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Fundamentals of Collets and Collet Chucks

2/8/2023

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Technical Blog courtesy of Techniks USA
​
Edited and amended by Bernard Martin
Anatomy Components of an ER Collet
If you work in the metalcutting, signmaking or cabinet making manufacturing industry, the term “collets” is already very familiar to you.

​There are many types of collets used in many different industries and applications. This article is focused on collets used in rotary tool holders found in CNC milling machining centers and CNC Routers and also used in CNC Lathes and Swiss Style CNC's. 
​
 Let's cover the basics:

What are Collets?

Collets are the critical connection between the cutting tool and the tool holder, also called a collet chuck. Most collets are round, cone-shaped, and slotted. Collets encircle the cutting tool shank to evenly distribute holding power around its center bore.
​
Before getting too deep into the technical aspect of collets, It's going to be helpful to anyone new to the use of collets to understand the basic anatomy of collets and of a collet chuck system.

How Collets Work

Component Parts of a collet chuck anatomy
Collet ins depicted being held in a CAT 40 rotary collet chuck toolholder used in CNC milling machines.
The tapered collet base is made to fit into the collet pocket of the collet chuck body. The free release locking tapered (16°included, 8° per side) design of the collet base and collet pocket allows the collet to be centered in the pocket as it is pushed in by the collet nut on the lead face during setup.

This centering effect enables the collet to achieve a high degree of accuracy (concentricity); much more than drill chucks and side-lock style end mill holders.

As he collet nut is tightened down on the collet, it is pushed into the pocket collet chuck pocket.  The slots in the collet allow the I.D. bore to collapse and apply clamping pressure to the cutting tool shank. It's essentially a spring that is compressed tight around the shank of the cutting tool such as a drill or end mill.

​The result is a very strong and rigid clamping force on the cutting tool. Since the collet base is tapered to match the collet pocket, tool runout (T.I.R.) is reduced.

Total indicator runout (TIR) is a term often used in manufacturing, especially when dealing with rotating parts such as cutting tools, particularly endmills and drills. TIR is defined as the difference between the maximum and minimum values measured across an entire rotating surface about a reference axis.
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P3 Coated ER Collet Reduces Friction & Improves Tool Life

3/23/2022

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It’s been estimated that a tool with a run-out of 50% of the tool’s chip load will reduce its tool-life by 40%.

That means that a 1/8” tool with a 0.00019” chip load per tooth will lose 40% of its tool-life with a run-out of less than 0.0001”.
​
Excessive and inconsistent run-out from a properly setup ER collet chuck assembly typically occurs due to friction build-up between the 30° face of the collet and the collet nut.
As the collet nut presses down and turns against the 30° face of the collet, the collet face will tend to twist with the collet nut, distorting the shape of the collet.

​This radial distortion negatively affects tool run-out sine the collet bore is not longer straight.

Parlec’s new  P3 ER collets have a special anti-friction coating on the 30° face that dramatically reduces friction at this critical connection.
ER Collet face area of Friction
Parlec P3 Collet coating area
The result?
  • Improved tool runout
  • Longer tool-life
  • Less frequent tool changes
  • Improved surface finishes

Other Parlec P3 collet advantages:
  • 3 micron T.I.R
  • Fewer slots that standard collets making them more rigid – in the cut!
  • Special slotting seal for coolant up to 2,000 PSI

​Don’t throw away you ER collet chucks to improve accuracy
Try Parlec P3 collets and supercharge your ER collet system.

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Uncoated Import versus Techniks-Parlec PowerCOAT Collet Nuts - Put to the Test

12/7/2021

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Written and edited by Bernard Martin
PowerCOAT Collet Nuts provide up to a 75% increase in holding power!
Techniks PowerCOAT collet nut up to a 75% increase in holding power.
One of the most important elements of the toolholding 'system' is the collet nut. Each toolholder "system" consists of a precision ER tool holder that comes with a special "Power Coated" high power nut that holds tighter than any other nuts.

According to Techniks, the 'Power Coat' nut is the secret to their high holding power. Because it holds so tight, the 'Power Coat' nut improves T.I.R., extends carbide tool life, and improves finish in heavy milling operations.

Techniks recommends that for best results always tighten the nut to the proper torque using a torque wrench with a tightening stand, and never over-tighten the nut because this can damage both the collet and the collet pocket.

To demonstrate the difference between an uncoated and coated collet nut, Mike Eneix, from Techniks did some testing.

