Basic Workholding Techniques

Basic
Workholding
Techniques
Hardinge Inc.
One Hardinge Drive
Elmira, New York 14902
Phone: 800-843-8801
Fax: 607-734-3886
www.hardingetooling.com
Introduction
The "Basic Workholding Techniques" brochure is meant to be a resource for your
tool box, your desk or your reference library. It contains basic material that will
assist the new machinist or production engineer as well as the veteran looking for
a source on practical workholding techniques.
We hope that you find some new ideas to help you improve your productivity and
make your job easier. If you find that we have omitted some material or if you
have a better explanation of a particular process or idea, please let us know.
A companion publication "Precision Length Control" (2285) will help you with
length control techniques related to draw-in collets and step chucks. We hope
you enjoy "Basic Workholding Techniques".
NOTE: Information in this document is subject to change without notice.

In no event will Hardinge Inc. be responsible for indirect or consequential
damage resulting from the use or application of any of the information contained
in this document.
Table of
Contents
Basic
Collet
Introduction
CHAPTER 1
Basic Collet Configurations ......................................................... 8
Basic Collet Introduction ............................................................. 9
Head Angles ................................................................................ 9
Lathe Collet
Stationary Collet
Tool Holder Collet
Back Bearing ......................................................................... 9, 10
Stationary Screw Machine Collet .............................................. 10
Slot Design .......................................................................... 11, 12
Straight
Relief Hole
Tear Drop Relief
Double Slot
Angular
Zig-Zag
Reverse Tear Drop (Over-The-Shoulder Collet)
Collet
and Closer
Systems
CHAPTER 2
Draw-In Collets .......................................................................... 14
Push-Out Collets ....................................................................... 15
Push Sleeve (Stationary) Collets .............................................. 16
Toolholder Collets ..................................................................... 16
Actuating the System ................................................................ 17
Air-Operated Mechanical Closers ....................................... 17, 18
Pneumatic Closers .............................................................. 18, 19
Hydraulic Closers ...................................................................... 19
Machines Using Various Systems ............................................. 20
Types of
Collets
CHAPTER 3
Types of Collets ........................................................................ 22
Concentricity
and Spread
CHAPTER 4
Spindle Concentricity ................................................................ 25
TIR Spindle ............................................................................... 25
TIR Back Bearing ...................................................................... 25
Thread Run-Out & TIR .............................................................. 25
What is Spread .......................................................................... 26
Grind Outs ................................................................................. 26
Cam Grind ................................................................................. 27
Flat Grind .................................................................................. 27
Extra SpreadOver the Shoulder Collets ................................ 28
FormulaMaximum Opening for Over Shoulder ...................... 28
Collet
Hardness
and Wear
CHAPTER 5
Advantages of Hardened Collets .............................................. 30
Problems Caused by Improper Hardness ................................. 30
What Causes Collets To Wear Out .................................... 30 - 33
Wear: Illustrations of Causes .............................................. 31, 32
Wear: Multi-Spindle Automatics .......................................... 31, 32
Other Causes for Wear ............................................................. 33
4
Table of Contents
Materials
Held by Collets
CHAPTER 6
Charts .............................................................................. 36 - 38
Collet
Capacity
CHAPTER 7
Chucking Diameter Chart .......................................................... 40
Collet Capacities ....................................................................... 40
Collet: Correct Size ................................................................... 40
Oversize ............................................................................. 41
Undersize ........................................................................... 41
Extra-Extra Spread Collet ......................................................... 42
Four Split-Long Bearing ............................................................ 42
Angular Slotted .......................................................................... 43
Zig-Zag Collet ............................................................................ 43
Serrations
CHAPTER 8
Reasons for Serrations ............................................................. 46
Flat Serration ............................................................................. 46
Tap Serration ............................................................................ 46
Circular Serration ...................................................................... 46
Saw/Buttress Tooth Serration ................................................... 47
Diamond Serration .................................................................... 47
Last Serration ............................................................................ 47
Hex & Square Serrated Collets ................................................. 47
Disadvantages .......................................................................... 47
Concentricity
and Gripping
Force
CHAPTER 9
Order Hole (Collet Bore) ........................................................... 50
Smooth Bore ............................................................................. 50
Serrated Bore ............................................................................ 50
Diameter of the Order Hole ....................................................... 51
Bar Work ............................................................................. 51
Maximum Grip .............................................................. 51
Ground Rod & Tubing .................................................. 51
Best Concentricity ........................................................ 51
2nd Operation Work ........................................................... 52
Best Concentricity ........................................................ 52
Results of a Large Order Hole ..................................... 52
Results of Undersize Collet .......................................... 52
Length of Bearing ...................................................................... 53
Short Bearing ............................................................................ 53
Split Bearing .............................................................................. 53
Extended Nose Collet ............................................................... 53
Number of Slots .................................................................. 54, 55
Micro-Finish of Order Hole ........................................................ 56
Cloverleaf Grind ........................................................................ 56
Basic Workholding
Techniques
Expanding
Collets
CHAPTER 10
Expanding Collets ..................................................................... 58
Preparing the Blank ................................................................... 58
Reasons for Out-of-Round Blanks ...................................... 59, 60
Styles
Spindle-Mounted ................................................................ 61
Basic Parts ............................................................. 62, 63
Work Locating Stops .................................................... 63
Advantages .................................................................. 64
Special Considerations ................................................ 64
Master Expansion Collets ................................................... 65
Parts ....................................................................... 65, 66
Collet Pads ................................................................... 67
Advantages .................................................................. 68
Special Comments ................................................. 68, 69
Small Diameter Work ................................................... 69
Other Styles ........................................................................ 69
Master
Collets and
Feed Fingers
CHAPTER 11
Major Classifications ................................................................. 72
Master Collets ..................................................................... 72
Advantages/Disadvantages of Master Collets/Pads ................. 72
Style S Collet ............................................................... 72 - 74
Style S Pads ................................................................. 74, 75
Martin Collets ...................................................................... 76
Martin Pads ........................................................................ 77
CT Collets & Pads .............................................................. 78
CB Collets & Pads .............................................................. 79
New Britain Collets & Pads ................................................. 80
Standard Master Collets & Pads ........................................ 81
Manufacturing of Hex and Square Pads ............................. 82
Master Feed Fingers
Style "B" .................................................................. 84, 85, 86
BX/DX Adjustable ............................................................... 87
AF Adjustable ............................................................... 88, 89
Style "A" .............................................................................. 90
Adjustable Feed Fingers
Dial-Adjustable ............................................................. 92, 93
Squirrel Cage ................................................................ 94, 95
Stock Saver ........................................................................ 95
Solid Feed Fingers
Standard Solid Feed Finger ................................................ 96
Brazed On .......................................................................... 97
Milled Through .................................................................... 98
Bar Stock Puller .................................................................. 99
6
Table of Contents
Chucks
vs.
Collets
Bar Stock
Pullers
Parts
Loading
and
Unloading
CHAPTER 12
Reasons For Selecting
Chucks .............................................................................. 102
Collets ............................................................................... 103
Reasons for Switching to Collets ............................................ 103
Chucks
MechanicalManual ........................................................ 104
Pneumatic ......................................................................... 105
Hydraulic ........................................................................... 105
Electro-Magnetic ............................................................... 106
Vacuum ............................................................................ 106
CHAPTER 13
Bar Pullers ............................................................................... 108
CHAPTER 14
Rotating Parts Loader ..................................................... 110, 111
Basic Workholding
Techniques
R D I N GE
A
H
CHAPTER
ONE
O
DE
SI Z
BASIC
COLLET
INTRODUCTION
CHAPTER 1
Basic Collet Introduction
THREAD
HEAD
ANGLE
KEYWAY
R D I N GE
HA
FACE
CAPACITY
HOLE
BACK DRILL
L
SI Z
DE
STOP THREAD
ORDER
HOLE
BACK BEARING
THREAD
RELIEF
BEARING
LENGTH
LENGTH
3 BASIC COLLET CONFIGURATIONS

SPANNER WRENCH
HOLE
DRAW-IN
COLLET
PILOT
DIAMETER
OVERALL LENGTH
STATIONARY
COLLET
SLOT SEAL
HOLE
SHOULDER
FOR CAP
BACK
BEARING
PUSH-OUT
COLLET
SLOT
RELIEF
SLOT
HEAD
ANGLE
Basic Workholding
Techniques

The collet is a workholding device that grips the workpiece or tool in a machine tool spindle. The
more common machines that use collets are lathes, milling machines and cylindrical grinding
machines.
The basic collet is illustrated on the previous page. The common names of the various parts of
the collet are shown.
The collet is pulled or pushed into a mating taper in the machines spindle or tool holder. As the
collet is moved linearly, it closes down on the workpiece or tool. The collet continues to close until
it can no longer move. The amount of force is determined by the closing mechanism such as an
air closer, hydraulic closer, or mechanical closer.
THE HEAD ANGLE
10
Lathe Collet
Lathe collets generally have a head angle of approximately 10 degrees.
When the head angle of the collet is less than 7 degrees it will have a
tendency to stick (not open when the closing force is removed).
Stationary Collet
High production machines use stationary collets. Their head angle is much
steeper than lathe collets, usually up to 15 degrees. This helps eliminate
sticking and aids in opening the collet.
15
Toolholder Collet
Toolholder collets are made with less taper (7 degrees and lower) which
gives them greater holding power. Sticking is not as much of a concern
because the collet is not opened and closed during the production cycle.
7
BACK BEARING
SPINDLE ANGLE
BACK BEARING
HEAD ANGLE
Probably one of the least (but most) critical factors in

close tolerance machining is the allowance between
the back bearing of the collet and the spindle.
When the clearance is too great, the collet will pivot or
shift when tool pressure is applied to the part, causing
excessive runout.
Excessive runout can be caused by a worn spindle
back bearing or a worn collet back bearing. For more
information see chapter 4, page 25.
10
CHAPTER 1
Items such as the headstock center have their back

bearings held extremely close (.0002"), which
minimizes the clearance, assuring the best concentricity.
When a collet requires an extreme amount of spread, as do most screw machine collets, the back
bearing often develops a 3- or 4-point out-of-round condition due to the distortion caused by
spreading. Because this condition can cause sticking of the collet, additional clearance is allowed
on the back bearing of the screw machine collets.
Face of Spindle & Cap
Nose Cap
Sleeve Back Bearing
Draw Bar
Collet Back Bearing
Labyrinth Seal
Sleeve
Stationary Screw Machine Collet

