E Vacuum. clampingtechnology

Transcription

1 E Vacuum clampingtechnology

2 2 WITTE GERÄTEBAU VACUUM-CLAMPING SYSTEMS Witte Gerätebau Horst Witte Gerätebau, founded 1969, manufactures not only their own range of products but also ultra precision products for aerospace, medical technology etc. Among a broad range the emphasis lies on the development and manufacture of advanced workpiece clamping systems for universal application. Witte has taken up the lead in the branches of flexible fixturing and vacuum technology as a result of many patented solutions. The range is complemented with contour milling attachments. Horst Witte Gerätebau D Barskamp Horndorfer Weg Tel.: +49 (0) / Fax.:+49 (0) / witte-28@horst-witte.de witte-33@horst-witte.de Internet: The high quality of all Witte products is verified according to DIN 9003: Qualified staff and a modern machine shop are further guarantees for quality. A wide network of agents ensures support in all important industrial nations.

3 VACUUM CLAMPING SYSTEMS CONTENTS 3 Vacuum supply from page 8 Pumps, Units, Compressors Accessories WITTE VAC-MAT TM from page 23 Application, Starter Sets, Accessories Vacuum-chucks from page 32 Grid, Sintermetal, Vacudisc-ceramic, Metapor, Slot, Rubber adapter mat, Covering foil, Perforated-grid, Ice Vice FLIP-POD TM from page 59 Application, Sets, Accessories Circular chucks from page 70 Grid, Sintermetal Liquid separators from page 74 Conventional, Automatic Accessories from page 76 Seal, Grease, Pressure switch, Safety appliances, Manifold distributors Rotary joints, Valves, Gauges Connections, Plugs, Nozzles, Hoses METAPOR from page 92

4 4 VACUUM CLAMPING SYSTEMS Vacuum clamping fixture for external and internal grinding of cylindrical quartz glass workpieces Vacuum Clamping Systems Vacuum clamping systems give you a technological advantage. Use your time more profitably! Possibilities: - reducing clamping times - carrying out various machining operations (i.e. milling, grinding, turning, engraving, sparking, checking and measuring, coating, drilling, reaming and chamfering under certain conditions) - using a universal clamping system for different workpieces - clamping non-magnetic materials - machining aluminium, non-ferrous metals, graphite, plastics, glass, wood, ceramic, titanium, and steel - machining without oscillation or vibration VAC-MAT TM modular chuck in use: 5-side machining in one clamping procedure, machining through the workpiece without having to use a special fixture - only one clamping procedure for 5 side machining - clamping extremely thin workpieces and foils - milling through workpieces We offer proven clamping solutions to fulfill these requirements

5 VACUUM CLAMPING SYSTEMS 5 Setting up a vacuum system Vacuum supply: A modular vacuum unit with integrated liquid separator, storage tank and pressure control. Other pumps/units are available. Vacuum distributor, connection unit or safety appliance: Distribution of operating vacuum to the chucks. Gauges, choice of manual or magnetic valves and pressure controls for watching over operating vacuum level. All these variations are available. Vacuum chucks: Chucks to accomodate your requirements and clamping operations. Photo shows VAC-MAT TM chucks for 5 side machining

6 6 VACUUM CLAMPING SYSTEMS Clamping with vacuum Workpiece shape Slot chuck with perforated rubber adapter mat Grid chuck Witte VAC-MAT TM

7 VACUUM CLAMPING SYSTEMS 7 Clamping with vacuum Workpieces with small surfaces Slot chuck with perforated rubber adapter mat Circular grid chuck Witte VAC-MAT TM Chuck specially designed for workpieces Chuck with insert made out of sintered metal, Witte Metapor or made of a ceramic material for foils and skins

8 8 VACUUM-UNITS VACUUM CLAMPING SYSTEMS Choosing a vacuum unit or pump Depending on your operation Witte offers different vacuum supply systems: Handheld pumps / Pumps Pages 8 and 9 Vacuum units Pages 10 and 11 Modular vacuum unit Pages 12 and13 Standard solution, almost all of which can be used together with our liquid separators if fluids are used during machining. In addition to the pumps mentioned above the vacuum units also have an additional vacuum tank as well as various safety devices. In addition to the pump and tank the modular vacuum units also have an integrated liquid separator and various safety devices. Choose your vacuum supply according to the clamping area: Area Suction Type No. Motor max. lxwxh Kg capacity V/kW mbar mm <100cm 2 3m 3 /h Vacuum pump /0, x152x120 6,3 <1200cm 2 6m 3 /h Vacuum pump /0, x152x120 7,9 6m 3 /h Vacuum pump /0, x135x m 3 /h Vacuum unit /0, x315x m 3 /h Vacuum unit /0, x315x m 3 /h Modular unit /0,37 50 ø500x m 3 /h Modular unit /0,37 50 ø500x <5000cm 2 16m 3 /h Vacuum pump /0, x226x m 3 /h Modular unit /0,55 20 ø500x <1m 2 21m 3 /h Vacuum pump /0, x230x m 3 /h Vacuum unit /0, x315x m 3 /h Modular unit /0,75 20 ø500x <2m 2 63m 3 /h Vacuum pump /1, x406x m 3 /h Modular unit, mobile /1, x600x <3m 2 100m 3 Vacuum pump /3, x406x <4,5m 2 160m 3 Vacuum pump /5, x478x m 3 Vacuum unit, mobile /5, x800x m 3 Vacuum pump /5, x523x m 3 Vacuum unit, mobile /5, x800x Witte VAC-MAT TM No. of Mats Required suction capacity 1 3-6m 3 /h m 3 /h m 3 /h m 3 /h FLIP-POD TM Each m 2 of FLIP-POD TM surface requires m 3 /h vacuum suction Vacuum pump Nos and are dry running. All other pumps and units are oil lubricated. All pumps and units are also available in 110V/60Hz.

9 VACUUM CLAMPING SYSTEMS VACUUM-UNITS 9 Choosing a vacuum unit or pump Choosing vacuum supply according to working conditions: Dry machining Working with fluids Handheld pump small clamping area, small loss of vacuum low machining forces + Handheld pump with liquid separator Vacuum unit larger clamping area, higher loss of vacuum, higher machining forces + Vacuum unit with liquid separator Modular vacuum unit large clamping area high loss of vacuum high machining forces Modular vacuum units and workstations are suitable for dry and lubricated machining Vacuum workstation very large clamping area very high vacuum loss very high machining forces + Mobile modular vacuum unit Vacuum unit, mobile, with automatic liquid separator

10 10 VACUUM PUMPS VACUUM CLAMPING SYSTEMS Vacuum pumps Oil lubricated vacuum pumps offer the following advantages: air-cooled, therefore do not require coolant highly reliable low operating costs good resistance to condensation integrated oil mist separator, oil filter, check valve on suction side with sieve Vacuum pump 6m 3 /h Supply includes: 3m wire spiral hose 3/2 way aerated handvalve and vacuummeter Vacuum pump 16 m 3 /h Vacuum pump 21 m 3 /h

11 VACUUM CLAMPING SYSTEMS VACUUM PUMPS 11 Vacuum pumps, 230/400 V working voltage No. Suction- Motor Lubricant max. db(a) lxwxh Kg capacity V/kW mbar mm m 3 /h 230/0,12 dry x152x120 6, m 3 /h 230/0,25 dry x152x120 7, m 3 /h 230/0,37 oil x135x m 3 /h 230/0,55 oil x226x m 3 /h 400/0,55 oil x226x m 3 /h 230/0,75 oil x230x m 3 /h 400/0,75 oil x230x m 3 /h 400/1,5 oil x406x m 3 /h 400/3 oil x406x m 3 /h 400/5,5 oil x478x m 3 /h 400/5,5 oil x523x Vacuum pump 63 m 3 /h

12 12 VACUUM UNITS VACUUM CLAMPING SYSTEMS Vacuum units The operating vacuum required can be produced in many ways. Witte vacuum units feature the following: oil lubricated vacuum pumps with an end vacuum rate of 20mbar absolute at full suction capability of i.e. 3m 3 upto 250m 3 per hour integrated pressure difference switch, which automatically switches the vacuum pump on or off thereby ensuring vacuum during machining but avoiding unnecessary idle running protection switch which protects electric motor from overheating air filter which protects pump from dirt (made of acrylic glass with exchangeable air filter cartridge) careful assembly of compatible components guarantee trouble-free and almost maintenance-free operation using Witte vacuum units in many applications drainage screw for coolants which have been sucked in 3m connecting cable with CEE or Schuko plug The standard components of these tried and tested vacuum units are: a. vacuum storage tank b. oil lubricated vacuum pump c. vacuum valve unit d. air filter e. vacuum hose connector f. pressure difference switch g. on/off switch h. electric cable with plug i. overload protection Supply includes: 1 Pce connection unit complete with vacuum gauge, 3/2 way hand valve, 3m vacuum hose with quick coupling d a b c e f g h i i Vacuum unit 21m 3 /h

13 VACUUM CLAMPING SYSTEMS VACUUM UNITS 13 Vacuum units 230/400 V working voltage Mobile vacuum unit No. Type Suction Motor max. db(a) lxwxh Kg capacity V/kW mbar mm Vacuum unit 6m 3 /h 230/0, x315x Vacuum unit 6m 3 /h 400/0, x315x Vacuum unit 16m 3 /h 230/0, x315x Vacuum unit 16m 3 /h 400/0, x315x Vacuum unit 21m 3 /h 230/0, x315x Vacuum unit 21m 3 /h 400/0, x315x Vacuum unit 63m 3 /h 400/1, x500x Vacuum unit, mobile 100m 3 /h 400/ x800x Vacuum unit, mobile 160m 3 /h 400/5, x800x Vacuum unit, mobile 250m 3 /h 400/5, x800x All pumps and units are also available in 110V/60Hz.