He took an uncoated, imported nut and put it to the test against the Parlec PowerCOAT nut. Mike took them to the limit to see which one gives you more holding power.  Check out the video below!

What makes the difference?

As anyone knows who has changed a flat tire on their car, tightening down a nut on a 60 degree thread involves some friction as the mating metal surfaces interact.  That's why nuts can be a bit 'hot' to the touch when you take them off.  The objective with the "Power Coated" nuts was multifold:

First Techniks needed to reduce the coefficient of friction on the thread angle to enable more lubricity for the nut to tighten down farther. As we all know 'heat' causes metal to "grow" so what may at first appear to be tight, in fact, loosens, as soon as you stop tightening it.

Second they needed to make sure that the front surface of the collet that engages the shorter 30 degree taper on the front of an ER collet did not 'twist' as the night tightened down.

Both problems really involved reducing friction and through a combination of engineering tolerances and unique coating process we believe that we've found the most economical solution to eliminate the use of cheater bars and collet over torque. Here's what  they've found  out in testing the "Power Coated" Nuts:

  • Up to a 75% increase in holding power
  • Can extend tool life by 20% by reducing TIR
  • "Engineered" balance for high speed machining

“Power Coat” is an innovative, permanent coating that increases clamping pressure of the nut up to 75% compared to standard ER nuts. More holding power reduces the chance of spinning the shank of the tool inside the collet, which can cause premature failure of the collet.
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INDICATION MARKS ON PULL STUDS ​IS NOT NORMAL

5/25/2021

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by Bernard Martin
There have been some who claim that drawbar gripper fingers and/or ball marks that appear on retention knob head after several tool changes is normal.
Picture
It is NOT.  
​THAT IS FALSE. 
​

According to Haas CNC, ball or gripper marks on the edge of the pull stud indicate that the drawbar does not open completely.

​If you see these indication marks you should check your drawbar and replace these pull studs immediately.

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Don't Take Your Retention Knobs for Granted

2/16/2021

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​by Bernard Martin
Retention Knobs are the critical connection between your machine tool and the tool holder and they are the only thing holding a steep taper tool holder in the machine’s spindle.

​Techniks has recently introduced their MegaFORCE retention knobs that have some rather unique features when compared to standard pull studs.  Before delving into the features of the MegaFORCE pull studs, let's review some things that you may not know, or think about, on a daily basis. 
1 Retention knob pull stud casues of failure

Retention knobs go through thousands of tool changes which means that they are subjected to the very high pulling forces from the spindle’s drawbar.

This force can be up to 2300 ft. lbs. for 40 taper toolholders and up to 5000 ft. lbs. for 50 taper toolholders.
​According to Haas, you should expect a service life of about 6000-8000 hours for a retention knob.  

​Most all rotary toolholder manufacturers state that you should be replacing your pull studs at least every three years.

However, if you're running multiple shifts, 24-7, making lots of tool changes, making very heavy cuts with long reach or heavy cutting tools, and/or have ball lock style grippers instead of collet type grippers used on the retention knob, you will probably need to replace your studs at least every six months.

Given the spindle speeds that we are running at to remain competitive, retention knobs are not an item that you want to take a chance on breaking.  I can tell you firsthand that 5 pound toolholder with a drill in it flying out of the spindle at 23,000 RPM is not something you want to experience. 

METAL FATIGUE: WHY THEY FAIL

Pull studs encounter catastrophic failure as a result of metal fatigue. The metal fatigue can be caused by a number of reasons including poor choice of base material, engineering design, machining process, poor heat treatment, and, sometimes, they have just met or exceeded their service life. We're going to dig into each of these reasons below but first let's look at some threading fundamentals.
The threads on your retention knob will stretch slightly when load is applied and the loading borne on each thread is different.

When you apply a tensile load on a threaded pull stud, the first thread at the point of connection sees the highest percentage of the load.
Percentage of Load on a Retention Knob Thread
Percentage of Load on each thread of a Retention Knob.
The load on each subsequent thread decreases from there, as show in the table. Any threads beyond the first six are purely cosmetic and provide no mechanical advantage. ​

Additional threads beyond the sixth thread will not further distribute the load and will not make the connection any stronger. 

That is why the length of engagement of the thread on a pull stud is generally limited to approximately one to one & a half nominal diameter. After that, there is no appreciable increase in strength. Once the applied load has exceeded the first thread's capacity, it will fail and subsequently cause the remaining threads to fail in succession.