With the stationary screw machine collet, concentricity is more difficult to obtain because there is
a sleeve clearance as well as a back bearing clearance.
With this style collet, it is important that the face of the cap is perpendicular to the spindle and
that the face of the collet is perpendicular to the back bearing and the head angle.
Basic Workholding
Techniques
Slot Designs
Lets take a look at the slots in a collet. There are slot variations. Some of the more common ones
are shown below. The Straight, Slot with Relief Hole and Tear-Drop Slot are used to make the
collet more flexible.
Straight
Slot
Straight-Slot
The straight slot is the least flexible and is used
for collets that have very little spread, such as
lathe collets. "Spread" is the amount a collet
opens beyond the size of the collet. A .500"
collet may spread to .510" when the bore is
measured. This measurement is taken with the
collet outside of the machine.
Relief Hole
Slot with Relief Hole

The relief hole is designed for flexibility in a
collet requiring more spread than the straightslot shown above.
Tear-Drop Slot
(Screw Machine Collet)
Tear-Drop Slot
Screw machine collets, which require considerable spread, use the tear-drop slot for maximum
flexibility.
Double-Slot
The double slot is used for small order hole
collets where a standard slot would be bigger
than the order hole. The secondary slot can be
as narrow as .005" wide.
Angular-Slot
Double-Slot
Angular-Slot
The angular-slotted collet is used when holding

regular shaped polygons (hex, octagon, square,
and triangles) on their corners, or outside
diameter, instead of on the flats. The angular
slot prevents the corners of the stock from falling
into the slots.
Zig-Zag Slot
The zig-zag slotted collet solves the same
problem as the angular slotted collet but is used
for stock under 1/4". The corners of small stock
may fall into the slots of the angular slotted
collet, making it impractical. Because of the high
cost of the zig zag slot, always consider the
angular slotted collet first.
Zig-Zag
Slot
11
12
CHAPTER 1
Over-The-Shoulder Collets
When more flexibility is needed, such as when using the over-the-shoulder collet, not only is the
tear-drop relief slot used but the wall thickness is also reduced. This practice will reduce the life of
the collet but is necessary to be able to grip the part over a shoulder. Part of the requirement for
greater flexibility needed for the over-the-shoulder collet can be achieved by increasing the
number of slots.
CAUTION: The amount the collet will open is controlled by the stroke of the collet closer.
Other Slot Designs

Other slot designs, such as those shown below, are used for special applications.
Basic Workholding
Techniques
R D I N GE
A
H
CHAPTER
TWO
O
DE
SI Z
COLLET
AND
CLOSER SYSTEMS
13
14
CHAPTER 2
Collet and Closure Systems
Collet Systems
There are three different types of collet systems
the Draw-In, the Push-Out, and the Stationary.
Nose Cap
Coolant Shield
Collet Back Bearing
Head Angle
Spindle
Draw Tube
Collet
Draw-In Collet
The Draw-In collet is the most common and also the most accurate for holding concentricity. To
close the collet, it is drawn into the spindle angle. The only moving part (other than the collet) is
the draw tube.
Concentricity depends on the accuracy of the spindle and the collet. The order hole of the collet
must run concentric with its head angle and back bearing which also must be concentric with
each other. There are no other factors involved.
Basic Workholding
Techniques
Spindle
Back Bearing
Nose Cap
Push Bar
Labyrinth Seal
Push-Out Collet
The Push-Out collet is becoming obsolete. In the past, it was used in many manual turret lathes.
To close the collet, it is pushed against a cap which is threaded or bolted to the spindle. The cap
has an internal angle which mates with the front angle of the collet. The collet is closed by a
forward force from the push tube.
There are several items that affect concentricity: the collet, the spindle and the cap, along with its
locating shoulder. All of these items require a tolerance when being manufactured. It is the build
up of these tolerances which effects the total concentricity and accuracy of this system. Other
items that affect concentricity are worn caps and caps that are not square with the face of the
spindle.
15
16
CHAPTER 2
Spindle
Collet Back Bearing
Face of Spindle
and Cap
Nose
Cap
Draw Tube
Sleeve
Labyrinth Seal
Collet
Push SleeveStationary Collet

The Push Sleeve system is the only system that allows length control of the workpiece. This is
possible because the face of the collet is located against the back face of the hardened spindle
cap. The collet is closed with a sleeve which pushes against the angle on the collet causing the
collet to close, but not move longitudinally. Note: There are collets designed for part length
control that are available for other collet systems.
There are even more parts in this system to affect concentricity: the collet; the cap and how it
aligns with its locating shoulder and thread; the sleeve with its allowance; as well as the clearance between the spindle back bearing and the collets back bearing. This system is the least
accurate when trying to hold concentricity because of the large number of parts involved.
Collet
Toolholder
Collet
Assembly
The collet is closed by
tightening a threaded
cap on the tool holder
sleeve.
Drill Stop
Cap
Basic Workholding
Techniques
Actuating the System

Each one of these collet systems require some means for opening or
closing the collet. The following closing systems are used.
Mechanical Collet Closer

Mechanical closers are used on manual machines. Because they require human intervention to
operate them, they are seldom used on automatic machines. The exception is the cam-operated
machines which still use a mechanical closer, but it is closed with a cam instead.
Air-Operated Mechanical Closers are manual closers that have been fitted with an air cylinder to
actuate them. These were common on the first Hardinge Automatic machines. They were eventually phased out for the totally air-operated closers.
17
18
CHAPTER 2
Pneumatic or Hydraulic Closers
Basic Workholding
Techniques
Pneumatic and Hydraulic Closers
Pneumatic - Air
The Pneumatic closer allows the light chucking pressures necessary when gripping thin-walled
parts or tubing. When doing precision work, this system is most versatile. When doing extremely
heavy stock removal work, the gripping pressures may not be adequate.
Disadvantages:
Air is compressible, therefore any tool pressure that pulls on the workpiece could actually loosen
the collet if its force is greater than the force created by the air pressure against the piston.
Hydraulic
The Hydraulic and the Pneumatic closer systems look almost identical. The major difference is
the pressure medium (hydraulic oil /air) and the higher pressures that are used. Hydraulic oil is
not compressible, therefore any pressures opposite the piston force should not allow the collet to
open. The pneumatic closer uses shop air pressure, usually 90 - 100 PSI, whereas the Hydraulic
closer pressures can be as high as 1000 PSI. The same size piston used on a pneumatic closer
will now deliver 10 times the force.
Disadvantages:
Disadvantages include the added expense required for the hydraulic pump and sump. The
hydraulic collet systems cannot be used for delicate or thin-walled parts. The pressures cannot be
turned down low enough to eliminate crushing the workpiece.
19
20
CHAPTER 2
Machines that use the various collet systems
DRAW-IN COLLET:
Acme Gridley
Cone
Davenport
Euroturn
Gildemeister
Greenlee
Grinder Collets
Hardinge
Lathe Collets
Mill Collets
National Acme
New Britain
Schutte
Tornos
Warner Swasey
Wickman
PUSH-OUT COLLET:
Turret Lathes
Warner & Swasey
Jones & Lamson
Gisholt
PUSH SLEEVE - STATIONARY COLLET:

Brown & Sharpe
B. S. A.
Index
Basic Workholding
Techniques
R D I N GE
A
H
CHAPTER
THREE
O
L
E
D
SI Z
TYPES
OF
COLLETS
21
22
CHAPTER 3
Types of Collets
Types of Collets
There are many types of collets available to the machine tool industry.
Listed below are the styles available for 5C spindles. These same styles
can be made for other types of collets.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
Fractional sizes
Decimal sizes
Number
Letter
Metric sizes
Special Accuracy (.0002" TIR for
5C collets only)
4-Split Long Bearing (Drill Collet)
Angular Slotted
Zig-Zag Slotted
Angular Hole
Flat Face
Taper Hole
Short Bearing
Long Bearing (5C ST & others)
Bearing Relief
Light Force
Heavy Duty
Stop Collets (SC)
Blanks
Serrated
Hex
Square
Rectangular
Special Shape & Extruded
Octagon
Eccentric
Stepped
Plug Chucks
Extended-Nose
30. Extended-Taper Nose

31. Emergency
32. Contact Lens
a. Extended Nose Step Collet
b. Solid Extended Taper
c. Shank
33. Solid Collet
34. Brass Collet
35. Nylon Collet
36. Morse Taper Collet - Female
37. Threaded - Solid - Order Hole
38. Threaded - Split - Order Hole
39. Dead-Length Collet
40. Dead-Length - Thru Hole
41. Mill Arbor
42. Expansion Collet- Spindle
mounted
43. Master Expansion - Collet type
44. Step Chucks
a. Hardened & Ground
b. Emergency
c. Extra-Depth
d. Closers for all Step Chucks
e. Dead-Length Step Chucks
45. Pin Step Chucks (Dead Length)
46. Male Headstock Centers
47 Female Centers
48. Driver Center
49. SURE-GRIP Expansion Collets
50. Dead-Length Step Chuck-Spider
Stop
Basic Workholding
E
G
N
HA
Techniques
S
I
Z
EL
CHAPTER
FOUR
CONCENTRICITY
AND
SPREAD
23
24
CHAPTER 4
Concentricity and Spread
.0 0
1"
Concentricity
Concentricity is measured by putting a gauge pin or ground plug in the collet order hole and
measuring the Total Indicator Reading (TIR) of the pins runout with a .0001" dial indicator at a
specific distance from the face of the collet.
There are many factors to be considered when trying to achieve the best concentricity possible.
The Concentricity of the Spindle
1. TIR of the spindle angle

