Machines have revolutionized the job, and there is a machine for almost every industrial job you can think of. The use of heavy machines in the manufacturing industry has been the biggest breakthrough for the manufacturing processes. However, when you are working with different kinds of machines, it&#;s important that you know about every part and function of a machine. When we talk about machines, the shift from manual machines to CNC machines
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has also been a big miracle and convenience for the industry. The CNC machines work on pre-programmed software that gives instructions to the machine and works on the workpiece installed. CNC machines have a wide range of applications in the manufacturing processes of almost all industries.
There are several parts of machines, some installed externally while others attached to them permanently. Chuck is also a part of machines like milling machine, drills, etc., which holds the object of radial symmetry during the process. A chuck looks like a clamp, and it serves different purposes in different types of machines.
There are several types of chucks: collet chucks, electrostatic chucks, vacuum chucks, safety chucks, and magnetic chucks. In today&#;s article, we will talk about magnetic chucks for CNC machines, magnetic chucks for milling machines, and their application on CNC machines by magnetic chuck type. So let&#;s get into it.
As the name suggests, the magnetic chucks use magnetic force from permanent magnets and clamp the workpieces for secure processing. Magnetic chucks are an alternative to traditional chucks installed in different types of machines. These chucks have a consistent clamping pressure that leads to no variations in the holding of the workpiece. Therefore, the technicians&#; working safety, the machining, and the work&#;s accuracy are achieved with magnetic chucks.
The modern alternative to traditional chucks has a magnetic conductive panel, and when the metal workpiece comes in contact with the panel surface. The magnetic chuck sucks it, and the workpiece remains intact. The use of magnetic chuck is very common for surface grinders. But with time, its applications have also extended to CNC machines, machining centers, and lathes.
One specific thing about magnetic chucks is that you can only work on ferrous metals when using them, as they can hold ferro-metallic workpieces. The magnetic chuck generally comprises a plate, an electromagnet, and a controller. It transforms a magnetic field to attract the ferrometals. When the material comes in close proximity, it gives a clamping effect.
2. Types of Magnetic Chucks
A magnetic chuck has several further types having specific applications. Following are the types of magnetic chucks:
Electromagnetic chucks
Permanent magnetic chuck
Electro-permanent magnetic chuck
Each type of magnetic chuck has a different use, holding strengths, and working principles. You will have to choose the right type of magnetic chuck depending on the machine and your requirements. To know more about the types of magnetic chucks, their working principles, and applications, check out:
Everything You Need To Know About Magnetic Chucks
3. Types Of Magnetic Chuck Based On Application
We already discussed the purpose of magnetic checks, their working principle, and different types of magnetic chucks used in different applications. However, we still need to explore the magnetic chucks for CNC machines based on their application in each machine. So, here are the types of magnetic chucks based on their applications for different machining processes.
3.1 Magnet Chuck For Grinding Machine
As mentioned earlier, grinding machines have the most extensive application of magnetic chucks. Whether you want to grind tiny, thin, or large parts of the workpiece, magnetic chucks provide accuracy and efficiency in performing the process.
The compact clamping surfaces of the magnetic chucks make it feasible for a variety of workpieces. The electromagnetic chuck is the most feasible type of magnetic chuck for surface grinders and grinding machines.
You can check out the GME Magnetic Chucks for Grinding Machines here. The disk clamping tools are fast, accurate, and highly efficient in reducing labor costs and saving production costs.
The magnetic chuck for surface grinders can work on the workpieces with five faces and larger workpieces. The strong and uniform magnetic force of the chuck allows high-precision processing. You can check out the Surface Grinder Magnetic Chuck by GME Magnet here.
3.2 Magnet Chuck For Milling Machine
Magnetic chucks are also used in CNC milling machines. A milling machine is used to remove material from a workpiece. The cutting tool is rotated and moved into the workpiece to get rid of extra parts. The milling machines can be used for drilling, boring, cutting gears, threads, etc.
The purpose of a magnetic chuck for a milling machine is to perform the desired operations on the workpiece. The magnetic chuck used for milling machines allows for achieving machining accuracy and precision in chip removal from the workpiece. According to an estimate, using a magnetic chuck for a milling machine can improve machining efficiency by 30-60%. Not only this, but the service life of the milling machine also increases with vibration-free operations.