14 14 VACUUM UNITS VACUUM CLAMPING SYSTEMS Modular vacuum units Advantages: vacuum storage unit and liquid separator are integrated - an additional liquid separator is not required space saving assembly of all components see-through unit for liquid separator and vacuum storage unit all in one means safety at a glance different storage volumes possible simply by changing acrylic glass cylinder integrated air filter, drain separator, overvoltage relay, pressure difference switch available with different pump types from 6m 3 to 63m 3, on request also available with dry running pumps l. u. s. r. n. m. p. f, g h. i. k. t. a. e. d. c. b. a. storage accumulator cover b. storage accumulator bottom c. acrylic glass cylinder d. threaded stud e. mist collector f. profile seal g. drainage plug h. e-motor i. pressure difference switch k circuit relay l. airfilter m. oil filling plug n. vacuum pump p. exhaust air valve r. oil level gauge s Schuko/CEE-Plug with overvoltage relay t. on/off switch u. wire spiral hose

15 VACUUM CLAMPING SYSTEMS VACUUM UNITS Modular unit 63m 3 /h, (mobile)

16 16 VACUUM UNITS VACUUM CLAMPING SYSTEMS Modular vacuum units, 230/400 V working voltage No. Type Suction Motor max. db(a) lxwxh Kg capacity m 3 /h V/kW mbar mm Modular vac. unit 6 230/0, ø500x Modular vac. unit 6 400/0, ø500x Modular vac. unit /0, ø500x Modular vac. unit /0, ø500x Modular vac. unit /0, ø500x Modular vac. unit /0, ø500x Modular vac. unit, /1, x600x mobile Modular vac. unit, / x700x mobile All pumps oil lubricated. Dry running pumps for modular units are available on request All pumps and units are also available in 110V/60Hz. Supply includes: 1 Pce. connection unit with 2m vacuum hose, 3/2 way ventilated hand valve, vacuum gauge

17 VACUUM CLAMPING SYSTEMS VACUUM UNITS 17 Vacuum fixture on a lathe for clamping alu wheel rims Special chuck for helmets Circular grid chucks

18 18 COMPRESSORS VACUUM CLAMPING SYSTEMS WITTE radial compressor Radial compressors can be used when mechanical forces involved during machining are low, or when a high loss of vacuum occurs i.e. clamping porous materials large vacuum chucks (i.e. perforated grid plates) the surface of which cannot be covered completely by the workpiece Advantages of Witte radial compressors : maintenance free due to permanently lubricated bearings, surface cooled motor, and contact free turbine wheel environmental-friendly due to oil-free seals low running costs high through-flow of vacuum Radial compressor

19 VACUUM CLAMPING SYSTEMS COMPRESSORS 19 WITTE radial compressor No. Name Thru-flow- Motor max. db(a) Connector lxwxh Kg volume mbar thread mm SE 0040 C 40m 3 /h 0,10kW R1 1/4 176x196x204 5, SE 0070 C 80m 3 /h 0,37kW R1 1/4 205x238x255 9, SE 0120 C 140m 3 /h 0,75kW R1 1/2 263x287x SE 0170 C 220m 3 /h 1,10kW R1 1/2 294x327x SE 0170 C 220m 3 /h 1,50kW R1 1/2 294x327x SE 0300 C 340m 3 /h 2,20kW R2 319x375x SE 0300 C 340m 3 /h 3,00kW R2 319x375x384 28, SE 0420 C 510m 3 /h 4,00kW R2 1/2 486x493x SE 0420 C 510m 3 /h 5,00kW R2 1/2 486x493x Also available for different voltages Supply includes: 3m electro cable, on/off switch with integrated overvoltage protection relay Sound absorber for radial compressor No. Description Sound absorber SE 0040 C Sound absorberr SE 0070 C Sound absorber SE 0120 C Sound absorber SE 0170 C Sound absorber SE 0300 C Sound absorber SE 0420 C Radial compressor

20 20 ACCESSORIES VACUUM CLAMPING SYSTEMS Maintenance and service kits Maintenance and service kits for regular care of vacuum units and pumps No. For pump/unit with lxwxh kg suction capacity m 3, oil lubricated 100x200x210 1, m 3, oil lubricated 200x200x260 1, m 3, oil lubricated 200x200x260 1, m 3, oil lubricated 220x280x380 6, m 3, oil lubricated m 3, oil lubricated Our maintenance and service kits guarantee trouble-free operation of Witte vacuum pumps and units Comprising of: No. Oil Air filter Oil Seal O-Ring Oil level Oil filter separator gauge x x x0,2l 2x x x x x0,6l 2x x x x x x0,75l 2x x x x x x x0,4l 2x x x X X x5l 1x x x X X x10l 1x x x

21 VACUUM CLAMPING SYSTEMS ACCESSORIES 21 Valve units No. Type For hose inner dia T-shape 6mm T-shape 12mm straight 12mm straight 18mm straight 24mm straight 32mm straight 50mm Supply includes: 1 Pce 3/2 way aerated hand valve, 3m vacuum suction hose with wire spiral, 1 Pce vacuummeter, 2 Pcs vacuum hose connectors Additional vacuum tank for increasing vacuum storage volume of units acts as additional filter and separator for dirt or fluid reduces actual running time of vacuum pump The tank is equipped with two viewing glasses. Dirt and fluid can be seen and drained immediately. No. lxwxh Connection Volume/ l kg x315x325 Inner thread R 3/ x500x530 Inner thread R 3/

22 22 WORKSTATIONS VACUUM CLAMPING SYSTEMS WITTE vacuum workstation Vacuum workstation for mobile use in the workshop, with integrated vacuum pump, liquid separator, 3-fold vacuum distributor, connectors and gauges vacuum storage tank, pressure difference switch and safety appliance guarantee a triple safety factor solid steel design on castors also has drawers for vacuum chucks and accessories No. Type Suction capacity Motor max. db(a) lxwxh Kg m 3 /h V/kW mbar mm Vac. workstation, /0, x650x mobile Vac. workstation, /1, x650x mobile Also available as 110V/60 Hz unit Both vacuum workstations have oil lubricated vacuum pumps Supply includes: 1 maintenance and service kit, 5 l liquid seperator, 10m wire spiral hose, 1 safety appliance, 5m electro cable with CEE-plug 10A

23 VACUUM CLAMPING SYSTEMS WITTE VAC MAT TM 23 Witte VAC-MAT TM The vacuum system you can cut right into! All vacuum chucks have a common factor. In order to maintain their clamping function, air leaks must be avoided at all cost. With VAC-MAT TM it s different. VAC-MAT TM s properties allow the operator to cut or drill right through the mat and machine contours, without losing vacuum. To clamp simply place the mat on the special VAC-MAT TM chuck and press the workpiece onto the mat. No seals are required, no covering over with foil, no suction bores to block off, all these procedures are not applicable when using VAC-MAT TM. VAC-MAT TM allows cutting or drilling right through as well as contour milling of workpieces through to their base. Certain workpiece sizes can even be machined on 5-sides in one clamping procedure, thereby considerably reducing idle times compared to conventional clamping methods. Height adjustable stops available as an optional extra

24 24 WITTE VAC MAT TM VACUUM CLAMPING SYSTEMS VAC-MAT TM Application What is VAC-MAT TM? It is a thin soft polymer mat with many spaced out vacuum points, suckers in different sizes with a fine hole in each centre and a raised lip. On the underside there are six lugs which locate in the special VAC-MAT TM chuck. Further there are grid shaped grooves which distribute the vacuum to each of the small holes. A lip right around the outside edge ensures no leakage. What size is VAC-MAT TM? All VAC-MATs are 2,5 x200 x 300mm. The tolerance lies at +/-0,02mm. To increase the size of the working area, the modular VAC-MAT TM chucks are connected to one another and VAC-MAT TM s are simply placed on as described. The lugs underneath the mat guarantee fast and accurate positioning of the VAC-MAT TM on the special modular vacuum chuck Is VAC-MAT TM reusable? The working life of a VAC-MAT TM depends on the number and size of cuts made into the mat during machining. What kinds of VAC-MAT TM are available? There are 4 types of mat available: Blue mats, standard for normal machining Green mats, slightly harder in consistency for heavier machining Red mats, only to be used once Black mats, are used to seal the areas not required on the VAC-MAT TM chucks during machining. 5 sided-milling an aperture on a VAC-MAT TM clamping system VAC-MAT TM allows fast and economical machining with only one clamping procedure. Not only is clamping very fast but break-outs, deburring and hand finishing become a thing of the past. The modular concept allows connection of several vacuum chucks. The vacuum supply to each chuck continues through the connection elements.