​RETENTION KNOB DESIGN

Repetitive cycles of loading and unloading subject the retention knob to stress that can cause fatigue and cracking at weak areas of the pull stud.

What are the weak areas of a standard retention knob?  ​
For the same reason we put corner radiuses on end mills, sharp corners are a common area of failure for any mechanical device.

​The same holds true with your pull studs:  The sharp angles on the head of the retention knob and at the minor diameter of the threads are common locations of catastrophic material failure.
Retention Knob Metal Fatigue
These are the two weakest points of any retention knob.
The most common failure point for a retention knob is at the top of the first thread and the underside of the pull stud where the grippers or ball bearings of the drawbar engage and draw the toolholder into the spindle.

Remember, bigger Radii are stronger than sharp corners. ​More on that soon.
Styles of Retention Knob for Rotary Toolholders
Styles of MegaFORCE Retention Knobs

MATERIAL

Not all retention knobs are made from the same material, however, material alone does not make for a superior retention knob. Careful attention to design and manufacturing methods must be followed to avoid introducing potential areas of failure.

Techniks MegaFORCE retention knobs are made from 8620H. AISI 8620 is a hardenable chromium, molybdenum, nickel low alloy steel often used for carburizing to develop a case-hardened part. This case-hardening will result in good wear characteristics.  8620 has high hardenability, no tempering brittleness, good weldability, little tendency to form a cold crack, good maintainability, and cold strain plasticity.

There are some companies making retention knobs from 9310. The main difference is the lower carbon content in the 9310. 9310 has a tad more Chromium, while 8620 has a tad more nickel.  Ultimate Tensile Strength (UTS) is the force at which a material will break. The UTS of 8620H is 650 Mpa (megapascals: a measure of force). The UTS of 9310H is 820 Mpa. So, 9310H does have a UTS that is 26% greater than 8620H.

​That said, Techniks chose 8620 as their material of choice because of the higher nickel content.  Nickel tends to work harden more readily and age harden over time which brings the core hardness higher as the pull stud gets older. The work hardening property of 8620 makes it ideally suited for cold forming of threads on the MegaFORCE retention knobs.

​It should be noted that some companies are using H13. H13 shares 93% of their average alloy composition in common with 9310. 

ROLLED THREADS VS. CUT THREADS

5. Cut thread vs rolled thread retention knob
A cut thread, image 1, has a higher coefficient of friction due the the cutting process, while a roll formed thread, image 2, has a lower coefficient of friction which means that it engages deeper into the toolholder bore when subjected to the same torque. You will notice that Cutting threads tears at the material and creates small fractures that become points of weakness that can lead to failure. Rolled threads have burnished roots and crests that are smooth and absent of the fractures common in cut threads.
Rolled threads produce a radiused root and crest of the thread and exhibit between a 40% and 300% increase in tensile strength over a cut thread. The Techniks MegaFORCE retention knobs feature rolled threads that improve the strength of the knob by 40%.  
6. LMT Fette - Thread rolling with F2 Rolling head on CNC lathe
Shown here is a Fette head cold forming a thread. Note how the three roller forms center and maintain near perfect concentricity of the pull stud shaft.
In cold forming, the thread rolls are pressed into the component, stressing the material beyond its yield point. This causes the component material to be deformed plastically, and thus, permanently.

There are three rollers in the typical thread rolling head that maintain better concentricity by default than single point cutting of the threads.

Also, unlike thread cutting, the grain structure of the material is displaced not removed.
Rolled threads produce grain flows that follow the contour of the threads making for a stronger thread at the pitch diameter which is the highest point of wear. 

The cold forming process also cold works the material which takes advantage of the nickel work hardening properties of 8620.
7. Fette Turning Concepts Thread Rolling Magnaflux
Photo courtesy Mike Roden at Fette Tool. www.turningconcepts.com
By comparison, cut threads interrupt the grain flow creating weak points.

MEGAFORCE GEOMETRIC DESIGN

MegaForce Retention Knob features vs standard pull stud
Overall Length
There are some claims that a longer projection engages threads deeper in the tool holder preventing taper swelling. While a deeper thread engagement can help prevent taper swelling, applying proper torque to the retention knob is an effective way to reduce taper swelling.

An over-tightened retention knob may still cause taper swelling regardless of how deep it engages the threads of the tool holder. Additionally, the longer undercut section above the threads presents a weak point in the retention knob.
Blended Radii
With the new Techniks MegaFORCE pull studs, stress risers of sharp angles have been eliminated through the blended radii on the neck where the gripper engages under the head of the pull stud.
9. Techniks MegaFORCE Pull Studs
Ground Pilot
There is a ground pilot, underneath the flange, which provides greater stability. The pilot means the center line of the tool holder and pull stud are perfectly aligned.

