TRP Sealing Systems is a specialist in the supply of seals, gaskets and technical mouldings, and the Hereford-based company has invested in the first Wele bridge-type machining centre in the UK in support of its work, supplied by 2D CNC Machinery.
TRP had no doubt that magnetic workholding was key to the success of its purpose-refurbished toolroom, since the method clearly provided a quick, secure, and accurate method of clamping. But Eclipse Magnetics had the job of proving that it was an effective method of securing both the large steel plates and existing moulds in a known and repeatable position, for both manufacture and refurbishment.
The moulds are manufactured from steel plate and range in thickness from 16 to 30 mm. Plate dimensions range from 860 by 830 mm up to a massive 3,900 by 1,750 mm. The key to manufacture is to ensure that the plates are held flat during machining so that opposing faces are parallel, while also providing clearance off the table for back chamfering.
The solution was the Power Matrix permanent electromagnetic chuck; a bed of magnets supplied in 14 sections.
The overall size of the Power Matrix milling system is 4,000 by 2,000 by 66 mm high and the system includes controls for selectable zones. It allows five-side access to the workpiece, as well as consistent, uniform clamping over the entire workpiece delivered by high intensity neodymium magnets.
But in addition to this base requirement of flat clamping and repeatable positioning, the system also provides reduced vibration and chatter, extends tool life and also significantly improves surface finish.
Says John Urbanski, engineering manager at TRP Sealing Systems: “The Power Matrix has enabled us to not only reduce our set-up time significantly, but also to ensure that the tool manufacture is of the highest quality possible. We were able to collaborate effectively with Eclipse Magnetics to ensure that the installation process was swift and efficient; everything went like clockwork.”