3.3 Magnet Chuck For Lathe Machine
A lathe is also a machining tool for rotating workpieces about the axis of rotation for different machining operations like sanding, deformation, facing, drilling, cutting, turning, etc. Magnetic chucks are used for lathe machines as it is very important in holding short workpieces as well as the ones with large diameters as done in the lathe.
In the lathe machine, the magnetic chuck provides a consistent clamping pressure, thus not allowing it to be too loose or too tight to get accurate machining. The magnetic chuck blocks are added when needed in the lathe to get accurate and consistent machining. For instance, in the turning operations, the workpiece is rotated in a lathe, and the cutting tool moves linearly to remove chips along the diameter.
4. Advantages Of Magnetic Chucks
The pros and cons of using varying magnetic chuck types differ from each other due to different specifications. Therefore, we will overview the benefits of each magnetic chuck type:
4.1 Permanent Magnetic Chuck
1. You don&#;t need electric power to clamp with the permanent magnets
2. No heat generation when clamping with a permanent magnet, so you don&#;t have to worry about workpiece or pole plate deformation
3. Easy to install and move from machine to machine for different processes
4.2 Electromagnetic Chuck
1. You can operate the electromagnetic chuck with control units and regulate the holding force, demagnetizing cycle, etc.,
2. There is less internal wear and tear since no moving parts are inside the electromagnetic chuck.
3. Has a very good magnetic force that gives a strong clamping on rough workpieces
4. You can produce various dimensions for the chuck to meet different workpiece size requirements.
4.3 Electro Permanent Chuck
1. No electric power is needed for general processing but only for magnetization and demagnetization.
2. You can control the operations with a control unit that allows automated use.
3. Minimal electricity use with greater safety
4. You get access to five sides of a mold, making it ideal for multi-side milling machines.
5. No heat generation and hence, no deformation of the pole plate or workpiece
5. Disadvantages Of Magnetic C
huck
Like everything has certain advantages, there are certain downsides as well. So here are the disadvantages of magnetic chuck types:
5.1 Permanent Magnetic Chuck
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1. You can&#;t work in multi-dimensions with the permanent magnetic chuck making it unsuitable for heavy and bigger workpieces.
2. The useful life is shortened due to internal wear and tear of moving parts
3. You can&#;t use the chuck for any component with a temperature above 80&#;
4. Automated work can&#;t be done due to mechanical switching
5.2 Electromagnetic Chuck
1. High electricity usage as a constant power supply is needed for machining
2. The backup power supply is often needed for safety purposes; any power failure might cause the chuck to release parts leading to an accident
3. Heat generation leads to deformation and distortion of the parts, eventually affecting the machining accuracy
5.3 Electro Permanent Chuck
1. The costs of electro-permanent chucks are on the higher side when compared with permanent magnetic chucks.
2. These magnets are highly sensitive to air gaps between the workpieces and chucks.
3. Fine-tuning the magnetic field and clamping force with electro-permanent magnets is difficult.
6. How To Buy The Best Magnetic Chuck For CNC Machines Applications?
Now you know how magnetic chucks are used in different machining operations for different CNC machines and machining centers. Unlike popular belief, the strongest magnetic chuck is not always the best for a specific workpiece holding job. Depending on the machine, the magnetic chuck type is chosen and employed.
Therefore, we will guide you on how to buy the best magnetic chuck for a CNC machine, depending on the operations you want to perform. When you&#;re selecting the magnetic chuck type for the specific job, here are the considerations you need to keep in mind regarding the type of chuck:
6.1 Material Of The Workpiece
First things first, the material of the workpiece under operation is most important when choosing a magnetic chuck. Generally, magnetic chuck is preferred for ferromagnetic materials that are easily sucked by the magnet. When you&#;re working with low-carbon steels, the magnetic field is the strongest between the chuck and metal. However, a stronger clamp is needed in the case of high-carbon or alloy steels since more non-magnetic elements are present in them.
6.2 Magnetic Chuck For CNC Machines Varying In Operations
The second most important consideration when choosing a magnetic chuck for CNC machining operations is the operation type or machines used.