If the spindle angle does not
run concentric, it is impossible
for the collet and workpiece
to run concentric.
Spindle Angle
Back Bearing
Head Angle
Basic Workholding
Techniques
1"
2. TIR and wear on the back bearing

a. The back bearing must also run concentric because it will affect the concentricity
of the collet.
b. If the back bearing of the spindle is worn, it will allow the back bearing of the collet to
pivot, which will cause excessive runout.
1"
3. Runout of the collet thread

a. The thread must run concentric and square with the head angle and the order hole of
the collet.
b. If these conditions are not met, the pressures will be exerted on one leaf of the collet
instead of all three. The parts manufactured with this collet will not be concentric with
the chucking diameter. The uneven forces on the collet leaves may cause them to
break.
25
26
CHAPTER 4
What is Spread?
Spread is what puts the spring in the collet to help open it. This spring keeps the collet angle
against the spindle angle, helping to eliminate chips which would cause runout. When the collet
closer on a screw machine is opened, it is the spread in the collet that opens the collet so that the
workpiece can be loaded or unloaded. Too much spread makes it harder to close the collet,
reducing the gripping force on the workpiece. There is very little spread in a lathe collet, just
enough to allow the workpiece to be loaded when the collet is opened. When a Brown and
Sharpe style collet is not in the machine, the workpiece will very easily slide into the collet with
plenty of room to spare. With other types of collets, such as lathe collets, a .003" (minimum)
oversize plug will slide through the order hole (bore).
Screw Machine Collet - Large Amount of Spread
Lathe Collet Very Little Spread
Grind Outs
Grind-outs are collets that have been finished and are then re-ground to a new larger size. This
process is used when a quick turnaround is needed. Maximum stock removal is 1/64" on case
hardened collets. If more than a 1/64" is removed from the order hole, it will be softer than a
standard collet because most of the case has been removed. There is no limit to grinding the ID
when thru-hardening steel is used to manufacture the collet.
Basic Workholding
Techniques
NEW COLLET-NO CAM GRIND
WORN ORDER HOLE - NO CAM GRIND
CAM and Flat Grind

Screw Machine Collets, 16C, 20C, 25C Collets
(5C collets and standard lathe collets are not cam ground)
The cam grinding process helps reduce sticking problems. As the order hole of the collet wears,
the collet is drawn further into the spindle seat. When this happens, the bearing area shifts from a
full bearing to a bearing on the edges of the leaf (see above illustration). This edge bearing is
most undesirable because it reduces the bearing (surface contact) between the spindle and the
collet. To help alleviate this condition, collets are cam ground or flat ground (see illustration on
next page). These two processes remove material from the slot area of the collet. This allows the
collet order hole to wear and still maintain a bearing between the center of each leaf and the
spindle angle.
AT
FL
M
CA
CAM GRIND
FLAT GRIND
27
28
CHAPTER 4
Extra-Spread
Extra-Spread (Over-The-Shoulder) collets are used when gripping on a diameter that is smaller
than the first area of the part which goes into the collet. These are commonly called Over-TheShoulder Collets.
There are restrictions on its use:

The collet closer must have enough linear stroke to allow the collet to open up sufficiently
to clear the larger diameter.
The Davenport automatic, with the special burring attachment, uses pick-off collets which
can handle a shoulder that is .100" larger than its gripping diameter.
Collet closers with a 1/2" stroke and a 10-degree spindle head angle may use a special
collet which can handle a part with a shoulder approximately .150" larger than the bore.
To find the amount that a special collet can open in relationship to the stroke of the collet closer,
multiply the tangent of the collet head angle by the maximum closer stroke, then multiply the
answer by 2. Dont forget there will be some loss due to manufacturing tolerances.
EXAMPLE: 16C Collet = 2 (Tan 10 degrees x stroke)

16C Collet = 2 (.17633 X 5)
16C Collet = .1762" (maximum difference in diameters)
Over-The-Shoulder collets are special collets which are custom designed and manufactured for
each part or family of parts. They require special collet head angle designs, special slots and very
precise heat treatment.
Basic Workholding
G
N
I
HA
Techniques
S
I
Z
EL
CHAPTER
FIVE
COLLET
HARDNESS
AND WEAR
29
30
CHAPTER 5
Collet Hardness and Wear
Advantages of Hardened Collets

Hardened collets have a longer life than collets not hardened
The harder the surface, the longer the life - wear resistance.
Reduces the cost of running a job because fewer collets or pads have to
be purchased.
Reduces downtime because there are less collet changes.
PROBLEMS CAUSED BY IMPROPER HARDNESS
Collets that are made too hard will be brittle and will break easily.
When collets are not tempered properly will lose their spring.
Collets that are too soft will wear out very quickly.
What Causes Collets and Pads

to Wear Out?
Poor housekeeping
Not keeping the collets & draw tubes clean. Take them out and
clean them after each job.
Not using seals with screw machine collets.
Surface condition of the material being gripped
Hot-Rolled Stockit is rough with surface scale. The out-ofroundness causes irregular contact with surface of order hole.
Cast Barssame as hot rolled stock.
Types of materials
Abrasive materials shorten lifeAluminum, Cast Iron, Carbon and Ceramics.
Basic Workholding
Techniques
Types of Machining Operations

that may cause collets to break down:
Heavy stock removal and

heavy drilling may cause push back.
Heavy forming-cross slide tends to open the collet.

May cause stock to slip which would cause wear.
Forming and drilling at the same time.
31
32
CHAPTER 5
Types of Machining Operations

that may cause collets to break down:
Intermittent cuts can cause radial slippage.
Out of Balance parts. Uneven pressure on the leaves.
All of the illustrated applications are common machining practices. Slippage can be overcome by
using a properly designed workholding system which includes a collet that has the right head
angle design, the proper serration and hardness, a collet actuating system with adequate draw
bar force, a spindle drive system with adequate horsepower and torque, cutting tools that are
properly sharpened and centered, and proper feed rates and spindle speeds for the tooling and
material selected.
Basic Workholding
Techniques
Other Causes for Wear

Multi-Spindle Machines
(Causes also related to single spindle machines)
The feed tube and the collet are not keyed togetherthis causes radial
slippage when the collet opens and closes.
Crooked or bent bars put stress on one leaf of the collet or feed finger which
causes slippage and loss of tension in that leaf.
Dirty bars create a very abrasive action between the bar and the feed finger
and/or collet.
Bent feed tubes cause runout of bar and excessive wear on the leaves of the
collet and feed fingers. The tubes are bent due to running bent or crooked
stock and with considerable use.
Excessive tension on feed fingers. This is hard to check. You can push down
on scale to check tension.
33
34
CHAPTER 5
notes:
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
Basic Workholding
G
N
I
HA
Techniques
SI
EL
CHAPTER
SIX
MATERIALS
HELD BY
COLLETS
35
36
CHAPTER 6
Materials Held By Collets
Materials Held by Collets

MATERIAL
SPECS.
PROBLEMS
RECOMMEND
Steel
Thru- hardening
None
None
Standard
Standard
HOT-ROLLED
Certain alloys cant

be cold drawnhot
rolling is less expensive
than cold drawing
Stock is not round,

diameter varies
considerably and
they have a very
rough surface finish
Saw Tooth,
Serrated,
or 3-Jaw
Power Chuck
COLD-DRAWN
Most common steel

used for screw machine
stock
None
Standard
Special-shaped stock
(Made by drawing
thru a series of dies in
a semi-molten state)
In most instances
cannot be held in
a round colletshape
usually does not
conform exactly to the
print, therefore
actual samples of
stock must be sent
with the order
Special-shape
(Usually
made using
EDM methods)
COLD-HEADED
Part is cold-formed to
near net shapemany
are done from coil stock
Chucking diameters
are not always
accurate, out-of-round,
etc.
Serrated
collet or
Power Chuck
SHEET METAL
Punched from flat stock
Size variation
Standard &
Serrated
SHEET METAL
EXTRUDED
Extruded thru several

diessuch as a can shape
Size variations
& thin walled
Standard,
special-shaped
& tapped hole
STAINLESS
There are many different

kindsmagnetic, nonmagnetic, corrosion
resistant, etc.300 & 400
Seriessome are hardenable and some aren't
Marks very easily
Standard &
Serrated
CARBON STEEL
TOOL STEEL
EXTRUDED
Basic Workholding
Techniques

MATERIAL
SPECS.
PROBLEMS
RECOMMEND
Made same as cold

Darwin steelwe use
Nickel Alloy-Dura bar
can be hardened to
42-45 Rockwell C
None
Standard &
serrated
Made same as hotrolled steel
Scale, out-of-round
Serrated
Produces very fine

grain ironcan be
round or special-shaped
Variation of
chucking area
Serrated
and/or
special-shaped
Permold and sand

castings
Large variations
draft angle, rough
surface finish
3-jaw power
chuck,
serrated
Cold-drawn bars
Easy to work
marks easily
Standard &
serrated
nylon for
highly polished
stock
Near-net shape drawn

through dies
Requires special
shapes
Special-shaped
need a
piece of stock 8"
long to use as
EDM electrode
BRASS
CASTINGS
Sand casting process

die-type castings
Large variation
on chucking
surface, draft
angles and rough
surface finish
3-jaw power
chuck,
special-shaped
& serrated
ALUMINUM
BARS
Cold-drawn
Stock is abrasive
cutting tools
wear fast
Standard
IRON
COLD ROLLED
IRON
CAST BARS
IRON
CONTINUOUS
CAST BARS
IRON
CASTINGS
BRASS &
BRONZE
BRASS
EXTRUSIONS
37
38
CHAPTER 6
Materials Held By Collets

