electropermanent magnetic chuck doesn't require a certified electrician. After you turn on the chuck, you remove the electric cable that was attached to it. There's no need to draw a cord through the chuck to install it, and no cable gets in the way of the machining.
Nevertheless, one drawback of electropermanent chucks' independence from electricity is that their clamping force cannot be consistently adjusted. It can only be increased in significant increments, and increasing the clamping force requires an electrical connection to the chuck. You may even need to conduct a demagnetization cycle on the workpiece in order to completely deactivate the chuck before you can reduce the clamping force.
Positively, one major advantage is that an electropermanent chuck can function without the requirement for electricity. The chuck remains cold. That's essential for accurate machining because accuracy suffers at higher temperatures. The ideal option for your production facility is an electropermanent magnetic chuck if accuracy is crucial.
Our electropermanent magnetic chuck, is well-liked in manufacturing facilities where rigorous machining operations requiring a high degree of precision are carried out with a high clamping force.
It comes with a compensated magnetic circuit and without it as well.
• A combined magnetic core consisting of an aluminum-nickel-cobalt alloy and neodymium produces a compensated magnetic circuit. With its increased power, this magnet is appropriate for sophisticated machining tasks like power grinding and lathe turning. To remove your workpiece from this sort of circular magnetic chuck, you must demagnetize it because it has a stronger residual magnetism.
• An alloy of aluminum, nickel, and cobalt serves as the magnetic core of a non-compensated magnetic circuit. Because it is weaker, it works better for finishing and grinding lathe work. There isn't much magnetism left in it after machining, therefore there's no need to do a demagnetization cycle.
Electro permanent Magnetic Chucks
Electromagnets require constant electrical power. Their magnetic power, which is the strongest of all magnets, is their most valued advantage. You have the option to adjust the clamping force in both directions. The safest and most effective clamping method available for thin workpieces.However, the heating of an electromagnetic chuck poses a drawback when it comes to high-precision grinding, and its power consumption must be considered.The machining device's control unit can be linked to electromagnetic chucks. When it comes to installation, they require a little more work, you have to plug them in via a connector ring that is positioned in the center of the chuck.
Wrap Up
To ensure the safe and efficient operation of electro-permanent magnetic chucks, it is advised to speak with the manufacturer, follow their instructions, and take the necessary safety precautions, just like with any other apparatus or equipmentIf you are looking for an electro permanent magnetic chuck, make sure to get in touch with our experts and get your hands on the best electro permanent magnetic chuck. For additional guidance, reach out to us!