This document is an instruction manual for the SMW-AUTOBLOK Shaft Chuck Type W, a workholding device designed for turning machines. It is available in both compensating and self-centering jaw versions, allowing for versatile clamping applications.
Function Description
The Shaft Chuck Type W is designed for the complete machining of shafts in a single setup. Its primary function is to securely clamp workpieces, enabling operations such as machining clamping diameters, rough machining, and finish machining. The chuck features a retractable jaw carrier, which facilitates complete machining of shafts in one operation. The face driver, which can be power-operated, is a quick-change component with a taper for centering. The chuck and the power-operated face driver are actuated by a double piston cylinder.
For self-centering chucks, the jaws are retracted, and the component is clamped between centers and driven by the face driver. This operation can be eliminated if the clamping diameter is already machined when the center bore is manufactured. For rough machining, the part is driven with the high gripping force of the jaws, allowing for high chip removal. During finish machining, the chuck body is retracted, and the part is clamped between centers and driven by the face driver, enabling the complete outline to be machined with perfect concentricity.
Important Technical Specifications
The manual provides detailed technical data for various chuck sizes (W-215, W-260, W-325, W-460). Key specifications include:
- Chuck Outside Diameter: Ranging from 215 mm (W-215) to 460 mm (W-460).
- Chuck Height: Varies by size and mounting type (e.g., 176 mm for W-215 A6, 344 mm for W-460 A11).
- Max. Clamping Diameter: From 145 mm (W-215) to 335 mm (W-460).
- Axial Movement/Jaw Carrier: Ranges from 44 mm (W-215) to 65 mm (W-460).
- Piston Stroke for Jaw Clamping: From 15 mm (W-215) to 32.5 mm (W-460).
- Max. Speed: From 5000 r.p.m. (W-215) to 1800 r.p.m. (W-460).
- Max. Draw Pull: From 30 kN (W-215) to 100 kN (W-460).
- Max. Grip Force at Reference Distance h*: From 60 kN (W-215) to 200 kN (W-460).
- Moment of Inertia: From 0.236 kg-m² (W-215 A6) to 9.35 kg-m² (W-460 A11).
- Weight (without top jaws): From 40 kg (W-215 A6) to 364 kg (W-460 A11).
- Oil Volume for Horizontal Use: From 0.25 liters (W-215) to 1.50 liters (W-460).
- Oil Volume for Vertical Use: From 0.50 liters (W-215) to 3.00 liters (W-460).
- Center Offset (at compensating jaw chuck): Max. < 0.6 mm (W-215) to < 4 mm (W-460).
- Actuating Cylinder: Double piston cylinders (ZHVD-SZ) are specified with corresponding Id. Nos.
- Oil Specification: CGLP ISO VG 68 for permanent oil bath lubrication.
The chuck is completely sealed and permanently lubricated by an oil bath. The data for maximum actuating force F and maximum spindle speed n are engraved on the chuck body. Always use original SMW-AUTOBLOK top jaws, which are permanently marked with the max. allowed actuating force F and max. speed n.
Usage Features
The manual emphasizes several key usage features and safety precautions:
- Correct Use: Chucks are designed for clamping components on turning machines according to specifications. Any other use can be hazardous.
- Qualified Personnel: Installation, operation, and maintenance must be performed by qualified and regularly trained personnel.
- Spindle Operation: The machine spindle must only start if the hydraulic pressure in the cylinder is fully reached and the component is clamped within the permissible working range. The chuck can only be opened when the machine spindle is stopped.
- Actuating Cylinder: Actuation must be carried out by suitable cylinders. The actuating force of the cylinder must not exceed the max. permitted actuating force of the chuck.
- Face Driver Mounting: The face driver is mounted using a mounting wrench. For Morse taper versions, reachable runout on the center point should be 0.02mm TIR. For short taper versions, runout on the center point should be < 0.005 mm (for adjustable versions).
- Top Jaw Mounting: Top jaws must be mounted with socket head cap screws of class 12.9 and tightened with specified torque. Ensure sufficient thread engagement (min. 1.25 x thread dia.).
- Balancing: For high demands of accuracy and surface quality, the chuck must be fine-balanced after installation, only with the jaw carrier retracted. The chuck has 9 balancing weight chambers equally spaced around the jaw carrier, filled with washers. Imbalance is eliminated by removing washers.
- Pre-Production Checklist: Before starting production, operators must check top jaw mounting bolts, clamping diameter, residual jaw stroke, hydraulic pressure, grip force, max. speed, face driver concentricity, locking nut tightness, and imbalance.
Maintenance Features
Regular and documented maintenance is crucial for the safe function, long lifetime, precision, and grip force of the chuck, and to ensure warranty validity.
- Maintenance Plan: A maintenance plan outlines daily, weekly, monthly, and yearly checks.
- Daily: Visible leakage.
- Weekly: Oil level check/refill oil, cleaning outside.
- Monthly: Measuring of grip force, check jaw carrier and master jaws for smooth movement.
- Yearly: Revision including disassembling, changing all seals and wear parts, checking for cracks, and refilling with fresh oil.
- Oil Level Check and Refill:
- Horizontal Machines: Bring the oil refill plug to the 12:00 o'clock position (jaw No. 3 in 9:00 o'clock position). Open the oil refill and oil level control plug. Refill with CGLP ISO VG 68 until it flows out from the oil control plug port.
- Vertical Machines (inverted spindle): Open one stop bolt, refill with CGLP ISO VG 68 until oil flows out from the refilling plug port, then close the stop bolt.
- Vertical Machines (upright, special version): Remove one spring pack in "chuck open" position, close the chuck, fill with oil until it flows out from the oil control plug, then open the chuck and reinstall the spring pack.
- Oil Consumption: If refill volume exceeds max values (e.g., 100 ml for W-215 horizontal, 200 ml for W-260 horizontal), the chuck must be inspected, and seals changed.
- Disassembly and Assembly: Detailed instructions are provided for disassembling and assembling master jaws, plugs, the stop ring, chuck body, and jaw carrier.
- Seal Replacement: It is recommended to use a new seal kit every time the chuck is assembled. All parts should be cleaned and oiled before assembly.
- Damage Prevention: Never apply force during disassembly/assembly. Do not damage seals. Do not use gasoline or diesel for cleaning. Dispose of cleaning liquid properly. Replace damaged or worn parts with original SMW-Autoblok spare parts only.
- Grip Force Measurement: Check the grip force regularly with an SMW-AUTOBLOK GFT-X grip meter.
- Environmental Protection: Handle environmentally hazardous materials (lubricants, oil, grease) correctly and dispose of them through suitable waste management companies.
- Warranty: A 12-month warranty is provided, with an optional 24-month extension for an additional fee, subject to specific conditions including documented maintenance.
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