Multi-part clamping revolutionises CNC machining efficiency

Sinco multi-part workholding enhances CNC machining efficiency

With hundreds of zero-points across the table or pallet of a vertical or horizontal machining centre, Sinco MultiZero workholding offers ultimate modularity and exceptionally high precision for securing multiple components for milling and drilling. The Slovenian-made systems are sold into the UK and Irish markets under an exclusive agency agreement with 1st Machine Tool Accessories, Salisbury, which describes here how manufacturers wishing to maximise productivity and accuracy can harness the advantages of the workholding equipment.

Central to Sinco's approach to increasing CNC machining efficiency and profitability are the novel, virtually limitless workpiece clamping arrangements made possible by its MultiZero base plate. It features across its entire surface an array of precisely spaced, conical, zero-point locations at 50 or 100mm centres. The high-density grid maximises usage of machine capacity by simplifying multi-part clamping over the entire table, utilising matching centring elements on the underside of other MultiZero modules that fit accurately into the conical holes.

Pictured right: multiple workpieces clamped with modular vices on the MultiZero base plate

These additional elements include pallets that attach to the base plate and can hold workpieces directly. Five different types are available for manual or automatic clamping of parts on a machining centre, while a die-sink or wire-cut EDM platform, measuring machine or assembly station may be similarly equipped. Pallets can be supplied fitted with an RFID chip to allow integration into an Industry 4.0 factory environment, enabling automation, digitalisation, automatic data capture and scheduling of production.

Other accessories such as modular vices, stoppers and risers can be mounted on top of the pallets in countless ways to suit different workpiece sizes and shapes. The absence of unnecessary jaws exposes the maximum surface of the part, reducing the number of set-ups and operations needed for completing the machining or inspection. Sinco claims a repeatability of five microns each time a new clamping elements is added to one of their workholding set-ups, allowing very high precision metalcutting.

Each mechanical element is secured with an M12 screw having 65kN of holding power, while pneumatic modules are rated at 55kN. Pallets are held to the base plate with a force of 260kN, making the whole configuration very rigid.

Unprecedented levels of productivity
In today’s highly competitive manufacturing environment, where every second of machine uptime directly impacts the bottom line, the ability to maximise utilisation and reduce costly idle time is paramount. The Sinco MultiZero system meets these challenges by offering a robust, flexible and extremely accurate workholding solution that empowers machine shops to achieve unprecedented levels of productivity by clamping multiple parts at the same time.

In this way, a machine can continue cutting for significantly longer without manual intervention. It not only extends unattended production time but also frees up skilled operators to manage several machines concurrently, or to focus on higher-value tasks such as programming, quality control or strategic planning.

Pictured left: aluminium workpieces (left) held in modular vices on a MultiZero base plate, with additional copper workpieces (right) prepared for electrode production on MultiZero EDM pallets

The traditional bottlenecks associated with frequent workpiece changeovers, tool exchanges and machine set-up adjustments are dramatically reduced, leading to a substantial increase in factory throughput and a reduction in the overall cost per part produced. These improvements are magnified if the extended spindle engagement time allows a machine shop to move towards more lights-out manufacturing.

Beyond set-up efficiencies, the Sinco MultiZero system contributes to a reduced number of tool changes, leading to increased productivity. If a batch of identical workpieces is involved, instead of changing tools multiple times for each individual part, a single cutter can perform the same operation across all clamped components before it needs to be returned to the magazine, leading to a more streamlined and faster machining cycle.

While the benefits of multi-part clamping are clear, implementing such a strategy can present difficulties, particularly concerning complex programming, accommodating variations in workpiece sizes and the need for adaptable fixturing. Sinco MultiZero directly addresses these challenges through its innovative design and the provision of a virtual model for each workholding element. The 3-D data can be integrated into the programmer’s CAD/CAM system to allow the pre-planning of clamping strategies, improving the effectiveness of the cutting cycle that is generated and preventing potential problems later in the process.