25 VACUUM CLAMPING SYSTEMS WITTE VAC MAT TM 25 Thin workpieces can also be clamped and machined securely but gently using VAC-MAT TM Vertical clamping can also be carried out reliably with VAC-MAT TM

26 26 WITTE VAC MAT TM VACUUM CLAMPING SYSTEMS Witte VAC-MAT TM in use; Above: Direct milling through a work-piece on a modular plate 400x600mm. Right: Fast handling, short clamping times of the workpiece all in one step. Above: Witte VAC-MAT TM - modular plates can be joined according to required size, the vacuum is maintained by the connection elements.

27 VACUUM CLAMPING SYSTEMS WITTE VAC MAT TM 27 Combined special clamping system made out of Witte VAC-MAT TM and FLIP-POD TM Left: Modular-built Witte VAC-MAT TM - chuck 1600 x1200 mm

28 28 WITTE VAC MAT TM VACUUM CLAMPING SYSTEMS Starter-Sets These starter sets are designed to give the operator a complete solution to set up and start machining immediately. All plates are modular and can be extended with a simple connector at any time. Modular VAC-MAT TM plates are made of high-tensile aluminium. Steel versions are available on request.

29 VACUUM CLAMPING SYSTEMS WITTE VAC MAT TM 29 I II III No. Description lxwxh kg VAC-MAT TM Modular plate 300x200x VAC-MAT TM Modular plate 300x400x VAC-MAT TM Modular plate 600x400x30 20 I Supply includes: 1 x tail end, 1 x coupling, 7 x blind plug, 10 x O-ring 8 x crosspieces, 10 x VAC-MAT TM blue 1m vacuum suction hose with wire spiral 18/12 II Additional, height adjustable end stops are also available. For fixing end stops, threaded holes have to be made in the plate by the customer. III Height adjustable end stops in form of eccentric washers No. pcs. ø height of plate knurled nut/ mm mm grub screw ,5 M ,0 M ,0 M6 The delivery includes: Sketch with dimension for threaded holes, suitable knurled nuts and grub screws. The threaded holes must be made by the customer. Special dimensions are available on request! Modular VAC-MAT TM plates are made of high-tensile aluminium. Steel versions are available on request.

30 30 WITTE VAC MAT TM VACUUM CLAMPING SYSTEMS Accessories VAC-MAT TM s No. Name lxwxh VAC-MAT TM /blue, normal machining 300x200x2, VAC-MAT TM /green, heavier machining 300x200x2, VAC-MAT TM /red, only used once 300x200x2, VAC-MAT TM /black, 300x200x2,5 for covering areas not required during machining

31 VACUUM CLAMPING SYSTEMS WITTE VAC MAT TM 31 Accessories VAC-MAT TM chuck accessories I II III IV V No. Name Dimension Hose connector ø1 = 23 incl. O-Ring ø2 = Vacuum chuck adapter ø1 = 23 incl. O-Ring Plug ø1 = 23 incl. O-Ring O-Ring ø16x2, Tool for setting up ø15x VAC-MAT TM - Video VHS I II III IV V Demonstration VAC-MAT TM video available. Please ask.

32 32 VACUUM CHUCKS VACUUM CLAMPING SYSTEMS Grid type vacuum chucks One of the commonest vacuum chucks since clamping with vacuum was discovered is the grid chuck. This type of chuck is used for clamping simple geometrically shaped workpieces with or without cutouts. Special seals laid out according to the workpiece contour (but incorporating the vacuum supply bore) help to even out pronounced uneven or rough surfaces, whilst still securely holding the workpiece during the application. ideal for heavy milling and grinding we recommend a larger O shaped seal diameter when large-sized workpieces are very rough or uneven. O-shaped seal is available in diameters from 2-10mm the grid distance required depends on the workpiece Picture shows a large grid type fixture with different grids enabling simultaneous clamping of different size workpieces contour and size. We can machine practically any grid dimension. The depth and width of the grooves depend on the O-shaped seal diameter to be used. Vacuum grid type plate with additional threaded bores

33 VACUUM CLAMPING SYSTEMS VACUUM CHUCKS 33 Strong downforces allow high milling performance Vacuum connection with switch on a grid plate with eccentric-stops Vacuum chuck with different grids to allow for simultaneous clamping of different sized workpieces

34 34 VACUUM CHUCKS VACUUM CLAMPING SYSTEMS Grid type vacuum chucks Witte grid chucks are designed and manufactured according to customer s requirements. Dimensions of chuck and clamping area, grid size, slot width, downforce and best type of clamping surface are all details taken into account to supply a chuck wich gives optimal results for the application in question. Use our inquiry form on page 98 or get in touch with our agent in your area or with us directly. The modular concept allows connection of several vacuum chucks. The vacuum supply to each chuck continues through the connection elements.

35 VACUUM CLAMPING SYSTEMS VACUUM CHUCKS 35 Modular- Grid Chuck No. Grid lxwxh kg Grid x200x32, Grid x400x32, Grid x400x32, Grid 12,5 300x200x32, Grid 12,5 400x300x32, Grid 12,5 600x400x32,5 20 Supply includes: 1 x tail end, 7 x blind plug, 10 x O-ring, 1 x plug, inside dia 12, 10m O-shaped seal 1m vacuum suction hose with wire spiral 18/12 height adjustable, excentric end stops with discs Special dimensions available on request! Witte grid chucks are manufactured in high-tensile aluminium. Steel versions are available on request.

36 36 VACUUM CHUCKS VACUUM CLAMPING SYSTEMS Sinter metal chucks sinter metal vacuum chucks are ideal for extremely thin-walled workpieces and for very soft materials (i.e. rubber, foils, metal bands etc.) or for use in precision optical work. ideally suited for extremely thin workpieces (<1mm finished Dim., depending on the material) and equally for foils down to less than 0,1mm thickness. due to absence of grooves and holes workpieces are not deformed for instance on inserts of sinter bronze. frequently used in precision machining in the optical industry and for measuring and checking in micrometer and nanometer ranges. sinter metal chucks must be covered entirely or to the largest possible extent. Covering unused areas with foil also improves the holding force. Witte sinter metal chucks are also available in a modular version if required. Sinter metal surface is hard and has high resistance to wear and tear No. lxwxh kg x200x32, x400x32, x400x32,5 24 Witte sinter metal chucks are manufactured in high-tensile aluminium. Steel versions and special dimensions are available on request. Special dimensiones available on request

37 VACUUM CLAMPING SYSTEMS VACUUM CHUCKS 37 WITTE-METAPOR for machining thin walled and flexible workpieces Sinter metal vacuum chuck with special adapter plate for clamping hard metal blanks during high precision laser machining. It has an integrated cooling labyrinth which prevents inaccuracies, due to development of warmth which occurs during the laser machining process Any machineable contour, also 3D shapes, can be machined into this porous material

38 38 VACUUM CHUCKS VACUUM CLAMPING SYSTEMS METAPOR -Vacuum chucks BF100 / MC100 Vacuum chucks with porous aluminium for extremely thin workpieces, very soft workpieces (i.e. rubber, foil thin metals etc.) of for use in fine optical areas Suitable for really thin materials (<1mm finished dimension) depending on material) and also for foils up to less than 0,1mm thickness Deformation of workpiece is impossible because there are no slots or holes Often used in fine optical processes for measuring and checking in micrometer and nanometer range Porous vacuum chucks should be completely or largely covered by the workpiece. Placing foil on uncovered areas improves the holding force METAPOR vacuum chucks are made of high-tensile aluminium. Steel versions are available on request. Witte METAPOR chucks are also available in a modular version if required METAPOR -Vacuum chucks BF100: Nr lxwxh kg x200x x400x x400x38 20 METAPOR -Vacuum chucks MC100: Supply includes: 1 x tail end, 7 x blind plug, 10 x O-ring 1 x plug, inside dia 12, 1m vacuum suction hose with wire spiral 18/12, height adjustable excentric end stops Nr lxwxh kg x200x x400x x400x38 20