Magnetic Particle Tested
Each Techniks MegaFORCE retention knob is magnetic particle tested to ensure material integrity and physical soundness. MegaFORCE retention knobs are tested at 2.5X the pulling forces of the drawbar.
MegaFORCE Technical Specs
  • Material: SAE8620
  • All knobs are case carbrized, hardened, and tempered to:
    • Case depth: 0.025” – 0.030”
    • Surface hardness: HRc 56-60
    • Core hardness: HRc 44 minimum
Torque Specs
The following are the guidelines for torquing your pull studs according to Techniks.
  • BT 30 36 ft. lbs.
  • ISO 30 - 36 ft. lbs.
  • 40 taper - 76 ft. lbs.
  • 50 Taper - 100 ft. lbs.

RETENTION KNOB BEST PRACTICES

In order to maximize the life of your retention knob and prevent catastrophic failure here are some technical tips to keep your shop productive and safe.
  • Regularly inspect retention knobs for signs of wear. Wear may appear as dimples or grooves under the head or visible corrosion anywhere on the retention knob. 
Picture
  • If the retention knob demonstrates any signs of wear replace it immediately
  • Make sure to properly torque the retention knob to the manufacturer’s specifications. Use a torque wrench and retention knob adapter to ensure proper torque. 
  • Overtightening can overly stress the retention knob leading to premature failure and can cause the tool holder taper to swell leading to a poor fit between the machine spindle and the tool holder.
  • Apply a light coat of grease to the retention knob MONTHLY to lubricate the drawbar. If you use through-spindle coolant (TSC), apply grease to the retention knobs WEEKLY.

Special thanks for Greg Webb at Techniks and Mike Roden from Fette Tools/ Turning Concepts, for providing technical insights. 
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NEW ShrinkLOCKED Technology for Shrink Fit Holders to Improve Gripping Power.

8/19/2020

3 Comments

 
by, Bernard Martin
Techniks Shrink Locked Rotary Toolholder
As carbide end mills gain higher and higher speeds and metal removal rates there has also been a trend by round tool manufacturers to tighten up the tolerances on both the cutting diameter and the shank diameter to improve concentricity. At the same time, shrink fit holders have become more and more popular because they hold a tighter concentricity as well.  To achieve this both the shank and the bore now have similar surface finishes and this has led to a problem  The tools pull out in the cut.

Shrink fit holders are the most accurate for TIR as the toolholder engages completely around round shank tools with a bore tolerance of -0.0001" to  -0.0003".  As high performance end mills have tightened shank tolerances to the same range of -0.0001" to  -0.0003" they have used finer and finer grain grinding wheels which give the shanks a 'shiny' appearance. 

Shiny means that the superfinished shank has a lower coefficient of friction. So, although the TIR is tighter, the shank is more "slippery".   End mills traditionally had surface finish of about 8 μin on the tool shank. But that's changed.  It's been recommended that tool shanks used in shrink fit holders should not have a finish finer than 16 μin. for optimum holding power, but tell that to the guy who just superfinished the end mill to a super cocncentric tolerance that you don't want it looking that good.

Everyone knows that the last thing you want is for the end mill to slip in the middle of a heavy cut or on the finishing pass of a high tolerance part.  These 'hi performance' end mills, often times have higher helix angles which are great for ejecting chips but also create a higher pull out force on that slippery shank. And reducing the helix angle is not the answer.

We  already know that the gripping pressure is a function of the interference between the tool shank  and the shrink fit toolholder bore. Most shrink fit holders have a already bore surface finish of between 12 μin. and 16 μin.  So they are ground to a very high tolerance and have about the same surface finish as the toolholder shank.

End mill manufacturers and machinist have tried a variety of methods over the years to stop the tools from pulling out. This has ranged from grit blasting the shank to rubbing chalk on the shank, but most everyone in the industry has felt that the problem really needs to be addressed by the longer life toolholder rather than the replaceable cutting tool.

That's the problem that Techniks wanted to address. Techniks claims that their "proprietary non-slip TTG594 compound virtually fuses the tool shank with the shrink fit toolholder."