MATERIAL
ALUMINUM
EXTRUSIONS
ALUMINUM
CASTINGS
ALUMINUM
DIE CASTING
SPECS.
PROBLEMS
RECOMMEND
Near-net shape
drawn thru dies
Requires special
shapesneed a
piece of stock 8"
long which is
used to make the
EDM electrode
Special-shaped
Sand casting process

die type castings
Large variation
on chucking surface,
draft angles and rough
surface finish
3-jaw power
chuck,
special-serrated
collets
Much more precision

than sand casting
Some variation on
chucking surface,
out-of-round,
good finish
Special-shaped
& sometimes
serrated
Size variation, soft,

marks easily
much of this material is
slipperyrequires light
chucking pressure
Standard
Very brittle, will break if

chucked too tight
powdery and abrasive
causes collets and the
machine tool to wear out
very quickly
Standard
PLASTICS:
Nylon - Delrin
Teflon - Bakelite
Acrylic - Glassfilled - Synthene
CARBON
CARBIDE
GRAPHITE
CERAMICS
Comes in cast bars

castings and molds
Basic Workholding
Techniques
CHAPTER
SEVEN
COLLET
CAPACITIES
39
40
CHAPTER 7
Collet Capacity
Chucking Diameter
COLLET
ORDER
HOLE
ACCEPTABLE
BAR SIZE
FOR BEST
CONCENTRICITY
ORDER HOLE
GROUND TO
5C Standard
Fractional
+.002 to -.001
.001 Under order

hole size
.001 under the

order hole
5C Standard
Decimal
+.002 to -.001
Same as order
hole size
Same as the
order hole
16C Standard
Fractional
+.002 to -.001
.001 Under order.

hole size
.001 under the

order hole
16C Standard
Decimal
+.002 to -.001
Same as order
hole size
Same as the
order hole
Screw Machine
Fractional
+.002 to -.001
.001 Under order

hole size
.001 under the

order hole
Screw Machine
Decimal
+.002 to -.001
Same as order
hole size
Same as the
order hole
Master Collets
Hole size
Order hole
There are many discussions as to how much variation in stock size a collet can handle. Hardinge
collet engineering has developed a chart (above) of suggested stock sizes that an order hole can
handle. This refers to bar stock or chucking diameter.
Correct Collet Size

When the collet is the proper size for the workpiece, there is full bearing along the angle and the
circumference of each segment of the collet where they mate with the spindle angle (seat). The
result will be good concentricity and excellent holding power.
Basic Workholding
Techniques
Collet is Oversize
If the collet is oversize as shown above, the part may pivot at the line of contact. The turned
diameters may not be concentric with the bar or chucking diameters, and the machined diameters
can be out-of-round. There will be line contact at the center of the leaf.
Collet is Undersize
If the collet is undersize, the contact will be at the head of the head angle on the spindle angle
and the order hole. This can help with bar push-back because the more tool pressure exerted on
the bar the tighter the collet becomes. The part may pivot around the point of contact when
excessive chucking pressure is NOT applied. The turned diameters may not be concentric with
the bar or chucking diameters. The edges of the slots will bite into the workpiece and may cause
damage or mark the bar.
41
CHAPTER 7
Collet Capacity
.050" Max.
Extra, Extra-Spread Collets
IN
GE
The shoulder normally cannot be larger than the chucking diameter by more than .100" on the
diameter. As the length of the bearing in the order hole gets shorter, the collet can be made to
clear larger diameter shoulders.
HA
42
Four-Split, Long-Bearing Collets

Four - split collets are also called 5ST Collets or Drill Collets. They come standard in various
sizes for the 5C style spindles. Those with under 1/16" order hole are two-split. The various
styles are:
Number sizes
Letter Sizes
Fractional from 1/64 to 1-1/16" (5C collets)
Decimal (special order)
Basic Workholding
Techniques
Angular-Slotted Collets
These are special-order collets that are used to grip triangular, hex, square and other eccentric
stock with corners that would normally fall into the slots of the collet. The angular-slotted collet
has the following characteristics:
The slots are normally cut on a 7-degree angle instead of straight
The parts are gripped by the outside diameter of their corners
They are used for high production loading by eliminating the need for
orienting the part with the shaped hole in the collet
Greatest use is for carburetor needle valves
Zig-Zag Slotted Collets

These are special-order collets that are used to grip small diameter triangular, hex, square, and
other eccentric stock with corners that would normally fall into the slots of the angular slotted
collet. The zig-zag slotted collet has the following characteristics:
The slots are double-cut with the zig-zag EDMed (Electrical Discharged
Machine) as the second slot
The parts are gripped by the outside diameter of their corners
They are used for high-production loading by eliminating the need for
orienting the part with the shaped hole of the collet
The Zig-Zag overlaps even in the relaxed (open) position so that even the
corners of the smallest stock cannot get into the slot
Expensive
43
44
CHAPTER 7
Collet Capacity
notes:
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
Basic Workholding
Techniques
CHAPTER
EIGHT
COLLET
SERRATIONS
45
46
CHAPTER 8
Serrations
Serrations
Why do we use serrations?
Better gripping pressure by concentrating force in a smaller area

Reduces push-back of stock under the load of cutting
Reduces spinning or rotation of the stock
Under a heavy cut they may help prevent stock from "walking out" of the collet
Maximum contact area when gripping irregular surfaces such as
hot-rolled & cast bars
Standard Flat Serration

Increases gripping pressure but
does not score the workpiece when
using the correct closing pressure.
This is the best all-around serration.
Tap Serration
Tap serrations are used on pads
with small holes that are
impractical to groove and broach.
Circular Serration
Circular serration is used to increase the gripping pressure but not
bite into the workpiece as much as
other serrations would.
Basic Workholding
Techniques
Sawtooth/Buttress
Serration
The grooves and broach have the
same shape as a buttress thread.
This helps prevent both push-back
and radial slipping of the workpiece.
The sawtooth serration is the best
design when doing heavy forming
and/or drilling. This serration is
designed to bite into the stock or
workpiece.
Diamond Serration
The grooves and broach have a 90degree V shape. This serration is
designed to bite into the stock.
Hex and Square Collet

Serrations
Circular serrations are used on
Hex, Square and Polygons.
Additional Information
If the last serration is less than one
full serration in length, the last
groove will not be cut. This makes
for a stronger area and eliminates
chipping out of the serrations when
loading bars.
Disadvantages of Serrations
Serrations may score the stock or workpiece, and generally cost more than smooth pads or collets.
Additional information in the following chapter.
47
48
CHAPTER 8
Serrations
notes:
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
Basic Workholding
Techniques
CHAPTER
NINE
CONCENTRICITY
AND
GRIPPING FORCE
49
50
CHAPTER 9
Concentricity and Gripping Force
Chucking Surfaces
The Order Hole
The bore, order hole, or ID of the collet comes in many different surface finishes, diameters and
bearing lengths. Let's take a look at these aspects.
Smooth Bore
Most lathe collets are smooth bore. They achieve a full bearing on a finished part.
They are typically less expensive than serrated collets and are used whenever the stock surface
cannot be marked.
Serrated Bore
Serrated Bore gives maximum gripping force when doing heavy machining operations. They are
used for cast or hot-rolled stock which is usually out-of-round and has a rough surface finish. The
serrations will bite into the material and reduce slippage and push back.
Basic Workholding
Techniques
Diameter of the Order Hole

For Bar Work
Small Order Hole

The order hole should
be smaller than the bar
stock size for maximum
gripping.
Exact Size
or Slightly Under
The order hole should be
exact size when running
ground rod or tubing.
Decimal-size order holes
are made to the exact
three place decimal size.
Exact Decimal Size

(3 decimal places)
The order hole should
be exactly the same size
as the bar for best
concentricity and least
possibility for marking the
stock. If you were running
1/2" stock, and needed
best concentricity, but
the stock actually measured .497, you should
purchase a .497 decimal
collet.
51
52
CHAPTER 9
Holding Power When Doing Chucking Work

Exact Size
For best results without marking, the order hole
should be exactly the same size as the stock,
resulting in:
Full bearing on chucking diameter
The best concentricity possible
Oversize
When the order hole is larger than the chucking
diameter, the following happens:
Less gripping force due to line contact
at center of leaves
Diameter runout
Radial marks on the chucking diameter
Undersize
When the order hole is smaller than the part
chucking diameter, the following happens:
Distortion of the part
Diameter runout
Linear marks on chucking diameter
BUT, the holding power will be greater.
For Best Concentricity

When Holding Any Workpiece
The order hole should be exactly the same size as
the workpiece's chucked diameter.
Basic Workholding
Techniques
Length of Bearing
Short Bearing
The smaller the order hole, the shorter the

bearing length, mainly due to the length of the
grinding wheel used during manufacturing.
A short bearing would be used to clear threads on

a part. The threads could be damaged with a
standard collet.
Special over-the-shoulder collets have very short

bearings to allow for maximum opening with
minimum collet stroke.
Split-Bearing (Bearing Relief)

Improves gripping pressure with the same
amount of force. Many Davenport and Brown &
Sharpe collets come standard with split bearings.
CAUTION: Extended-Nose Collets

Extended-nose collets are used to extend the part out far
enough to clear tooling interferences. This collet is easily
damaged by applying moderate closing forces. Because the
griping area of the collet is substantially forward of the head
angle, the collet will bellmouth. This creates what is called a
scissors grip on the part which is very unstable. Concentricity is
difficult to hold using this style collet. Extended-nose collets
should only be used for the lightest of cuts. If you need an
extended-nose collet for normal machining, you're using the
wrong machine tool.
53
54
CHAPTER 9
Number of Slots
No Slots
Plug chucks and blank collets

Used for arbors and fixtures
Taper-hole collets - Morse, B&S
Headstock centers
Stub arbors
Headstock mill drivers
Two Slots
Two-slotted collets are used for special applications.
2 Split Drill 5CST
TWO SPLIT ANGULAR
Three Slots
Three slots are most common. It is the most accurate design for centering a workpiece.
They are usually used for Round, Hex and Square collets.
ROUND
SQUARE
HEX
Basic Workholding
Techniques
Four Slots
Four slots are used on larger collets to reduce closing pressure and are very common for square
and rectangular collets.
SQUARE
HEX
RECTANGULAR
More Than 4 Slots

More than four slots are used on larger collets to reduce closing pressure, for crimping collets,
special collets and other special applications.
9-SPLIT
6-SPLIT Crimping
8-SPLIT
55
56
CHAPTER 9
Micro-Finish of the Order Hole (Bore)

Machinedlathe bored
Emergency style are usually bored by the operator. Special applications collets and brass collets
are usually bored for the customer.
Grind
Grinding is the most common method for finishing the order hole.
LapHonePolish
Extremely small collets that are too small
to grind.
Extremely Small
Stripper collets used to pull the workpiece

off a die.
Capsule collets that require a very fine
surface finish.
Workpieces that cannot be scratched.
Collets used on extremely high-speed
machines where operating parts must
be super-finished.
Stripper Collet
Capsule Collet
Clover Leaf GrindSpecial Process