39 VACUUM CLAMPING SYSTEMS VACUUM CHUCKS 39 METAPOR -Vacuum chucks CE100 Witte METAPOR CE 100 white is a fine poroused material with a medium pore diameter which is lower than that of BF-100 or MC 100. The surface is white and easy to machine. The material has a very homogenous total porosity. Especially interesting for silizium wafer production METAPOR -Vacuum chucks BF100: Nr lxwxh kg x200x x400x x400x38 20 Vacuum chucks with porous aluminium for extremely thin workpieces, very soft workpieces (i.e. rubber, foil thin metals etc.) of for use in fine optical areas Suitable for really thin materials (<1mm finished dimension) depending on material) and also for foils up to less than 0,1mm thickness Deformation of workpiece is impossible because there are no slots or holes Often used in fine optical processes for measuring and checking in micrometer and nanometer range Porous vacuum chucks should be completely or largely covered by the workpiece. Placing foil on uncovered areas improves the holding force METAPOR vacuum chucks are made of high-tensile aluminium. Steel versions are available on request. Supply includes: Special dimensions available on request! 1 x tail end, 7 x blind plug, 10 x O-ring 1 x plug, inside dia 12, 1m vacuum suction hose with wire spiral 18/12, height adjustable excentric end stops

40 40 VACUUM CHUCKS VACUUM CLAMPING SYSTEMS METAPOR -Vacuum chucks INOX 100 METAPOR -Vacuum chucks INOX100: Nr lxwxh kg x200x38 6, x400x38 12, x400x38 24,8 Unique porous, corrosion-free steel Porosity lies approx between that of METAPOR BF Al and MC 100 Al. A special difference to the BF, MC and CE materials is in the substantially higher ball pressure hardness of INOX 100 FE Vacuum chucks with porous aluminium for extremely thin workpieces, very soft workpieces (i.e. rubber, foil thin metals etc.) of for use in fine optical areas Suitable for really thin materials (<1mm finished dimension) depending on material) and also for foils up to less than 0,1mm thickness Deformation of workpiece is impossible because there are no slots or holes Often used in fine optical processes for measuring and checking in micrometer and nanometer range Porous vacuum chucks should be completely or largely covered by the workpiece. Placing foil on uncovered areas improves the holding force METAPOR vacuum chucks are made of high-tensile aluminium. Steel versions are available on request. Supply includes: Special dimensions available on request! 1 x tail end, 7 x blind plug, 10 x O-ring 1 x plug, inside dia 12, 1m vacuum suction hose with wire spiral 18/12, height adjustable excentric end stops

41 VACUUM CLAMPING SYSTEMS VACUUM CHUCKS 41 Combined METAPOR grid type chuck for friction stir welding application

42 42 VACUUM CHUCKS VACUUM CLAMPING SYSTEMS Slot vacuum chucks Unmistakeable unique characteristics: very flat, only 28mm high very light, made of high tensile aluminium (Steel versions available on request) height adjustable end stops Especially suitable for: engraving light milling work light drilling work All vacuum slot chucks have a 10 mm clamping edge. The slot width is 1 mm with a middle distance of 5 mm. Using the slot chuck together with a rubber adapter mat offers further advantages milling and drilling of i.e conductor plates without loss of vacuum engraving machines with a limited working height can easily be equipped with a Witte slot chuck simply define the vacuum area by pushing plastic clip into the slot marked with guiding lines

43 VACUUM CLAMPING SYSTEMS VACUUM CHUCKS 43 Slot vacuum chucks Slot chucks No. Clamping area Total dim. kg lxw l 1 xb 1 xh x x100x28 1, x x100x28 1, x x150x28 3, x x200x28 3, x x150x28 3, x x150x28 4, x x200x28 6, x x250x28 7, x x300x28 7, x x250x28 8, x x300x28 10, x x400x28 13, x x300x28 12, x x300x28 14, x x400x28 19,2 Supply includes: 1 vacuum stopper 1 rubber adapter mat, 3 height adjustable end stops 1m hose with connector for quick coupling Special dimensions available on request!

44 44 VACUUM CHUCKS VACUUM CLAMPING SYSTEMS Rubber adapter mats for slot vacuum chucks Rubber adapter mats, red, for use on slot type vacuum chucks (see also page 46) Dimension tolerances: DIN 7715 Part 5 Rubber adapter mats with lower tolerances (0,05mm) are available on request No. Dim lxwxh x100x x100x x150x x200x x500x x600x x150x x150x x200x x250x x300x x250x3 No. Dim lxwxh x300x x400x x300x x500x x1000x x300x x400x x1000x x2000x x2000x x2000x1,5

45 VACUUM CLAMPING SYSTEMS VACUUM CHUCKS 45 Rubber adapter mats for slot vacuum chucks No. Dm lxwxh x150x x200x x250x x200x x500x x600x x300x x400x x350x x300x3 No. Dm lxwxh x400x x400x x400x x500x x500x x600x x600x x1000x x1000x x2000x3 Rubber adapter mats, black, for use on slot type vacuum chucks made of synthetic elastomer. These mats can be milled over and allow high plane parallelism

46 46 VACUUM CHUCKS VACUUM CLAMPING SYSTEMS Slot vacuum chucks and rubber adapter mat 1 2 Lay the rubber adapter mat onto the chuck covering all the slots. Position workpiece with the help of adjustable end stops. Then draw round the contour using an ordinary pen Application Simply follow steps 1-5 and a custom built fixture is ready in seconds. When vacuum is switched on the mat and the workpiece are sucked down together. The excellent friction values offer especially good resistance to displacement forces during machining. Using the slot chuck with the rubber adapter mat allows drilling of holes and milling or cutting of pockets and cutouts into the mat to a depth of 1,5mm without losing vacuum. As the mat suffers hardly any wear and tear it can be used often for workpieces with the same contour. Certain applications allow the tool to work to depths of 1,5mm into the mat. Height tolerance of the mats lie in the range of +/-0,3mm. (DIN 7715, part Kl. P2)

47 VACUUM CLAMPING SYSTEMS VACUUM CHUCKS Here you can see the workpiece contour Remove the mat and punch holes into the area corresponding to the actual clamping surface of the workpiece. The holes should be approx. 3-8mm Dia. in a 10mm grid and lie on slots of the chuck 5 Replace workpiece onto the mat. The excellent friction of the rubber material counteracts high-displacement forces better than any other vacuum system.

48 48 VACUUM CHUCKS VACUUM CLAMPING SYSTEMS Slot vacuum chucks - special versions Slot vacuum chucks for workpieces with complicated geometrical forms, also with cut-outs i.e. screens; ideal for light machining operations like engraving or grinding etc. The vacuum supply is connected to a moveable hose within the plate. In order to reduce the area affected by vacuum the hose is pulled towards the user and the end sealed with a plastic chip put into the plate between the lines marked. All slots can be covered also using covering foil (accessories). On the same principle as the rubber adapter mat, the workpiece contour is traced onto the foil. The foil within the contour is then slit using a knife resulting in a custom built fixture in seconds. By using adapter plates it is also possible to create multiple fixtures Slot vacuum chuck with special adapter plate Slot vacuum chuck with 3 vacuum areas, which work combined or independantly

49 VACUUM CLAMPING SYSTEMS VACUUM CHUCKS 49 Covering foil This aluminium foil is a recommended accessory for every slot chuck. Application: cover the chuck completely with the foil lay workpiece on to chuck in area nearest vacuum supply draw round workpiece pierce foil within the contour of workpiece. All kinds of workpieces can be clamped using this method. After use the foil is simply peeled off. No rest-adhesive remains on the chuck. The application is similar to using a rubber adapter mat (see page 46). The difference is that the foil is cut along the slot using a knife. The workpiece should have an even and flat surface for optimal results Covering foil The foil thickness is: 0,06-0,11mm No. lxw pcs. kg x , x , x , x , x , x , x , x ,2 No. lxw pcs. kg x , x , x , x , x , x , x , x , x ,2

