For manufacturers faced with the challenge of machining hard and brittle materials or companies with difficulties undertaking micromachining operations, Hyfore Workholding has now introduced a new range of ultrasonic tool holders. Manufactured by Acrow and available through Coventry based Hyfore, the exciting new ultrasonic tool holders are ideal for machining everything from carbide and PEEK through to Zirconia, Sapphire, SiC, AlSiC, Quartz, Boron Nitride and many more.

The ultrasonic tool holders can be retrofitted to virtually any machine tool and by utilising ultrasonic vibrations that resonate at a frequency range of 20 to 60kHz, the cutting tool oscillates in an upward and downward motion at a frequency of beyond 20,000 times per second. For the end-user, this high-speed frequency exceeds the frequency of sound waves and it can significantly improve tool life and machining performance whilst demonstrating astounding surface finishes on the most difficult materials known to the industry.

The impressive new system incorporates an ultrasonic generator with automatic frequency detection and tracking unit that is located outside the machine and is connected to an ultrasonic tool holder. The externally connected generator has a 24kHz frequency with 30W auto frequency tracking that generates a high-power output that is rigorously designed for machine shop environments. This generator is suitable for high precision continuous operations with its integrated electronic circuitry and the ability to automatically switch power supply for AC100-240V and 50/60Hz.

Connecting to this externally positioned generator is an ultrasonic tool holder that is available to suit most machine tools with BT30, BT40, HSK63A, CV40 and DV40 connections available. The ultrasonic tool holders have a maximum weight of 2.4 to 3.4kg depending on connection type and it is recommended the spindles run at a speed of up to 6,000rpm with a maximum runout of <5microns. With a frequency of 24kHz and an amplitude range of 2-10microns, the high-frequency vibration of 24,000 times per second equates to a machining speed of a staggering 240,000rpm.

Oscillating at such a high frequency, the Acrow ultrasonic spindles from Hyfore Workholding eliminate the need for specialist high-frequency machine tools for processing the most challenging materials in the industry. Despite being a specialist product application, the Acrow ultrasonic spindles facilitate through spindle coolant and can also work with automatic tool change units, making the system suitable for most machine tools.

This versatility affords any of your machine tools the ability to machine Monocrystalline silicone and ceramic packaging materials used in the semiconductor industry, optical display panel machining and LED substrate machining as well as ceramic bearing, brake pad, cylinder liners and injection nozzles in the automotive industry. The spindles are also ideal for composite, honeycomb and titanium machining in the aerospace sector; ceramic teeth, bone screws and more in the medical sector and it is the perfect problem solver for manufacturers in the micromachining and jewellery industries. If you have an unfathomably difficult material that needs machining and you don’t know what to do, it’s time to ask the experts at Hyfore Workholding.

As well as providing groundbreaking solutions such as the ultrasonic tool holders, Hyfore Workholding is also the UK’s leading supplier of standard and specialist workholding solutions as well as the industry’s leading bespoke workholding, clamping and automation experts. With an internal team of design engineers and a state-of-the-art manufacturing facility, Hyfore has a team of 30 engineers that can go above and beyond your requirements to engineer, implement and prove out a workholding, fixturing, jig or clamping system and even automate the solution to meet the exact needs of your business. So, if you want something as simple as a tool holder or vice through to specialist products like the ultrasonic tool holders or even bespoke hydraulic workholding systems – it’s time to call Hyfore.