ShrinkLOCKED Toolholders eliminate cutting tool pull-out and provide 4X the friction drive force compared to un-treated shrink holders.
  • No modifications to your tool holder required.
  • Increase productivity with higher feed rates.
  • No impact on concentricity.
Shrinklocked Shrink Fit diagram
It’s not just a rougher bore finish that enhances the holding power. TTG-594 is a compound that has a much higher Brinell hardness than carbide so it can “bite” into the tool shank. But this does not affect the ability to perform tool changes.

Techniks arrived at their 4x the holding power comes from torsion testing vs. a standard shrink fit toolholder. They used a ¾” carbide gage pin in a standard holder and found the torque at which the tool will spin in the bore.

They then tested the ShrinkLOCKED holder using the same test.

According to Greg Webb, at Techniks,
"We actually could not find the point at which the tool would spin in the ShrinkLOCKED holder as we broke the carbide gage pins at 4x+ times the torque of the standard holder. The holding power is greater, we just have not found a way to measure this, so we kept our claims conservative at 4x."
Shrink-locked Techniks
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Rotary Toolholder Maintenance Best Practices

8/12/2015

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Picture
In order to get the maximum life out of your Steep taper rotary toolholders in your CNC milling machines, follow these best practices that you can implement in your shop.  Perhaps not all of them can be implemented every day or every time but it's well worth being aware of how to best protect your investment.
  • Remove the toolholder from the Spindle after each usage.
  • Clean the taper and the holder with a an air blast to remove any fine chips or dirt that may be adhering to the holder.
  • Wipe the holder with a clean shop rag.
  • Spray the holder down with anti-rust lublcricant.
  • Put the holder in an antitrust bag.
  • Place the holder in the proper storage rack for that type of holder. 
  • If you are not going to be original shipping container using it again for some time, store it in the original shipping container
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Choosing the right ER Collet Chuck Size

11/13/2013

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Collet Chuck Size
We often get asked to spec out tooling packages for new CNC mills and one of the questions we encounter most, or should, is how do you select the right toolholder collet size for your companies applications?  The real choice is in the size of the collet chuck itself. So several considerations should be reviewed...

What size are your tools?
Your first consideration should be the size of end mills or drills you will be using most often. If you are doing smaller work you would require smaller diameter range collets. Generally you may prefer the ER16 and ER32 sizes.

If the bulk of your tool requirements are in the mid range you can also use the ER20. The following is a list of tool diameters that can be used with each size collet chuck. Essentially, the most popular, and again, readily available from a number of sources, are the ER 16, ER20, and ER32... in no particular order.
  • ER11 0.019" - 0.275"
  • ER16 0.019" - 0.393"
  • ER20 0.039" - 0.511"
  • ER25 0.039" - 0.629"
  • ER32 0.078" - 0.787"
  • ER40 0.118” - 1.024”
If you need more detailed list of dimensions can be found at these links: 
  • ER Collet sizes Inch (Imperial)
  • ER Collet Sizes Metric
Picture
How far do you need to reach?
A second consideration is the actual reach of the tool. Not projection reach, also know as “gage length” "l1" but projection diameter “D”.  

Obviously, stubbier is better for projection reach "L1". But, you also need to review the families of parts that you intend to run on the machine.

If you intend to use the holder to "reach" into a tight fit then the OD of the projection "D" of the toolholder needs to be considered.

Many shops don't always consider this and end up using much longer carbide shanked end mills to get into deep pockets when getting a smaller diameter ER collet and collet chuck would be much less expensive over the life of the job.
Picture
Here is a list of the OD projection diameters:
  • D=ER11 0.748" (19mm)
  • D=ER16 1.259" (32mm)
  • D=ER20 1.338" (34mm)
  • D=ER25 1.653" (42mm)
  • D=ER32 1.968" (50mm)
  • D=ER40 2.480" (63mm)
Sometimes there is just no getting around having a custom tool made. Give us a call at 916.765.4227 or email us if you just can't seem to reach into the part with your toolholder. 
Picture
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    Technical Support Blog

    At Next Generation Tool we often run into many of the same technical questions from different customers. This section should answer many of your most common questions.

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Established 1995
​

Next Generation Tooling
10240 Cavalletti Drive
Sacramento CA 95829
916.765.4227
Northern California
23 Maxwell Street
Suite B
Lodi, CA 95240
Southern California
22343 La Palma Avenue
​Suite 126
Yorba Linda, CA 92887
© 2023 Next Generation Tooling, LLC. 
All Rights Reserved
Created by Rapid Production Marketing

Find us on Instagram @nextgentool

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