50 50 CLAMPING PLATES VACUUM CLAMPING SYSTEMS ICE-VICE Freeze clamp technology Clamping by freezing on a thin water film Workpieces can now be clamped for machining simply, accurately and tension-free using ice. Place the workpiece on the previously cooled plate and spray a thin film of water onto plate and workpiece. Approximately 90 seconds later the workpiece is frozen to the working surface. Experience has shown that a temperature of 10 has proven to be ideal for freeze clamp technology. At 10 the ice has not yet become brittle and cracked. By using custom-built adapter plates workpieces are positioned and clamped with repeatable accuracy. The use of coolants should be avoided during machining. If this is not possible we will gladly suggest or quote alternatives. We differentiate between two alternative methods of freezing workpieces: 1.) Ice-Vice -System 1.1) The so-called Ice-Vice clamping system comprises of two main components, the cooling unit and the freeze plate. With the help of integrated electronics a closed cooling system within these two components controls the temperature, which can be chosen freely and the set value remains within a tolerance of +/-2. Sensors check this procedure constantly. The ideal temperature is given at 10. The micro electronic controls check all functions. 1.2) Two freeze plates can be connected simultaneously to the cooling unit. This means two independant freeze plates can be used on two different machining centres. 1.3) After setting the ideal temperature according to experience, accuracy of +/-3µ can be achieved on the workpiece after machining. 1.4) Freezing the workpiece to the plate takes 90 seconds. Thawing is supported by a heating cartridge (integrated in the freeze plate) and requires approximately the same amount of time. Ice-Vice freeze plates can also be supplied with a vacuum connection for clamping workpiece specific adapter plates in order to shorten clamping cycles. This works best when one freeze plate is in use on the machine while the other plate is in a freezing or thawing modus. 2. Ice-Vice AFP System (Air Freeze Plate) 2.1) Cold air is produced by feeding in and compressing air at min 6 bar. This chuck can be connected to any available air compressor. In order to achieve the required C approx. 6 bar of compressed air is necessary (these values are valid for an environment temperature of 20 C, but also for the temperature of the compressed air). 2.2) By using a switch the compressed air inside the AFP plate can be changed round so that the compressed air warms the plate in order to thaw the ice. 2.3) The AFP system is also available for use on a lathe it has a steel base that can be clamped on a magnatc worktable. For further information or a quotation please contact: Europe: Rudolf Behn witte-28@horst-witte.de Overseas: Lesley Osborne witte-37@horst-witte.de or Jacob de Mol witte-83@horst-witte.de

51 VACUUM CLAMPING SYSTEMS CLAMPING PLATES 51 Examples of workpieces and materials which can be machined using freeze clamp technology: Glass and quartz parts which have to be held tension-free for instance to remove samples or remove small parts from a profile. Parts made of steel which have to be machined tension-free Complicated small plastic and graphite workpieces Machining at MOTOROLA Machining small graphite workpieces Metalcutting Watch and clock parts Aluminium and plastic housings If you belong to one of the following trades, freeze clamp technology could be the solution you are looking for: Processing and machining ceramics, manufacturing ceramics, processing graphite, semi-conductor industry, optical industry, watchmaker, glass processing, quartz processing, metal-machining, medicinal technology, small parts stainless steel machining, laboratories in high schools and institutes Milling of honeycomb structure Comparison between milling tool and ball point Ice-Vice chucks in pallet form are used to increase productivity

52 52 CLAMPING PLATES VACUUM CLAMPING ICE-VICE freeze chucks Clamping by freezing on a thin water film As in many other technical procedures the idea for development of freeze clamp technology came from nature itself. During clamping with Ice-Vice systems workpieces are frozen tight onto a chuck for machining by a capillary film of water. Also for relatively uneven workpieces the gaps are filled completely with water and thereby fozen. The adhesion, detaching and shearing forces are strong enough to be able to mill, grind, drill or polish parts. ICE-VICE -freeze plate with an even contact surface for freeze-clamping flat-lying workpieces

53 VACUUM CLAMPING SYSTEMS CLAMPING PLATES 53 ICE-VICE freeze plates ICE-VICE - Freeze plate with cavity for freezing unevenly shaped or unstable workpieces No. lxwxh area dm x150x105 1, x200x105 2, x300x105 3, x150x105 2, x200x105 3, x250x105 3, x300x105 4, x200x105 4,00 Workpiece frozen with gel x250x105 5, x300x105 6, x500x105 10, x320x105 10, Additional vacuum suction connection Also available in special sizes!

54 54 CLAMPING PLATES VACUUM CLAMPING SYSTEMS ICE-VICE supply unit No bxhxt Connection kg x770x V/50Hz x770x V/50Hz, 2-3kW x770x V/50Hz, 65 Prec. control unit ICE-VICE supply unit with two regular cooling cycles for using two freeze plates independantly; While one freeze plate is being used for machining the other can be prepared. After machining is finished the plate can be switched to thaw and the workpiece removed. Supply includes: 4m electric cable 3m coolant connection Nr bxhxt Anschluss kg x850x V/50Hz 50 Aggregat mit einfachem Anschluß für nur eine Gefrierspannplatte maximaler Größe 150x250mm.

55 VACUUM CLAMPING SYSTEMS CLAMPING PLATES 55 Vacuum adapter plates for ICE-VICE Nr Name Dim Vacuum adapter plate 125x Vacuum adapter plate 125x Vacuum adapter plate 150x Vacuum adapter plate 150x Vacuum adapter plate 150x Vacuum adapter plate 150x Vacuum adapter plate 200x Vacuum adapter plate 200x Vacuum adapter plate 200x Vacuum adapter plate 200x Vacuum adapter plate 400x400 ICE-VICE freeze plate with 400 workpieces frozen on the surface

56 56 CLAMPING PLATES VACUUM CLAMPING SYSTEMS ICE-VICE -AFP Freeze plates Producing cold with compressed air Fragile, unstable parts are clamped gently and securely. No deformation or breaks arise during clamping procedure. Almost all materials can be clamped. Composites, graphites, ceramic, rubber and also difficult honeycomb structures, which usually have complete hollows, can be clamped easily with a clamping force of upto approx. 140N/cm 2.

57 VACUUM CLAMPING SYSTEMS CLAMPING PLATES 57 ICE-VICE -AFP Freeze plates Palletizing possibility Freeze plates can be used for fast exchange Nr Name dim Freeze plate AFP x Freeze plate AFP x Adapter plate f AFP-140 7x100x Silencer Freeze plate AFC-20 ø 20 mm Gefrierspannfutter AFC-IOL-20 ø20mm Ersatz-Gefrierspannpl. AFC-IOL-20 ø20mm Gefrierspannfutter AFC-55 ø55mm Fixture for holding workpieces on lathe. Can be used for varying diameters Ersatz-Gefrierspannpl. AFC-55 ø55mm Gefrierspannplatte AFC-80 ø80mm Also available in special sizes! Silencer # 13052

58 58 VACUUM CHUCKS VACUUM CLAMPING SYSTEMS Perforated-grid chucks - special version Highly accurate vacuum chucks used in photo-optical processes i.e. extremely accurate clamping of printing plates or optical films/foils. Used on machines for the manufacture of printing plates during laser and UV exposure; exposure of film-foils or for thin aluminium base plates. Special dimensions, also division of suction area in several areas or sectors are available on request; i.e. Perforated grid chuck 1.400mm x 2.000mm with 30µ accuracy. Perforated-grid chuck with eccentric end stops These vacuum chucks are made according to customer s request and machine specification. Please use the form on page 98 for your inquiry Peforated-grid chuck for exposure machine

59 VACUUM CLAMPING SYSTEMS WITTE FLIP-POD TM 59 FLIP-POD TM vacuum system The FLIP-POD TM vacuum clamping system has been developed for clamping large workpieces in aluminium, plastics or wood. This system can be used on CNC milling or grinding machines. The advantages at a glance: thanks to a controlled vacuum supply, the workpiece remains in the correct position at all times during machining FLIP-POD TM is a modular system and can be used on all common CNC milling machines and even for drilling work Application demonstating active and inactive FLIP-POD TM s when not in use all pods store inside the hollows of the pod plate. They are available at any time for a fast changeover from one machining job to another FLIP-POD TM reduces preparation times between workpiece changes and thereby increases productivity FLIP-POD TM vacuum chuck 6m long made up of three segments FLIP-POD TM -clamping system for a CNC deburring machine, used on aeroplane parts

60 60 WITTE FLIP-POD TM VACUUM CLAMPING SYSTEMS FLIP-POD TM Vacuum system FLIP-POD TM clamping system in working position prepared for a large aluminium workpiece with cutouts 1 2 The round polymer pods (1) protrude out of the pod plate when in use. The pods not required lie in a recess cavity (2) of the pod plate. Simply flipping them over activates or deactivates the pods.