6.2.1 Milling
All-purpose magnetic chucks are commonly used for milling operations. The magnetic chuck you choose also varies depending on the size of the workpieces you&#;re working on within each type of operation.
6.2.2 Grinding
For grinding machines and surface grinding, electromagnetic chucks are usually preferred. However, the number of plates included in each chuck depends on the grinding operations. For instance, heavy-duty grinding requires a strong magnet with a robust build to hold the workpiece.
Similarly, precision grinding requires magnets that do not heat up to deform the workpiece. Therefore, electro-permanent magnets are usually considered the best option for precision grinding. For instance, you can check out our High Precision Electro Permanent Magnetic Chuck.
6.2.3 Lathe Turning
Usually, round magnetic chucks are preferred in lathe turning as they provide free access to the workpiece from all five sides giving full freedom and eliminating the need for reclamping again and again. You can check out our Radial-Pole Magnetic Round Chuck for turning operations in the lathe machine.
6.2.4 Precision Machining `
As already mentioned, precision machining is done best with electro-permanent magnetic chucks. Therefore, you should prefer them when making a choice for precision machining.
6.3 Thickness Of Workpiece
The choice of magnetic chuck also varies depending on the thick or thin workpiece. When you&#;re working with extremely thick workpieces as thin as 4mm, you might need a custom-made chuck for clamping. A standard magnetic chuck has enough strength to clamp a workpiece as thin as a 12mm cross-section. Besides, look for magnetic chucks with denser poles to clamp thin workpieces safely.
6.4 Shape Of Workpiece
What is the shape of the workpiece you&#;re working on?
If you&#;re working on the circular workpiece, the choice of magnetic chuck type shifts to round chucks. For instance, machining saw blades, cylinders, and ring bearings require round magnetic chucks for proper clamping. Besides, these chucks allow multiple machining operations to be done simultaneously.
6.5 Surface Of Workpiece
The surface of the workpiece you will work on is also an important consideration when choosing a magnetic chuck. If you&#;re going to work on an even, clean, and flat workpiece, it will be easier for the magnetic chuck of medium magnetic force to clamp it securely. However, if the workpiece is perforated, has several openings, uneven surfaces, additional layers like polish, paint, etc., or impurities, the holding force of the magnet decreases.
Therefore, depending on what kind of piece you&#;re working on, check the magnetic force of each magnet individually before buying it. You can also get guidance from the experts to choose the right magnetic chuck for the CNC machines.
6.6 Even Vs. Uneven Workpieces
The workpiece&#;s evenness also matters when choosing a magnetic chuck for CNC or milling machine. Even surfaces can be worked on with normal magnets, but uneven surfaces require stronger magnets for secure clamping. In fact, in most cases, you have to even out the uneven workpieces before they&#;re clamped with a magnet.
You need magnetic chucks with firm and flexible pole extensions to work best on uneven workpieces. The flexible pole extensions copy the shape of the workpiece, and firm extensions give a reference level making the workpiece perfectly even to work on.
6.7 Considering The Magnetic Chuck Type
Besides all the considerations about the CNC machines and material specifications, understanding the magnetic chuck types and choice for different cases is also important to know which magnet you will use for the machining process.
1. Electropermanent magnets have the highest strength and can be used to work on a very broad range of materials. Whether you want access to the workpiece from all five sides or want thru-hole machining, the design of electro-permanent magnets gives high accuracy.
2. Electric magnets are best for surface grinders and grinding machines with variable settings and decent holding power.
3. The permanent magnet fine pole allows a low magnetic penetration to the workpiece you&#;re working on. Therefore, you can easily work on the thinner workpieces without any side effects on sinker EDM operations.
4. The permanent magnet standard pole has a deeply penetrating magnetic circuit, thus maximizing the holding power.
7. Get An Instant Quote
We have guided you about magnetic chuck types and different magnetic chucks for CNC machines you can choose for machining processes. You know how the magnetic chucks vary depending on the machining process, and you can get instant quotes from GME. We have highly developed QC procedures and state-of-the-art testing devices to meet high-quality standards and compliance with customers&#; requirements. The global supplier of industrial magnets and magnetic solutions has got the right experts to help you find the right solution for your business needs.
Give us a call and get the right people on your side for the best solution!
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