The order hole is cleared at the slots using an end
mill or grinding wheel. Chucking force is increased.
Edges of the slots do not bite into oversized stock
and they help eliminate marking on nominal stock.
Used on hot-rolled stock.
Basic Workholding
Techniques
EXPANDING
COLLETS
57
58
CHAPTER 10
Expanding Collets
Expanding Collets
When doing secondary work, where extremely close length and concentricity tolerances are
required, most of us hope that the part has a hole in it. It has long been known that using an
expanding collet is the most accurate way to hold a workpiece.
True, there are certain machining practices that have to be adhered to when doing the first
operation on the workpiece. There are many different styles of expanding collets, each one
having their strengths as well as weaknesses.
Preparation of the Blank

Many people feel that as long as the part has a hole, it can be held accurately using an expansion
collet. Unfortunately, this is not the case.
When machining the bore, the section to be machined should not be inside the collet or under the
jaws of the chuck unless it is round. If it is not round, there may be considerable distortion of the
bore when it is removed from the workholding device.
Basic Workholding
Techniques
If the outside diameter of a solid blank is out-of-round, and that diameter is chucked using a collet
or step chuck, the bored hole will also be out of round after removal from the collet.
1. Out-of-Round Part
(Collet shown open)
2. Rough Bore
(Material flows into hole)
3. Finish Bore
(Rounds out)
4. Collet released
(OD returns to original shape
and ID follows)
A precision bore is required when gripping the part with an expansion collet. Prior to boring the
part, the outside chucking surface must be round within a tolerance that is less than the desired
bore tolerance.
59
CHAPTER 10
Expanding Collets
BORE
H
AR
D I N GE
L
DE
O
SI Z
SI Z
60
1. Tubing or
Drilled Hole
2. 1st bore not

round due to uneven tool pressure
3. Finish bore
truly round
When boring a part which will be held on an expansion collet, it should always be rough bored
and then finish bored.
When only one boring operation is done, the resulting hole will generally have the same out-ofroundness the blank or drilled hole had.
1. Blank
ID out-of-round
2. Chucked
ID forced round
3. Turned
4. Distortion after removal
If the bore to be gripped by the expansion collet is out-of-round, it will be forced round by the
closing pressure. Any outside diameter turning work accomplished while being held by the
expansion collet will be round until it is removed from the expansion collet. The bore will then
return to its original out-of-round condition which in turn will make the outside diameters also go
out-of-round.
Basic Workholding
Techniques
By now you have probably gotten the message, If you want to do precision work, while holding
with an expansion collet, the bore you are locating on must also be a precision bore.
Work done on the outside diameters will not be any better than the tolerances and condition of
the inside diameter being located on.
Styles
There are many different styles of expanding collets. Lets start out with a precision style, the
spindle-mounted expansion collet assembly.
Spindle-Mounted Expansion Collet

This system can only be used on Hardinge-style thread or taper-nose 5C spindles.
CAUTION: Do not use on Hydraulic Collet Closers with 5C spindle adapters. The assembly will
be damaged and will be unsafe to use.
61
62
CHAPTER 10
Expanding Collets
Basic Parts
of the Spindle-mounted Expansion Collet
Locating
Face
1. The Spindle Mount

The spindle mount bolts, threads or is
taper-locked onto the spindle nose of
the machine. It has a locating face that
is square with the spindle centerline.
The collet is held in and adjusted to
center with four adjusting screws. The
screws are used to center the collet and
force it against the locating face of the
spindle mount to square the collet up.
2. The Collet
Locating
Face
The collet is usually four-split, hardened

and ground. The 5C-version can handle
work with bores from 1/2" to 3". It has
an ID taper which accepts a draw plug.
The draw plug expands the collet as the
draw collet is closed (pulled into the
spindle). There is a locating face which
must be perpendicular with the collet
diameter.
3. The Draw Plug Assembly

The draw plug assembly consists of the draw plug with an angle which mates with the collets ID
angle. This plug mounts into a draw collet and is pulled pack by the collet closer. The draw collet
does not have a head like a regular collet. Its only purpose is to center the draw plug in the
spindle and to connect the collet to the collet closer. The clearance between the spindle back
bearing and the draw collets back bearing is much less than a standard collet. This feature
allows the assembly to hold part concentricities to within .0002" TIR.
Draw Collet
Draw Plug
Basic Workholding
Techniques
4. Machineable Work Locating Stop (Backing Plate)

This part is bolted to the spindle collar and machined by the operator to conform to the locating
point of the part. It gives greater stability to the collet and helps eliminate any flexing of the collet
by supporting the workpiece. Two common problems when NOT using a backing plate are chatter
and taper on the turned diameters which, many times, are caused by deflection of the collet.
Work Locating Stops for different applications
63
64
CHAPTER 10
Expanding Collets
Advantages of the Spindle-Mounted

Expansion Collet
One of the most accurate expansion collets available
Gives dead length control, even without a backing plate
Can hold .0002" concentricity between the bore and turned diameters
(the blank must be good to start with)
Can be used for large diameter work
Custom collets can be made with extra long bearings
Custom backing plates for complex datum surfaces
Longest lifehardened & ground
Soft blanks available for machine-in-place applications
Special Considerations
Long set up time10 to 30 minutes

Requires skilled personnel
Collet can be destroyed if collet is closed without a part on it
1/2" collets and above are guaranteed to have runout
Special collets as low as 5/16" with a special draw plug and adapter
can be easily destroyed by a careless operator, therefore, there is
no guarantee on collets smaller than 1/2"
Collets are available to a 3/8" minimum diameter
Basic Workholding
Techniques
Master Expanding Collet

5C & 16C colletsCollet-style
This expansion collet can be mounted in any machine or workholding device that uses 5C and
16C collets. It does not require a spindle mount. It mounts directly into the spindle and uses
interchangeable pads which are machined by the operator to fit the part. These pads can be
removed and saved for use on the same part at a later time. There are two exceptions to doing
this:
The pads must go back on the same master collet in their original position
The TIR tolerances cannot be critical
Parts of the Master Expanding Collet
1. The Body
The allowance between the body and the spindle back bearing is extremely close (much closer
than a collet). This assures very close tolerance capabilities. The master collet is part of the body
and is very large, giving extremely good stability. The leaves of the collet have holes threaded in
them to accept interchangeable collet pads.
65
66
CHAPTER 10
Expanding Collets
2. The Draw Plug

The plug is very large in diameter. This cuts down on the deflection normally associated with
draw plugs.
3. Keyed Special Thread

The draw plug is thread into this part. When the closer pulls back, this part goes back with it. The
threaded part pulls away from the body which, in turn, pulls the draw plug against the collet angle,
closing it.
4. Spring
The spring pushes against the back of the master collet body keeping the head angle in contact
with the spindle angle at all times. Without this spring, chips would get behind the master and
cause runout of the master collet.
Basic Workholding
Techniques
Master Collet Pads
Pads are made from steel (2" capacity) and aluminum (3" capacity). The steel pads are the
standard pads. These pads are bolted to the master collet with six screws. A limit ring (the ring
used for set up) is placed around them and the collet is very lightly closed, using just enough
pressure until the ring cannot be turned by hand. The pads are then machined to the exact
bore size.
The 3" aluminum pads are for large diameter light work. They are bolted to the master collet
leaves. Instead of a set ring going over the OD of the pads, there is a pilot on the front of the
pads. A cap is placed over this pilot. The collet is very lightly closed and the pads are machined
to the size of the part within a few ten thousandths.
LIMIT
RING
Hardened and Ground
PADS
For high production runs, hardened and ground collets should be used. When purchasing these
collets, you must also purchase the master collet body. The pads will then be ground on that
body, ensuring the best TIR possible.
67
68
CHAPTER 10
Expanding Collets
Advantages of Master Expanding Collets

Can be taken from the lathe to a milling fixture without the need
for special spindle fixturing
For noncritical work, pads can be remounted without re-machining
Pads can be re-machined for a smaller diameter workpiece
Concentricity is excellent because pads are machined in place
Small hole chucking.250" diameter to a depth of .250"
Part length control
Normal Slots in
Master Pads
Pads held in
step chuck for
re-machining
Pads have been

re-machined round
.100" diameter chucking is possible

Hold the pads in the customer-bored step chuck and re-bore the back counterbore. This eliminates the space in the slots, allowing a smaller chucking diameter to be turned.
Special CommentsScissor Gripping

This type of expansion collet is designed for light chucking only for small diameter work. Scissor
gripping of part may occur, especially when using 3" aluminum pads.
GOOD GRIP
POOR GRIP
Turned with set-ring to exact

size of bore
Turned undersize or without set-ring
Basic Workholding
Techniques
Special CommentsSmall Diameter Work

When doing small diameter work, overtightening the collet can permanently deform the pads.
Heavy tool pressure can deflect the collet. The backing plate used with the spindle mounted
expansion collet eliminates the problem.
1
1
SMALL DIAMETER
Ratio 1 : 1
OVER TIGHTENING
of small diameter work
deforms pads
Other Styles of Expansion Collets

Double-angle expansion collets
Hydraulic expansion collets
Hydraulic expansion arbors
Push-style expansion collets
69
70
CHAPTER 1
notes:
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
CHAPTER
11
MASTER COLLETS
AND
FEED FINGERS
72
CHAPTER 11
Master Collets and Feed Fingers

Master Collet
Major Classifications
Name
Standard Masters
Style "S"
Martin Master
CT (2 Holes in Pads)
CB (1 Hole in Pad)
New Britain Master
Feed Finger Classifications
Manufacturer
All
Hardinge
Hardinge/Patented design
Somma-Balas
All
All
Obsolete
Name
Style "B"
Adjustable Tension
AF Adjustable
Dial Adjustable
Style "A"
Style "PB"
Manufacturer
Hardinge
Hardinge
Hardinge
Somma/Balas
All
Somma/Balas (Obsolete)
Standard Feed Finger