61 VACUUM CLAMPING SYSTEMS WITTE FLIP-POD TM 61 FLIP-POD TM Vacuum system The cross section drawing shows how the pods work. Simply flipping them over puts them in working position. They are automatically switched on when the operator turns them over. All active pods stand 26mm above the pod plate surface, allowing contour milling and recess cutting on the outer contours. Fixed and retractable locator pods ensure high accuracy. Locator pods are available in both fixed and retractable versions, either of which fit in any pod cavity. After positioning the workpiece the retractable pods are drawn back into the pod plate as soon as vacuum is switched on, allowing a free path for the cutting tool. Alu FLIP-POD TM has an accurate, defined workpiece surface. Height tolerance is only 50µ. They are suitable for face machining on both surfaces, especially of metallic workpieces. FLIP-POD TM with sucker Retractable and fixed locator pods ALU FLIP-POD TM Supply FLIP-POD TM Set 100 includes No. Name Pcs FP Unit FP Sucker FP Center hole gasket FP Large gasket 100 FLIP-POD TM Sets, polymer version No. Description Area/Grid PODS FLIP-POD TM Set 100 1m 2 /100mm FLIP-POD TM Set 200 2m 2 /100mm FLIP-POD TM Set 300 3m 2 /100mm FLIP-POD TM Set 400 4m 2 /100mm FP Retractable locator pods FP Fixed locator pods 3

62 62 WITTE FLIP-POD TM VACUUM CLAMPING SYSTEMS FLIP-POD TM Accessories and spare parts I I II III IV No. Description FP Unit complete with filter element and ball FP Sucker, which is mounted onto the unit FP Large seal for the upper seal slot FP Center hole seal for the pod cavity II Complete Witte FLIP-POD TM Alternative version III IV

63 VACUUM CLAMPING SYSTEMS WITTE FLIP-POD TM 63 FLIP-POD TM Accessories and spare parts I II III IV No. Description FP Retractable locator pod automatically retract when vacuum is applied FP Polymer-Half-Pod (1/2), FP Lift ring 1/ FP Transfer Pod For easy positioning of large workpieces over the Flip-Pods I II I II III IV IV Witte Transfer FLIP-POD TM, polymer version

64 64 WITTE FLIP-POD TM VACUUM CLAMPING SYSTEMS FLIP-POD TM Accessories and spare parts I II No. Name FP Fixed locator pods incl. unit, pins and spacer disks FLIP-POD TM -Video II

65 VACUUM CLAMPING SYSTEMS WITTE FLIP-POD TM 65 Pod -Plate, ready for use, with ALU FLIP-POD TM s The sketches show a range of possible pod panel designs. The user can choose the panel design that best suits the parts being machined. The pod panel can be laid out in almost any design and combination.

66 66 WITTE FLIP POD TM VACUUM CLAMPING SYSTEMS ALU FLIP-POD TM Accessories and spare parts I II I II III IV V VI No. Name FP Complete with seal, filter element and ball (85662 and order seperately) FP Seal for Alu-Pod FP Polymer Ball ø15,8 mm FP Filter ø61 x3mm FP Large Seal for Pod Plate ø88 x4,5mm FP Center hole gasket for pod cavity ø38x6mm III IV Witte ALU-FLIP-POD TM in its basic state without seals V ca. VI

67 VACUUM CLAMPING SYSTEMS WITTE FLIP POD TM 67 ALU FLIP-POD TM Accessories and spare parts I No. Name FP Alu Half-Pod incl. 1m seal ø5mm Half pod, alu

68 68 WITTE FLIP POD TM VACUUM CLAMPING SYSTEMS Height adjustable ALU FLIP-POD TM I I II No. Name FP Height adjustable ALU Flip-Pod (special shape) FP Height adjustable ALU Flip-Pod II

69 VACUUM CLAMPING SYSTEMS APPLICATIONS Workpieces frozen on Ice-Vice TM 2. Vacuum plate for clamping the housing of a Lap-top 3. Clamping fixture for micro-chip cards 4. Circular chuck ø 1500 mm 4 5. Vacuum cube with integrated storage tank and distribution manifold, approx. 800 x800 x900 mm, used on machining centre with automatic 24 hour pallet exchange system. Parts held with vacuum during machining, transport and standing times.

70 70 CIRCULAR CHUCKS VACUUM CLAMPING SYSTEMS Circular grid type chucks Supply includes: Seal 10m (h=38mm) or 20m (from h=48mm), 4 stops These circular chucks are ideal for disk or circular type workpieces for machining i.e. on a lathe. They are used in glass and polymer processing industries, but metal machining is of course also possible. Aluminium Steel No. Grid dim. Dia.xh kg ,0 ø100x ,0 ø125x ,0 ø160x ,0 ø200x ,0 ø250x ,5 ø315x ,5 ø400x ,5 ø500x ,5 ø630x58 49 No. Grid dim. Dia.xh kg ,0 ø100x ,0 ø125x ,0 ø160x ,0 ø200x ,0 ø250x ,5 ø315x ,5 ø400x ,5 ø500x ,5 ø630x Special dimensions available on request!

71 VACUUM CLAMPING SYSTEMS CIRCULAR CHUCKS 71 Grid type vacuum chucks Circular grid chucks, special dimensions and specially designed. Other circular chucks are shown on page 17 and 37

72 72 CIRCULAR CHUCKS VACUUM CLAMPING SYSTEMS Circular sinter metal chucks The insert made of sinter bronze guarantees even and accurate clamping of different workpieces i.e. optical glass, wafer etc. Also available in METAPOR see page 73 Aluminium No. Dia xh kg ø100x38 0, ø125x38 1, ø160x38 2, ø200x38 3, ø250x38 5, ø315x48 10, ø400x48 16, ø500x58 31, ø630x58 49,0 Steel No. Dia x h kg ø100x38 2, ø125x38 3, ø160x38 6, ø200x38 9, ø250x38 14, ø315x48 29, ø400x48 47, ø500x58 89, ø630x58 142,0 Special dimensions available on request!

73 VACUUM CLAMPING SYSTEMS CIRCULAR CHUCKS 73 WITTE - METAPOR -circular vacuum chucks Vacuum-circular chuck with an air through-flow, fine porous and homogenous insert. Especially for tension free clamping of very thin foils or similar materials. The insert can be produced in two different WITTE - METAPOR materials, BF-100 and MC-100. Technical date can be found on pages 94/95. These materials can also be used for air film glide handling equipment using the standard quality BF 100. Aluminium No. Øxh kg ø100x38 0, ø125x38 1, ø160x38 2, ø200x38 3, ø250x38 5, ø315x48 10, ø400x48 16, ø500x58 31, ø630x58 49,0 Steel No. Øxh kg ø100x38 2, ø125x38 3, ø160x38 6, ø200x38 9, ø250x38 14, ø315x48 29, ø400x48 47, ø500x58 89, ø630x58 142,0 Special dimensions available on request!

74 74 LIQUID SEPARATOR VACUUM CLAMPING SYSTEMS Liquid separator Liquid separators are indispensable whenever coolants or lubricants are being used. Also acts as a retainer for dust, chips etc. Advantages: fluid level can be seen at all times aluminium and acrylic materials result in light weight easy handling due to its ergonomic design No. Volume lxbxh Hose connection kg l ø200x400 LW l ø300x500 LW

75 VACUUM CLAMPING SYSTEMS LIQUID SEPARATOR 75 Automatic liquid separator Fully automatic operation is guaranteed with an integrated magnetic valve and 2-chamber system. The separator is set up between vacuum chuck and pump, thereby protecting vacuum pump from the large amounts of fluid, which are absorbed and dispersed. The fluids, which are sucked in, are transported back to the machine by means of a hose system. Clamping of the workpiece is not interrupted at any time. Electricity supply of 230V is necessary for operation. Also available in 110V/60 Hz version No. l Fluid- Separation for suction l x b x h Hose entrance Hose exit kg capacity capacity l/h capacity m 3 /h inner Dim. inner Dim bis x400x670 R 1 1/4 R 1 1/4 8, x410x960 R 2 1/2 R 2 15

