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Clamping Products For Use On Machines And Fixtures |
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The KOSTYRKA® clamping sleeves are based on the idea of creating a shaft-hub joint actuated by adherence, thus supporting very efficiently the function of modern machine tools. The clamping elements should be able to transmit great forces, to open and to close with lightning speed and be program-controlled as well as to have a space-saving overall size. Hydraulic oil presented itself as the ideal pressure medium. A flexible metallic cylinder should be the load transmission element. Unfortunately a solid metal construction turned out to be to inflexible and a plastic jacket by itself as not resistant enough. Only the combination of a suitable synthetic material and a slitted metal cylinder resulted in the wanted success. |
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Principle of function: |
- Cylindrical clamping sleeves
- Flange type clamping sleeves
- Expanding type clamping sleeves
- Clamping rings
- Clamping strips
- Clamping discs
- Clamping cassettes
- Flexible tooling
- Hydraulic pressure intensifier
- Screw pistons
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KOSTYRKA® system slitted clamping sleeves have been approved elements since 1969 for over 200 000 applications on machines and fixtures. They secure with high clamping force pins, spindles, quill shafts, columns and piston rods.
How they work
Within the sealed space enclosed by the plastic jacket surrounding the slitted metal sleeve, hydraulic pressure is built up which converts directly and without loss of efficiency into radial acting clamping force. Clamping action is reaction-free, i.e. no axial displacement and no revolving motion of the workpiece takes place during the clamping process. KOSTYRKA® clamping sleeves are produced as a standard range with internal diameter between 10 and 150 mm (0.4–6 in.) by from 40 to 140 mm (1.6–5.5 in.) long, for operating pressures up to 450 bar (6500 psi). Other sizes are special sleeves and are available on request. |
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These sleeves absorb not only axial, but also tangential forces. They centre the parts without any tendency to axial movement and they develop extremely high forces in a very small space. Flange Type Clamping Sleeves are produced with clamping diameters up to 1200 mm (approx. 48 in.) and with an overall length of up to 750 mm (approx. 30 in.).
If KOSTYRKA® clamping sleeves are to be used not only to transmit axial forces but also to transmit torque, they must be provided with a flange ring. The method of operation, materials, operating conditions and general tolerances of the flange type clamping sleeves correspond to those of the cylindrical clamping sleeves.
KOSTYRKA® flange type clamping sleeves are only made to meet particular requirements, and are not produced as standard series.
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Expanding type clamping sleeves
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Expanding Sleeves, system KOSTYRKA®, were specially designed for clamping of turntables and dividing heads. The remarkable features of these sleeves are the high transmittable torque and the variety of applications. Based on the reversion of the functional principal of the Clamping Sleeves, the slitted housing of the Expanding Sleeves will be extended by the hydraulic pressure and thereby the circulating table will be clamped. As with all KOSTYRKA® Clamping Sleeves this kind of use is an important feature too, the table does not move during clamping. As the dimensions of the Expanding Sleeves depend on the required stress and the different kinds of usage a stock of standard sizes is impossible. Please contact us.
KOSTYRKA® expanding sleeves were developed specially for clamping turntables and dividing units.
Based on the inverse of the clamping sleeves’ functional principle, the expanding sleeve’s slotted jacket is expanded by oil pressure. Thus the surrounding table, for example, is gripped from inside. As with all the KOSTYRKA® clamping sleeves, an important feature here is that the table has no rotational movement as clamping is applied.
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The multiple tried and tested new KOSTYRKA® Clamping Rings represent highly efficient and extremely compact constructional clamping elements. They are used for clamping in general mechanical engineering as well as for parts of couplings and brakes.
Function: The ring, made from bronze with particularly good elastic properties and skilfull profiling, is expanded by oil pressure and returned to its original position when the pressure is released.
Since the form of KOSTYRKA® Clamping Rings is exclusively directed towards customer-specific requirements and situations, here, too, it is not possible to stock standard units. |
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Instantaneously acting and powerful, the hydraulic actuated Clamping Strips system KOSTYRKA® are used in machine tools, machining units, pallets and other machinery where a slide way must be locked during machining.
Clamping Strips are compact, require little space and act instantaneously with solid locking. When depressurized, KOSTYRKA® Clamping Strips apply no load or friction to the Slideways. Various design options are available: Spring-loaded retraction, chamfered end ramps and mounting brackets. Furthermore complete clamping cassettes (see picture above right) are also available. As there are hardly any limits to design potential we have only a small number of standard sizes in stock while the special sizes depend on demands by customers. Please do not hesitate to ask us. We help to solve your problems.
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The Clamping Discs operate in the same way as the Clamping Strips and are very effective in locking Slideways, pallets and supports.The essential advantage of this Clamping Disc is its compact design. Hydraulic pressure up to 250 bar allows a clamping force of up to 8.000 N per Clamping Disc with an efficiency of 99%.
Method of Operation
When pressure is applied, the KOSTYRKA® Clamping Discs are forced out of their housing like a piston, place themselves onto the component to be clamped and clamp it firmly, as determined by the amount of the oil pressure. After the oil pressure has completely released, the Clamping Discs ”spring” back approximately 0.01 mm (0.0004 in.), without the seal moving in the location hole. This feature eliminates wear and tear on the seals and assures long and trouble-free operation.
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Unfavourable space conditions can have the result of making the direct mounting of the necessary tensioning or clamping elements difficult, if not impossible.
With KOSTYRKA® Clamping Cassettes – in which the power-transmitting Clamping Strips are already integrated – an additional attachment is made possible. Especially with KOSTYRKA® Clamping Cassettes the retrofitting of old machine tools onto modern, more effective clamping elements is made significantly easier. Since the form of KOSTYRKA® Clamping Cassettes is exclusively directed towards customer-specific requirements and situations, it is not possible to stock standard units. Please make an inquiry if interested. |
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| Universal Holding Fixtures (UHF) avoid the high costs, single purpose fixtures and long set-up times traditionally required for holding large, contoured and/or variable geometry parts and structures. This paper describes some unique solutions of passive and active holding fixtures used in the aircraft-, aerospace and defense-industry for cutting, drilling, milling, riveting and assembly purposes. The Universal Holding Fixtures shown in this technical paper allow a high density of jack posts and withstand very high axial and radial loads without deflection. The active UHF systems concentrate on highly accurate solutions and „smart“ vacuum cups incorporating „intelligent“ features. |
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Hydraulic pressure intensifier
| Even modern machine tools often have insufficient non-optimal hydraulic pressure. But clamping devices for guideways used at machine construction as well as clamping and support elements used at hydraulic actuated devices often require higher accumulator pressure than the available working pressure from the machine tool. In some cases only pneumatic pressure is available.
The solution: |
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| Screw Pistons system KOSTYRKA® are mainly integrated direct into bores of machines and fixtures housing. Screw Pistons are also delivered as complete Hydraulic Pressure Generator resp. Screw Pumps. |
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