Classifications
Name
Solid Feed Fingers
Squirrel Cage
Setters Spiral Slot
Manufacturer
All
All
Setters
Master Collets
Master collets are available for automatic screw machines, turret lathes and most of the newer
CNC lathes. They were developed to reduce set up time. The collet no longer has to be taken out
of the spindle of the machine when changing to another size bar. Most can be replaced from the
front of the spindle, which only takes a few minutes. The standard master collet still requires the
collet to be removed when replacing the pads. This style is not very popular, due to this requirement.
The two major players are the Style "S" originally patented by Hardinge Inc. and the Martin
Master originally patented by Balas. The following pages show illustrations of each style collet
and pad along with the advantages and disadvantages of each.
Advantages of Master Collets over Solid Collets

Purchase masters only once
Pads are 60% less expensive than solid collets, while masters are roughly
30% more expensive than solid collets
Pads are available in different materials as a "special"
Pads are available in hex, square, and special shapes
Pads require less shelf space than collets
Many different machine masters use the same size pads
Emergency pads are less expensive than emergency collets
Hex and square pads are more accurate than hex and square solid collets
Basic Workholding
Techniques
Style "S" Master Collet and Pad Features
There are no holes in the collet head angle,

therefore no reduction of precision bearing
surface. Also there are no tapped holes in the
master collet.
Trouble-free
dovetail anchor
section
Pad has full bearing on the

stock. No threaded holes
through pads to reduce
bearing surface.
Dovetail
Independent clamp slides

freely in and out of master
collet. There are no threaded
holes to get damaged.
Clamp
Pad With Clamp
Independent clamp is a
self-contained unit which
slides into the master. The
dovetail anchors pad in place.
Mating dovetails anchor the pad

and clamp together independent of
the collet. The clamp cannot be
loosened by vibration.
73
74
CHAPTER 11
Collet
The Shoulder Takes the Thrust
Pad
There can be no strain on the clamp or

clamp screw due to impact of the bar
striking the back of the pad. This is
because the clamp is secured to the pad
only. All of the end thrust is being
absorbed by the pad shoulders in the
recess of the collet.
Bar Stock
Front
Shoulder
Rear Shoulder
Bar Stock
Rear Shoulder takes

Endworking Thrust
Collet
Pad
Endworking tools exert

a tremendous amount of
pressure. With the Style "S"
there is no strain on the clamp or clamp screw.
The force is absorbed directly by the pad shoulders
in the recess of the collet, thus affording positive
pad location and accurate work.
The clamps stay with the collet when stored.

Martin Masters require a set of clamps
with each set of pads.
Additional Style "S" Advantages

No holes or slots in the head angle of the collet. This gives the collet maximum
bearing surface between the spindle and head angle.
No uneven wear caused by holes and slots. High spots left after use of other masters
will reduce head angle bearing when using solid collets.
No threaded holes in the collet to be stripped or damaged.
If clamp screw is stripped or damaged they can be removed without damaging
the collet or the pad.
The pads are interchangeable without removing the master collet from the spindle.
Disadvantages
Clamps can come out of collet when being stored and are easy to lose.
Clamp screw threads and wrench sockets can be stripped due to overtightening.
Basic Workholding
Techniques
Style "S" Pad Advantages

Easily inserted and removed without taking the master collet out of the spindle.
Pads gives maximum gripping surface no matter what size.
Dovetail anchor securely holds pads in place when bar is loaded. They cannot be
dislodged. No other front-loading pad can make this claim.
No threaded holes in the pad that can be stripped or damaged.
Pads are available in standard sizes up to the rated capacity of the machine.
Available in round, hex, square and special-shapes to rated capacity of the machine.
Available in serrated or smooth to the rated capacity of the machine.
Available in English and metric sizes.
Available in the following materials:
Hardened Steel
Steel - Emergency Style
Bronze
Carbide Impregnated
Nylon
60% less expensive than purchasing solid collets.

Hex and square and special-shaped pads run more concentric than solid collets.
Clamps not fixed to pads, therefore less storage area is needed for style S in
comparison to Martin Pads.
Dovetail design pulls pads into the pad seat.
Disadvantagesnone
75
76
CHAPTER 11
Martin Master Collets
The Martin Master has a slot

in the face of the collet,
through the head angle. The
pad is held in the collet using
a square lug that is threaded
into the pad. Each lug has a
taper-threaded lockingscrew which clamps the pad
to the collet.
Collet
Tapered Screw
Pad
Clamp
Clamping cross section

Advantages
The collet does not have to be removed to change pads.
Disadvantages
Loss of bearing surface when mated to spindle due to slots for clamps.
Uneven wear caused to the machine tool spindle due to slots in collet.
This creates high spots on the spindle angle and causes solid collets to have
very poor bearing to the spindle angle.
Clamping the pads into the collet may distort the head of the collet.
Clamps and pads loosen very easily.
Pads can be knocked loose when loading a new bar.
These collets not stocked in all sizesmay require a special order.
Basic Workholding
Techniques
Martin Master Pads
Collet
Tapered Screw
Pad
Clamp

The Martin Master pad has a square
lug threaded into its side with a taper
threaded hole in the lug for tightening
it into the collet slot.
Advantages
Easily inserted and removed without taking master collet out of the spindle.
Clamps stay with the pads and cannot be lost.
Disadvantages
Machine capacity sizes are not available as standard pads because the clamp
would protrude into the bore. Depending upon the machine, between 1/16" to 1/8"
is lost from its maximum capacity when using these pads.
EXAMPLE: Maximum size standard pad for a 1" Acme is 15/16".
More space is needed to store Martin pads because the clamp stays with the pad.
Due to the lack of popularity, the stock is not as complete as with the Style S.
When locked, they are not drawn back into the pad seat.
77
78
CHAPTER 11
"CT" Style Master Collets
Collet
Cone Point
Set Screw
Pad

Each pad is locked into the collet using two
set screws (cone point) locating into detentes in the
shoulder of the pad. The threaded holes are in the
face of the collet. This collet was used as original
equipment on National Acme machines.
Advantages
Pads can be removed without removing the collet from the machine.
Disadvantages
Tapped holes for locking screws can be damaged by overtightening which
can destroy the collet.
Pads can be locked without the set screws being seated in the detentes on
the shoulder of the pad.
When loading new bar stock, the screws take all the shock, causing the pads
to loosen up. This allows chips to get behind the shoulder of the pad.
Pad Advantages
No clamps to lose.
Can be loaded without taking collet
out of the spindle.
Pads can be easily stored because
there are no clamping lugs.
Full bearing surface - no holes thru
pads on large capacity sizes.
Pad Disadvantages
Flaring of set screw detentes due to
over torquing of the set screws.
Can be dislocated when loading a
new bar.
Expensive to manufacture due
to special needs of set screw
location area.
Subject to cracking and/or chipping
if shoulder is not properly heat-treated.
Basic Workholding
Techniques
"CB" Style Master Collets

Collet
Cup-Point
Screw
Pad

The collet has one locking screw (cup point)
per pad. The back shoulder has a back taper
which helps lock pad in place. This collet
was used as original equipment on National
Acme Machines.
Advantages
Front-loading collet does not have to be removed to replace pads.
Locking screws stay in the master colletno clamps to lose.
Disadvantages
There is no way to make certain the pads are lined up with the set screw
before tightening.
Tapped holes for locking screws can be damaged by overtightening,
which can destroy the collet.
The screws take all the shock when loading new bars, causing the pads to loosen,
allowing chips to get behind the shoulders.
Any misalignment of the screw or detente in the pad will cause it not to seat properly.
Pad Advantages
No clamps to lose.
Can be loaded without taking collet
out of the spindle.
Pads can be easily stored because
there are no clamping lugs.
Full bearing surfaceno holes through
pads on large capacity sizes.
Pad Disadvantages
Flaring of set screw detentes
due to over torquing of set screws.
Can be easily dislocated when
loading a new bar.
Expensive to manufacture due to
special needs of set screw location.
Subject to cracking and/or chipping
if shoulder is not properly heat-treated.
79
80
CHAPTER 11
New Britain Master Collet

(O B S O L E T E)
Collet
Cone Point
Screw
Pad
The collet does not contain the lock screws. Two locking screws are in each pad which locks
against a detente in the collet back seat.
Advantages
Front loadingcollet does not have to be removed to replace pads.
No tapped holes in the collet.
Disadvantages
If the set screws are over-torqued, the collet can be permanently damaged.
The cutting pressure and load is against the set screws.
Pad Advantages
Locking mechanism stays with pads
and cannot be lost.
Pad Disadvantages
Cutting thrust is against the set screws
rather than the full back shoulder.
Some bearing loss due to holes
for seals.
Basic Workholding
Techniques
Standard Master Collet
Collet
Locking Bolt
Pad
A screw goes through the head angle of the collet and into the side of the pads shoulder.
The collet must be removed from the machine spindle to change the pads. These collets are
available for all style machines.
Advantages
Once the collet is purchased, the pads are less expensive than solid collets.
Disadvantages
Must remove the collet to replace the pads.
The hole in the collet bearing angle causes uneven wear of the spindle. The resulting
high spots make other style collets perform poorly.
Screw can be sheared when loading new bar stock.
Pad Advantages
Considerable savings over the price
of solid collets.
Firmly held into the master collet.
Pad Disadvantages
Must remove collet to change pads.
Threaded holes remove bearing area
on larger capacity pads.
Screws can shear when pad is hit
when replacing bar stock.
81
82
CHAPTER 11
Hex and Square Pads

Masters are Better Than Solids
Hex and square pads run much more concentric than hex and square solid
collets. If you are considering precision work and are going to grip on the flats of
the hex or square stock, always use Style "S" master collets and pads. Solid
collets will not run as true. Therefore, if the corners of your hex stock do not
clean up all the way around the part, switch to a master collet with hex pads and
they will clean up correctly.
The alternative to gripping on the flats of any polygon is to grip on the OD (corners) using either an angular-slotted collet or a zig-zag slotted collet (see chapter
1). The corners will not fall into the slots, making it easier to load the part and
hold them concentric.
Basic Workholding
Techniques
MASTER
FEED
FINGERS
Chapter 11 Continued
Master feed fingers come in several styles from nonadjustable to fully-adjustable.