76 76 ACCESSORIES VACUUM CLAMPING SYSTEMS Vacuum Switch with LED Display Vacuum switch with adjustable limit values. Used as safety switch Electronically controlled LCD Vacuum display showing 7 different units, lettersize 11mm, display in red or green: 0 to 1,013 bar (0 to 101,3 kpa) mmhg, kgf/cm 2, Inch/HG, PSI, kpa, MPa. Top and bottom vacuum limits freely adjustable. Adjustable response time 2,5 to 500 ms in 4 Steps. Can be used in N.O. (normal open) or N.C. (normal closed) state. 2 Vacuum suction bores R1/8 can be used optionally in 90 position. The cable 4,5x1,8, 2m long is connected to the machine control. Should the minimum vacuum drop below preset value the switch send a signal to the machine to stop No. Dim. U kg x31, 5 x 37 24V 0,05 The delivery includes: Operation manual, 2 mounting brackets, blind plug, 2 screws M3, display unit label Pressure regulator Switch Used to set underpressure on vacuum units, is infinitely adjustable. Switches off automatically when set vacuum is reached and switches on again when vacuum drops below permitted range setting range from 0-99,8% vacuum vacuum range approx 70 mbar made of black polymer The switch has two fixing bores for fillister head cap screws M4 DIN 912 No. lxwxh U kg x30x30 250V 0,07

77 VACUUM CLAMPING SYSTEMS ACCESSORIES 77 Safety appliance Nr The German Employer s Liability Insurance Association demands that machines having poweroperated workpiece clamping devices must be designed and installed in such a way that the driving spindle or feed mechanism can only be activated after completing the fixing or clamping procedure. The safety appliance is a must for all jobs on heavy-duty machines and can be integrated into the machine controls. When the vacuum drops below the pre-set value (infinitely adjustable) a visual signal is given. The built-in dead changer is integrated into the machine controls and sets off an emergency stop of spindle or feedstop. The range between maximum and minimum vacuum is 70 mbar. This version with magnetic valve allows the clamping procedure to be activated from the machine control panel. No. Name for hose inner Dia. Voltage Safety appliance with electronic vacuum switch ø12 mm 24 Volt Safety appliance with electronic vacuum switch ø18 mm 24 Volt Safety appliance with electronic vacuum switch ø18 mm 24 Volt Safety appliance with electronic vacuum switch ø25 mm 24 Volt Safety appliance with electronic vacuum switch ø32 mm 24 Volt Safety appliance with electronic vacuum switch ø50 mm 24 Volt

78 78 ACCESSORIES VACUUM CLAMPING SYSTEMS O-shaped seal Used for sealing grid chucks or workpiece specific contours. This high quality neoprene seal is placed into the suction slot of a vacuum grid type chuck to restrict the clamping area. (i.e. see page 35) The seal diameter is dependant on the cross section of the slot. If a plate is remachined then a seal with a smaller diameter will be required. Minimum order quantity 50m/per diameter No. Diameter ø 2,0mm ø 3,0mm ø 3,5mm ø 4,0mm ø 4,5mm ø 5,0mm ø 5,5mm ø 6,0mm ø 6,5mm ø 7,0mm ø 8,0mm ø 10,0mm Vacuum grease Used from time to time for the following: greasing suction hose sealing off workpieces with rough or scored surface No. Name Cont. kg Vacugrease 250g 0,29 Y distributor with female thread No. Thread Hose nozzle R3/8 3 x LW R1/2 3 x LW R1/2 1 x LW18, 2 x LW12

79 VACUUM CLAMPING SYSTEMS ANWENDUNGEN 79 Vacuum chuck for bottle tops in quality control Custom built vacuum chuck for the aerospace industry Picture shows a special sinter metal vacuum fixture used in quality control department of CD manufacturer

80 80 ACCESSORIES VACUUM CLAMPING SYSTEMS Manifold distributors All manifolds are supplied with corresponding hose-nozzles and on each exit there is a 3/2 way aerated vacuum valve with a vacuummeter The manifold can be upgraded to a safety appliance when assembled together with a safety pressure switch (80411, see page 76). Connection threads R 1/8 with blind plugs are already in place.

81 VACUUM CLAMPING SYSTEMS ACCESSORIES 81 No. Description Entrance Exit l x b x h connection connection Manifold distributor 1xLW18 4xLW12 43x43x Manifold distributor 1xLW24 3xLW Manifold distributor 1xLW25 6xLW12 84x84x Manifold distributor 1xLW32 4xLW Manifold distributor 1xLW32 6xLW12 84x84x Manifold distributor 1xLW32 4xLW Manifold distributor 1xLW32 6xLW18 84x84x Manifold distributor 1xLW32 2xLW Manifold distributor 1xLW50 6xLW Manifold distributor 1xLW50 3xLW Manifold distributor 1xLW50 4xLW25 84x84x Manifold distributor 1xLW50 5xLW Manifold distributor 1xLW50 2xLW Manifold distributor 1xLW50 4xLW32 84x84x510 Supply includes: Hose nozzle for vacuum pump exit, hose nozzle and aerated 3/2 way hand valve for each connection exit, vacuum gauge Various types available on request!

82 82 ACCESSORIES VACUUM CLAMPING SYSTEMS Rotation joints II I Ideal for using with circular vacuum chucks on lathes with a hollow spindle vacuum chucks on a rotating machine table with hollow spindle The Witte rotation joint allows rotary movement of circular or normal chuck but with a stationary vacuum supply without any vacuum loss. Standard rotation joints are available for three RPM ranges: upto 1500, 3000 and They come complete with polymer tubing, which connects the chuck through the hollow spindle with the rotation joint. It is the tubing which takes up the torque force Supply includes: 1,5m hose, plus connection parts

83 VACUUM CLAMPING SYSTEMS ACCESSORIES 83 Rotation joints I II No. max.rpm Dia l kg R ,3 3/8-3/ ,0 1/2-3/ ,0 1/2-3/8 I II Other sizes available on request! Airfilter Universally used dust filter, dirt immediately visible through the transparent housing. Designed to allow easy exchange of the filter cartridge. A fitting filter cartridge is included in the package. ø Filtercartridge I II No. H ø R Filter# / / H R R

84 84 ACCESSORIES VACUUM CLAMPING SYSTEMS Vacuum electro-magnetic valves All vacuum valves are 3/2 way with ventilation. For safety reasons the electro-magnetically operated vacuum valves are always open. That means that even if the electricity is cut off, the vacuum supply bore in the valve remains open, and supply of vacuum is guaranteed. This is valid for 230 volt AC or 24 volt DC 1 = Pump 2 = User/Vacuumplate 3 = Air Intake

85 VACUUM CLAMPING SYSTEMS ACCESSORIES 85 Vacuum electro-magnetic valves No. Connection Pumpe Vacuum Vacuum Weight thread max. m 3 /h min. max. kg /4 female/female 4 0, /8 female/female mm/HG 759,50mm/HG 0, /2 female/female 20 1, /4 female/female 60 1, female/female Torr 0,5 Torr 1, /2 female/female 180 2,00 Other sizes available on request! Supply includes: 24 volt solenoid and plug Supply does not include nozzles or connection elements. See next pages

86 86 ACCESSORIES VACUUM CLAMPING SYSTEMS Slide valve No. Connection thread /8 female/female /4 female/female /8 female/female /2 female/female Vacuum handvalve No. Connection thread /4 female/female /8 female/female /2 female/female /4 female/female female/female /4 female/female /2 female/female Foot switch No. Connection thread R1/4 Supply includes: 2 hose nozzles, 2x3m vacuum suction hose with wire spiral 18/12 Vacuum switch for vacuum chucks No. Connection thread R3/8 Siehe auch Abb. auf Seite 33

87 VACUUM CLAMPING SYSTEMS ACCESSORIES 87 Vacuum gauges Axial connection Radial connection No. Connection thread Diameter Range R1/8 axial ø40 0 bis -1 bar R1/8 radial ø40 0 bis -1 bar Screw hose connection for slot-type vacuum chucks No. Thread for hose inner Dia /8 ø 4, /4 ø 6 Quick coupling with male thread No. Thread for plug / / /

88 88 ACCESSORIES VACUUM CLAMPING SYSTEMS Plug for quick coupling No. for hose inner diameter ø ø ø ø 19 Hose nozzles No. Thread for hose WAF inner dia /8 ø /4 ø /4 ø /8 ø /8 ø /2 ø /2 ø /4 ø /4 ø ø ø /4 ø /2 ø ø 50 57

89 VACUUM CLAMPING SYSTEMS ACCESSORIES 89 Reducers male/female No. Thread Thread male female /4 1/ /8 1/ /8 1/ /2 1/ /2 1/ /2 3/ /4 1/ /4 3/ /4 1/ / / / /4 1/2 Screw hose connection No. Thread for hose inner dia /8 LW /2 LW / /2 1 Double nipple, detachable No. Thread /8 female/female /8 male/male /4 male/male male/male

90 90 ACCESSORIES VACUUM CLAMPING SYSTEMS Wire spiral hose Durable vacuum supply hose suitable for most chucks No. Bendable radius Outer/inner (minimal) diameter mm ø13/ mm ø18/ mm ø25/ mm ø34/ mm ø40/ mm ø60/50 Spiral hose, polymer Used with radial compressors No. Description inner diameter Spiral hose, polymer ø Spiral hose, polymer ø Spiral hose, polymer ø50