The main reason for buying master feed fingers is to reduce expense as compared to the cost of solid feed fingers. The storage requirements for the pads are
less than the area required for storing solid feed fingers.
83
84
CHAPTER 11
Style "B" Master Feed Finger
The Style "B" Master Feed Finger & Pads are the most practical feed finger for
high production bar machining. The pads & feed finger design is the most stable
on the market today. They were designed to take the abuse of your roughest
operator and still give you the precision your machine tool requires. Below is a
review of the Style "B" in greater detail.
Style "B" Features:
No Screw or Pins
to Hold Pads in Place
Three Pads
Several Standard Shapes
PAD
HA R D I N G E
BAR STOCK
PAD
Heat Treated for Tension Only

Pad diameter controls
different tensions
Full Bearing on the

Bar Stock
Basic Workholding
Techniques
Additional Advantages
Pads cannot come loose.
Quick changeover using Hardinge-designed wrenches.
Full bearing on the stock.
Disadvantages
Centrifugal force at high speeds can cause feed fingers to loose gripping force.
They are not adjustable.
Pad Advantages
Heat treated for hardness only. Maximum hardness possible which gives maximum
life.
Cheaper than solid feed fingers.
Normally stocked in 1/64" sizes. Many decimal sizes are also stocked.
Pads stocked in round, hex, square.
Take up less storage space than solid feed fingers.
Special feed fingers are made for rectangular, other polygon shapes and
extruded stock.
Pads come in many different materials.
Pad Disadvantages: None
85
86
CHAPTER 11
Materials Used for

Standard Stocked Pads
Hardened Steel
Used for hot-rolled and cold-drawn steel bars.
Long wearing and reasonable abrasion.
Hard Pads61-63 Rockwell C scale.
Nickel
Cast Iron
Used for brass, aluminum, polished and plated stockhelp eliminate scoring.
Greater life than bronze because they are harder. (If nickel scores, switch to bronze
pads)
Bronze
Used for ground drill rod, brass, aluminum, polished and plated stock. These will
eliminate scoring.
The best choice for stainless steel.
Only recommended when cast iron pads score the stockbronze pads
have a shorter life.
Nylon
Used on chrome-plated and highly-polished stock.
Basic Workholding
Techniques
"BX" and "DX" Adjustable-Tension

Master Feed Finger
Adjusting Sleeve
Body
Pad
The Style BX & DX feed finger has a sleeve that is moved to increase or decrease the tension on
the pads. The sleeve locks against the feed tube. This feature eliminates the possibility of having
it loosen up. The collet takes standard style B pads.
ADVANTAGES
Tension can be adjusted.

Adjustment is approximately 1/64" on diameter.
Takes standard B pads.
Positively locks against the feed tube.
Loss of tension due to centrifugal force is reduced.
DISADVANTAGES
Only available for B&S 00, 0, DA2 and 9/16 Cone.
87
CHAPTER 11
"AF" Style Master Feed Finger
Adjusting Cap
13/16
Pads
Support Bushing
13/16
88
The "AF" Style Feed Finger uses inexpensive pads which are adjustable in 5 - 7 pound increments. The feed finger has a support bushing in the back to eliminate bar whip within the feed
finger. No screws are used to hold the pads. They are adjustable for different tensions and stock
sizes.
Advantages
Can adjust for different size stocka full 1/32" adjustment from the rated size down.
Eliminates the need for decimal or metric pads and pads in 1/64" increments.
Feed bushings are used to control bar whip.
Eliminates feed hang ups.
Better finish on part because of less bar whip.
Adjustable tension on the stock.
More tension can be achieved using this feed finger than with any other feed
finger produced, whether master or solid finger.
Extremely light tension for thin wall tubing and delicate stock.
Basic Workholding
Techniques
Pad Advantages
Same master feed finger pads can be used for many different machines using the
same style feed finger, which results in reduced inventory.
One tool cabinet drawer can hold hundreds of pad sets and still only weigh a few
pounds. The same quantity of pads of any other type would take two or three tool
cabinets, not just one drawer.
AF Pads are less expensive than style B pads, and much less expensive than solid
feed fingers.
Pad Disadvantages
Cannot go under or over the rated capacity of the pad. For example, an AF6 pad for a
1" Acme feed finger has a minimum capacity is 3/8". If you wanted to feed a 1/4" bar,
another style feed finger would have to be used.
Cannot go to the maximum capacity of the machine.
Pads will break when used without the support bushing.
Some people feel it is difficult to change pads.
The Model 3A AF pads cannot be used under 3/16".
89
90
CHAPTER 11
MODEL "A" MASTER FEED FINGER
The pads are held in a groove with a shoulder locating the pad on both ends.
One key holds one pad in place which eliminates rotation of the other pads.
Advantages
No pins or screws used to hold pads into place.
Thrust supported by shoulders.
Pads less expensive than solid feed fingers.
Disadvantages
When loading bar stock, the pads can be knocked loose.
Pads are tricky to install.
Basic Workholding
Techniques
notes:
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
91
CHAPTER 11
Other Adjustable Feed Fingers

Dial-Adjustable Master Feed Finger By Balas
Rear Support Bushing

10
4
5
6
7
8
9
3
1
2
20
92
Inner Master
Outer Sleeve
2
3
4
Basic Workholding
Techniques
2
3
4
The dial adjustable master uses style A pads. It has a master body which accepts the pads. The body also accepts a rear support bushing. The outer sleeve
is turned counterclockwise to adjust for more tension on the inner master.
A wrench is required to spread the master collet for pad insertion. The same
wrench is used to adjust the outer sleeve. There are numbers on the master
body that indicate whether the tension is being increased or decreased.
Advantages
Tension is adjustable by hand. Wrenches are used to hold one member from turning.
Carbide pads available for maximum wear resistance.
Will not lose setting because feed tube locks against outer sleeve.
Minimally affected by centrifugal force.
Disadvantages
Outer assembly must be removed to change pads in the masters body.
Size restrictionmaximum capacity of machine cannot be utilized.
The same problem as with all adjustable masterstoo many pieces.
93
94
CHAPTER 11
Squirrel-Cage Feed Finger

(Adjustable, but not a Master)
Whack it here
with a hammer
ANVIL
Cross Section and Adjustment Method

The squirrel cage-style feed finger has slots like a cage. They are swagged to
size against an undersize plug and then heat treated.
Basic Workholding
Techniques
Advantages of Squirrel-Cage Feed Finger
Inexpensive.
Adjustable.
Not affected by centrifugal force as much as masters with pads or solid feed fingers.
No moving parts.
Disadvantages of Squirrel-Cage Feed Finger
Crude adjustmentwhack it with a hammer.

Concentricity problems after adjustment.
Tension life is short.
No precise way of telling what the tension is on the finger or a way to make certain that
each leaf has the same tension.
Stock-Saver Feed Finger

Whack it here
with a hammer
ANVIL
ANVIL
Stock-Saver Feed Finger (squirrel cage -style)

Same as the squirrel-cage but it has two adjustable areasone in front and one
in the middle of the finger.
95
96
CHAPTER 11
Types of Solid Feed Fingers
Standard Solid Feed Finger

Advantages
No moving parts.
One costs less than a master.
Disadvantages
Expensive if more than one is ever purchased.

Non-adjustable.
Tension controlled by heat treatment.
Require finger for each size stock.
Requires considerable storage space.
Entire feed finger must be replaced when worn.
Expensive because it requires additional feed tubes for each size stock.
Basic Workholding
Techniques
FEED TUBE
BRAZE
FEED FINGER
Brazed On / In Style Feed Finger

The brazed style feed finger is used when overcapacity stock is to be fed through
an oversize collet. Instead of threads, there is a machined diameter. The feed
tube threads are removed to the machined diameter on the special feed finger.
The two are then brazed together.
Advantages
Allows feeding of oversize stock not possible with standard feed fingers.
Disadvantages
Requires changing the "feed tube/finger" combination for each change in bar size.
97
98
CHAPTER 11
"Milled-Through" Solid Feed Fingers

The "milled-thru" feed finger accepts rectangular, square and hex stock that has a thickness
equal to the milled slot. One feed finger can do the work of several.
Example:
When there are four different flat stock jobs to run, a feed finger or pad would be needed for
each size. Suppose we have four pieces of flat stock: 1/4" square, 1/4" x 3/8", 1/4" x 9/16, and
1/4" x .744. When using a milled-thru 1/4" feed finger, all of these pieces of stock can be
handled by the same feed finger with a considerable dollar savings. A 1/4" hex could be fed, but
because of the small amount of bearing surface, feeding problems may result.
Basic Workholding
Techniques
Round Shank
Threaded Adapter
Feed Finger
Bar / Stock PullerFeed Finger Style

The feed finger style bar puller is used for pulling bar stock and also loading and unloading
workpieces. Every size bar or workpiece requires a separate feed finger. See section on parts
loadingchapter 14.
99
100
CHAPTER 11
notes:
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
Basic Workholding
Techniques
CHAPTER
12
JAW CHUCKS
VS.
COLLETS
101
102
CHAPTER 12
Chucks vs. Collets
Chucks vs. Collets

The collet and jaw chuck are the two major methods for holding workpieces or
tools on a machine tool or fixture. Throughout the years, machinists have debated which was the best device for holding a workpiece or tool. Let's take a look
at many of the different applications for each method of workholding. We will then
finish out the chapter by describing each style of jaw chuck.
Reasons for Selecting a Jaw Chuck

Variation of chucking diameter greater than the collet's limits.
Parts too large for the collet capacity of the machine.
Eliminate large inventory of collets.
Machine does not have collet or step chuck capabilities.
Cost of a collet for a short run job.
Delivery time for a new collet for a short run job.
Rough chucking surfaces such as castings.
Non-symmetrical work requiring a 2- or 4-jaw chuck.
Customer has the facilities to machine chuck jaws for complex shapes but does not
have them for machining collets.
Basic Workholding
Techniques
Reasons for Selecting a Collet

Maximum gripping forcemost critical on long overhang.
Life of a hardened and ground collet is much greater than machined chuck jaws.
Inexpensive precision workholding deviceless expensive when using pads.
Special-accuracy collets are available in hardened and ground styles for
super-precision chucking.
Collets are available in .001" increments (5C's).
Best TIR because there is no overhang. Most chucks extend from the face of the
spindle between 4 to 6 inches, not counting the length of the jaws.
Centrifugal force does not cause problems with collets or step chucks that use closers.
The working portion of the collet is completely enclosed and cannot expand at high
spindle speeds.
Part tolerance or a long-run job dictate a collet to reduce downtime and the necessity to
re-bore the chuck jaws.
Less chance of expensive wrecks.
One Shop's Reason For Switching to Collets

One shop with two machines started out with jaw chucks on their CNC
slant bed lathes. Within one year they had to replace the turret assembly twice,
replace the spindle once, replace the jaw chuck twice, rebuild the jaw chuck
three times, plus expend many man hours repairing the machines due to jaw
chuck interference related wrecks.
They then changed to collets and step chucks, which increased the gripping forces, decreased the overhang by 6 inches, increased their ability to hold
close tolerances, and reduced spindle tooling interference problems, which
eliminated major wrecks. Their down time was substantially reduced.
103
104
CHAPTER 12
Chucks vs. Collets
Types of Spindle Chucks

Mechanical (manual-operated)
Pneumatic (air-operated)
Hydraulic
Electro-Magnetic
Vacuum
Mechanical (manual-operated)
3-Jaw Universal
2-Jaw Universal
4-Jaw Independent
4-Jaw Universal
Pie Jaw
Comes in many versionsthe most common are shown above.

Inexpensive.
Uses a key wrench to tighten and loosen workpiece.
Basic Workholding
Techniques
Pneumatic (air-operated)
Allows for lighter gripping pressures than hydraulic chucks.

Smaller sizes can have accuracy very close to precision collets.
Air cylinder is usually mounted at the rear of the spindle with a draw tube running
through the spindle.
The air cylinder can also be part of the chuck. This style chuck is usually longer in
length than the rear-mounted cylinder chuck which increases the TIR problems.
This style is usually heavier, which puts more weight on the front of the spindle.
Some air chucks actually use the draw bar of the collet closer. These chucks usually
have a thru-hole capacity equivalent to the collet capacity of the machine tool.
The internal construction of the chuck can restrict the maximum RPM it can be run.
Precision air chucks usually cannot be run faster than 3,000 RPM. The exception is the
small 3" air chucks which can run at 5,000 RPM or higher.
Hydraulic Chucks
Much greater gripping pressures than air chucks.

The hydraulic cylinder may be either at the rear of the spindle or built into the actual
chuck.
Thin-wall tubing and delicate parts cannot usually be run with hydraulic chucks because the chucking pressure cannot be reduced enough.
Weighs more than air chucks creating additional spindle loads.
105
106
CHAPTER 12
Chucks vs. Collets
Electro-Magnetic Chucks
Normally used for flat magnetic steel and iron partsif surface is flat, there will be no
chucking distortion.
Expensive.
Cannot be used for nonmagnetic materials.
Requires special electrical rotating connection.
Requires a large power supply. This type of chuck uses an electric-powered magnet
which consumes large amounts of DC (direct current) power. A power supply is required to change the normal AC (alternating current) to DC. Because of the amount of
current that is required, a rather larger power supply is required.
Vacuum Chucks
Will hold all types of material with even chucking pressures.

No distortion caused by chucking if the chucking surface is not distorted to begin with.
Requires a separate vacuum pump.
Expensive.
Materials to be chucked cannot be porous.
There are universal rotary vacuum chucks that have vacuum ports that can be turned
off or on to conform to the chucking surface area.
There are special techniques for holding bandsawed blanks for the first operation.
Basic Workholding
Techniques
CHAPTER
CHAPTER
13
14
BAR STOCK
PULLERS
107
108
CHAPTER 13
Bar Stock Pullers
Bar Pullers
There are several different style bar pullers on the market. The two most
common are the feed finger style and the two-finger style.
Feed Finger Style

The feed finger style consists of an adapter
that fits in the machine's turret. The special
feed finger threads into the adapter. These
feed fingers can be acquired for all nominal
sizes, usually from stock. The bar puller
functions the same way that a feed finger
works in an automatic lathe. When using
a bar puller, the part has to be cut off
approximately 1/2" from the face of the
collet. The bar puller feeds onto the bar,
forcing the fingers to spread apart. There
must be enough tension on the fingers to be
able to pull the bar out, after the collet is
open, without slipping. A large diameter and/
or a long length of bar will require considerable tension.
Two-Finger Style
The two-finger style is universal. One
puller will handle stock from 1/8" to
1-5/8" and larger. This makes it less
costly to use than the feed finger style.
The unit can also be mounted parallel
to the centerline of the spindle as well
as perpendicular to it, and can be held
in either a round shank or square shank
holder.
Both Styles Feature
Up to 1-5/8" stock. (Hardinge-brand bar puller)

Can pull up to 12 foot bars when using a "non-pusher" type bar support.
Inexpensive.
Can pull short or long bars.
Uses spindle liners for precision parts with no whip.
CAUTION: Stock should never extend beyond the end of the machine tool spindle
unless supported with a Non-pusher style bar feed tube, or similar device.
Basic Workholding
Techniques
CHAPTER 14
PARTS LOADING
AND
UNLOADING
109
110
CHAPTER 14
Part Loading and Unloading
Parts Loading and Unloading Aids

Let's consider that we have a good operator but we want to assist him to increase his productivity by reducing potential scrap due to human errors.
These devices can be loaded by hand, but only if the machine functions have
been completely stopped, per OSHA (Occupational Safety & Health Administration) regulations.
Feed Finger Style Parts Loader
Solid Tube Parts Loader

Holds part with friction from the O ring. This device should be spring-loaded to hold the part
against the shoulder in the collet as it is closing.
Basic Workholding
Techniques
Rotating Parts Loader
Can load parts that are not round.

Can load round parts without scratching.
Requires special collet for each part.
To load parts that are not round or parts that cannot be scratched, a special step chuck
or driver plate is needed.
Parts Unloading Aid
Spring Ejector Stop

A spring ejector collet is used to eject the part into a parts catcher. The parts catcher can be an
air-operated parts chute.
A wire basket held by the turret or cross slide. Many times these are arranged to automatically
dump their contents at the return of the slide or index of the turret.
111
Hardinge Workholding Products
Swiss-Type Collets &

Guide Bushings:
Brochure #2283
Sure-Grip Expanding
Collet Systems:
Brochure #2270
Collets for
Automatics:
Brochure #2287
The Hardinge
Advantage:
Brochure #2327
HQC Quick-Change
Collet Systems:
Brochure #2339
Spindle Tooling for

Manual and CNC
Lathes:
Brochure #2348
Precision Tool
Holding Systems
& Mill Tooling:
Brochure #2350
Toolholder Collets,
Bushings & Round
Shank Holders:
Brochure #2351
HCAC Collet
Adaptation Chucks:
Brochure #2352
Machine Tool
Products Overview:
Brochure #1190
Sure-Grip 3-Jaw
Power Chucks for
All Brands of Lathes:
Brochure #2357
Worldwide Manufacturer of
Machine Tools and
Workholding/Industrial Products
Sure-Grip Chuck
Jaws for All
Brands of Chucks:
Brochure #2358
www.hardingetooling.com
your online purchasing source for workholding
Hardinge Inc.
One Hardinge Drive
P.O. Box 1507
Elmira, New York 14902-1507 USA
Brochure 2316B
Part No. HA B-0009500-2316
October 2002
To order in USA:
800-843-8801
To order in Canada:
800-468-5946
All other calls:
607-734-2281
Fax:
607-734-3886
Internet:
www.hardinge.com
www.hardingeworkholding.com
All specifications subject to change without notice.
All marks indicated by or are trademarks of Hardinge Inc.
Litho in USA
Hardinge Inc. 2002

Basic Workholding Techniques

Enviado por

Dados do documento

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

Basic Workholding Techniques

Enviado por

Direitos autorais:

Formatos disponíveis

Basic

NOTE: Information in this document is subject to change without notice.

3 BASIC COLLET CONFIGURATIONS

Basic Collet Introduction

THE HEAD ANGLE

Probably one of the least (but most) critical factors in

Items such as the headstock center have their back

Face of Spindle & Cap

Collet Back Bearing

Stationary Screw Machine Collet

Slot with Relief Hole

The angular-slotted collet is used when holding

Other Slot Designs

Collet Back Bearing

Collet Back Bearing

Push SleeveStationary Collet

Actuating the System

Mechanical Collet Closer

Pneumatic or Hydraulic Closers

Pneumatic and Hydraulic Closers

Machines that use the various collet systems

PUSH SLEEVE - STATIONARY COLLET:

30. Extended-Taper Nose

The Concentricity of the Spindle

1. TIR of the spindle angle

2. TIR and wear on the back bearing

3. Runout of the collet thread

Screw Machine Collet - Large Amount of Spread

Lathe Collet Very Little Spread

NEW COLLET-NO CAM GRIND

WORN ORDER HOLE - NO CAM GRIND

CAM and Flat Grind

There are restrictions on its use:

EXAMPLE: 16C Collet = 2 (Tan 10 degrees x stroke)

Advantages of Hardened Collets

PROBLEMS CAUSED BY IMPROPER HARDNESS

What Causes Collets and Pads

Types of Machining Operations

Heavy stock removal and

Heavy forming-cross slide tends to open the collet.

Forming and drilling at the same time.

Types of Machining Operations

Intermittent cuts can cause radial slippage.

Out of Balance parts. Uneven pressure on the leaves.

Other Causes for Wear

Materials Held by Collets

Certain alloys cant

Stock is not round,

Most common steel

Punched from flat stock

Extruded thru several

There are many different

Marks very easily

Materials Held by Collets

Made same as cold

Made same as hotrolled steel

Produces very fine

Permold and sand

Near-net shape drawn

Sand casting process

Materials Held by Collets

Sand casting process

Much more precision

Size variation, soft,