91 VACUUM CLAMPING SYSTEMS ACCESSORIES 91 Vacuum polymer tubing Used with rotation joints No. Description Outer/inner diameter Polymer tubing, black ø8/ Polymer tubing, black ø12/ Polymer tubing, black ø15/12 Polymer hose Used for slot-type chucks No. Description Outer/inner diameter Polymer hose, ø6/4 white Please state length in metres when ordering

92 92 WITTE METAPOR TM VACUUM CLAMPING SYSTEMS WITTE-METAPOR - Porous aluminium Instead of bores for vacuum and air pressure - METAPOR for vacuum and air pressure! Evacuation vacuum mould-forms made of METAPOR vacuum chucks made of METAPOR i.e. for clamping electronic workpieces and foils Lifting air film glide handling equipment made of METAPOR Through flow for agitating bases and conveyor channels made of METAPOR Molding/Demoulding deep drawn and die moulds made of METAPOR This unique porous aluminium compound material is suitable for die and mould, conveyance and clamping systems Ceramic and machined forms made of METAPOR Deep drawn form, made of WITTE - METAPOR

93 VACUUM CLAMPING SYSTEMS WITTE METAPOR TM 93 WITTE - METAPOR BF 100 AL Vacuum clamping technology The main feature of METAPOR vacuum clamping systems is suction over the complete surface area without suction bores. Foils are held absolutely flat. The pressure drop, which takes place within the structure means that it is not necessary to cover areas not in use. METAPOR is ideally suited for holding foils and electronic parts as well as for mould-forms and soft workpieces. Air film glide technology The pressure distribution in the METAPOR structure allows even surface airflow capacity, even if only part of the surface is covered. Air consumption and noise emission are considerably reduced. Trouble-free machining offers cost reduction on air flow components, a new perspective for rotation bearings, conveyance and extrusion beds. Through-flow technology The microporous METAPOR structure allows an even agitation of granulates and powders without bubbles ocurring. Low air consumption reduces friction and mechanical load. METAPOR ideal for mixing processes, coating, conveyance troughs and dismantling of silo bridges Molding technology Deep drawn moulds made of METAPOR do not require any bores. Bore imprints on the workpiece are avoided. Suction over the complete area allows structures to be complex without air pockets and distortions. The complete flow-through of air prevents high-temperature areas developing. Rational machining procedure and immediate usability promise a valuable technological advantage

94 94 WITTE METAPOR TM VACUUM CLAMPING SYSTEMS WITTE - METAPOR BF 100 AL Available in the following dimensions: No. lxwxh kg x500x10 4, x500x15 6, x500x20 9, x500x25 11, x500x30 13, x500x35 15, x500x40 18, x500x50 22, x500x60 27, x500x70 31, x500x80 36,0 The machineability of METAPOR is excellent and can be compared to easily machineable aluminium. METAPOR is machined without coolant in order to keep the pores clean Better surfaces are achieved with high cutting values. No noticeable warmth developing in the workpiece can be felt during machining. Technical data: Density 1,78 g/cm 3 Ball compression hardness 113 Shore hardness D 81 Brinell hardness HB 5/306,5 Norm EN Tensile strength DIN N/mm 2 Yield point DIN ,8 N/mm 2 E-Modul DIN N/mm 2 Impact tenacity DIN ,8 kj/m 2 Compression strength DIN N/mm 2 Average pore diameter 15 µm Total porosity 15 % Open porosity 8 % x500x100 45, x500x ,0 Thickness tolerance: -0/+0,3mm Larger dimensions available on request

95 VACUUM CLAMPING SYSTEMS WITTE METAPOR TM 95 WITTE - METAPOR MC 100 AL Available in the following dimensions: No. lxwxh kg x500x10 4,0 A new porous material, developed for free-form surfaces. This material has larger pores to allow air to pass freely. This enables greater clamping forces during milling, without the need for extra bores x500x15 6, x500x20 8, x500x25 10, x500x30 12, x500x35 14, x500x40 16, x500x50 20, x500x60 24, x500x70 28, x500x80 32, x500x100 40,0 Thickness tolerance: -0/+0,3mm Techical data: Density 1,7 g/cm 3 Ball compression hardness 113 Shore hardness D DIN E-Module DIN N/mm 2 Impact tenacity DIN ,5 kj/m 2 Average pore diameter 40 µm Total porosity 26 % Porosity in comparisson to BF 100 AL 600 % Larger sizes available

96 96 WITTE METAPOR TM VACUUM CLAMPING SYSTEMS WITTE - METAPOR CE 100 WHITE Available in following dimensions: No. lxwxh kg x500x10 4, x500x15 6, x500x20 8, x500x25 10, x500x30 12, x500x35 14, x500x40 16, x500x50 20, x500x60 24, x500x70 28, x500x80 32, x500x100 40,0 Thickness tolerance: -0/+0,3mm Technical details on request Witte Metapor CE 100 WHITE is an extremely fine porous material with a pore size smaller than BF 100 or MC 100. The surfaces is white and easily workable. The material on the whole is very homogenous in its porosity. It has proven to be very useful in silicon-wafer production, also as a surface for air handling equipment, where the even distribution of the air flow promotes a vibration free gliding of the glide material. Larger plates (i.e. 1m 2 oder 2m 2 glued plates supplied on request)

97 VACUUM CLAMPING SYSTEMS WITTE METAPOR TM 97 WITTE - METAPOR INOX 100 FE Available in following dimensions: Nr lxwxh kg x500x10 11, x500x15 16, x500x20 22, x500x25 28, x500x30 12,0 Unique porous, corrosion-free steel Porosity lies approx between that of METAPOR BF Al and MC 100 Al. Very good machinability. Also this material retains porosity after dry machining. A special difference to the BF, MC and CE materials is in the substantially higher ball pressure hardness of INOX 100 FE. Especially usable as a base for cutting tables or as a replacement for sinter metal plates x500x35 33, x500x40 44, x500x50 56, x500x60 24, x500x70 67, x500x80 89, x500x ,0 Thickness tolerance: -0/+0,3mm Technical details on request Larger plates (i.e. 1m 2 oder 2m 2 glued plates supplied on request)

98 98 INQUIRY-FORM VACUUM CLAMPING SYSTEMS Inquiry for vacuum equipment: Simply copy this form, complete and return to: Horst Witte Gerätebau Vacuum Clamping Technology Fax +49-(0) Tel: +49-(0) (Overseas) (Overseas) (Europe) Request for: Info Video Quotation on Grid chuck WITTE VAC-MAT TM FLIP-POD TM Slot plate WITTE METAPOR Circular Chucks In order to make a suitable quotation for your application, we need following information: What kind of material(s) are you machining: What size(s) of workpiece are you machining: Type of machining process (i.e. milling incl. speed and feed): How much material is removed: Is vacuum supply available: Do you use coolants: Name Postal code/town Company Street Type of work Tel / Fax

99 VACUUM CLAMPING SYSTEMS TABLES 99 Vacuum conversion table %Vacuum kpa mbar Torr -kpa -mmhg -inhg , , Atmospheric pressure At sea level 0 m 1013 mbar On the Zugspitze 2963 m 695 mbar On Mount Everest 8848 m 330 mbar 1 bar = 10N/cm 2 Formula for determing holding forces The pressure P is the result of the ratio to force F and area A F= PxA = N/cm 2 Example: Vacuumchuck 400 x 600 mm; Vacuum unit with under pressure of 85% Vacuum Whereby A =(40x60) 2400 cm 2 F= 0,85N/cm 2 x2400 cm 2 =2040 N F= P xa = 0,85bar x 2400 cm 2 =8,5N/cm 2 x 2400 cm 2 =24000 N Units: P=N/cm 2 F=N A=cm 2

100 100 APPLICATIONS VACUUM CLAMPING SYSTEMS Vacuum clamping using Alu Flip-Pod TM to hold a Styropor-container Alu Flip-Pod on a CNC controlled deburring machine

101 D E S I G N B Y (H O R S T W I T T E) Witte s registered trade marks : ALUFIX EUROFIX FIXMES POSIFIX MEGALU Gigalu VAC-MAT VACUCOMB 3

102 Aluminium Clamping Systems Alufix Clamping System Alufix XL Clamping System Alufix XS Clamping System FIXinspect Measuring Accessories Alufix Expert Software for automatic fixture designing HORST WITTE GERÄTEBAU HORNDORFER WEG D BLECKEDE TEL. +49 (0)5854 / 890 FAX +49 (0)5854 / info@vakuumsysteme.de