Machine vice. How to choose and use correctly?

During operation, the working tool processes metal, which moves relative to it in several planes. The master in many cases does not control the movement. The programmed machine itself carries out all the necessary manipulations. To hold the workpiece, machine vices for milling machines have been developed.

Machine vices for milling machines

Installing a milling vice

Before placing any vise on the machine table, be sure to clear the table of any shavings. If you have a T-slot table that you're mounting the vise on, you'll probably want to move the vise around for better placement as well.

Vise alignment is the procedure of using an indicator to move the vise jaw (you want a fixed jaw, not a movable one) so that you can adjust the position of the vise until the reamer shows that the vise jaw is parallel to the axis as it moves.

Learning to "square" a machine vise is one of those basic skills that every machinist should learn early on.

Place the machine vise on the milling machine table

A machine vise is usually attached to the milling machine table.

I used the step clamps that came with my table clamp kit until I purchased my Glacern 6″ Premium Vise:

Step clamps

The new vise came with a nice clamping kit that I like much better:

• New set of clamping jaws

The new clamps are simpler and more compact. It also helps that I switched to a couple of socket head screws for these clamps.

Once the vise is properly installed and secured, the next issue is proper use. In most cases we want the workpiece to be fairly high in the clamps. This is done both to provide access to the workpiece and because it allows for greater repeatability; the smaller the part being machined, the less room there is for unevenness to affect processing.

We typically set the workpiece high in the jaws, either with a parallel vise set or because we have the jaws set in a vise whose step is machined quite high on the jaws. We can either process the step ourselves (in the case of soft sponges), or purchase sponges with the step already processed.

Kinds

Machine rotary vices can be:

• manual;
• pneumatic;
• hydraulic.

It is necessary to analyze each type in more detail.

Manual milling rotary vice

At the base of these milling machine vices is a rotating disk that allows software or a machine operator to rotate them 360 degrees along with the object that is clamped in them.
The disk is fixed using a tight clamp, which is a metal rod with a thread and a static regulator located behind the rotating part. In addition, indentations are made in the rotary disk itself for stronger fixation. A conventional hand vice is bolted onto the rotary disc. They consist of two parallel metal plates, the inner surface of which is covered with damping material.

The control structure is a perpendicular threaded rod that is welded to the central part of the outer side of the plate. The other end of the rod has a handle, and it itself is threaded through a tightly fixed regulator, the inner surface of which also has a thread. The length of the rod is calculated so that the distance between the vise plates is about one millimeter, even with the rod fully untwisted. As a result, using the handle, you can set the desired distance between the plates, as well as adjust the clamping force of the workpiece, without fear of damaging the vice.

There are a large number of modifications of this design. For example, on some vices both plates can move at once due to the presence of a rather complex mechanism, while on others there is a lever instead of a handle and a transmission mechanism, which greatly facilitates the worker’s work.

A manual milling device is most often used in small workshops, as well as for working with fragile objects that should not be trusted with automation. Such a machine tool has a low cost , it is very practical and quite convenient to use.

Pneumatic Milling Rotary Vise

This design is also based on a rotating disk, to which a vice consisting of a rail and two plates is attached.
The control structure of the pneumatic milling machine vise is a sealed tube, one end of which is connected to the central part of the outer side of the movable plate, and the other to an electric or manual pump. If there is a need to increase the clamping force, a large amount of air is pumped into the tube using a pump, which begins to expand, as a result of which the plate begins to move forward. If it is necessary to reduce the force, they begin to bleed air from this tube and pump it into the second tube, which connects the moving plate to another pump and performs the opposite function.

If the vice is to be used in conjunction with an automatic machine, then instead of a clamp and clamp made of a rod, a miniature pneumatic vice will be used, and an electric drive is often built into the base of the disk. This design allows the machine software to control the movement of the cutter and the rotation of the workpiece itself , which makes the work more efficient.

Pneumatic machine rotary vises produce more force than manual ones, but a hydraulic design has come on the market and is the most efficient.

Hydraulic Milling Rotary Vise

In their design and principle of operation, they are fully consistent with pneumatic ones , only liquid is used instead of compressed air. This is mainly water, but to develop greater force, a more elastic and viscous liquid is often used. In addition, hydraulic machine pumps are connected to a reservoir containing the required fluid, rather than being left open to draw air. Hydraulic machine vices are very popular in various industries. These compact devices are also used in workshops.

Vise parallels and jaw steps

Setting the workpiece on the outside of the vice

Increased rigidity

Increasing rigidity is always important. This operation uses two 2-4-6 blocks as a vise jaw extension to better hold the plate at the end.

Using several vices, jaws, and modifying the vice

There's an old rule that if you want to get the most out of your machine, you need to use every square inch on the table. Most machine tables can accommodate multiple vises, and this is very common.

Our photo above of two vices shows one such setup. It is not uncommon to see four or even six vises on a large router. Bigger is better because the more vises you have, the more parts you can handle before machining has to stop so the operator can load new workpieces.

If several vices are installed on the machine, it is convenient if they coincide in all main dimensions within the tolerance. This way, if you duplicate the setup and get the vise in a different order, you'll be fine. Most vise manufacturers will sand the vise for you, or you can do it yourself using a grinder.

Another trick that is possible with two vises is to use the jaws for two vises when working with very long parts:

Connecting two vices with one set of jaws

I made this kit for a project that required machining a thin aluminum panel for some electronics and they worked great.

Selection principles

When choosing devices for fastening workpieces, take into account the following parameters:

• performing certain functions with a vice;
• execution of the fastening mechanism;
• the material from which the jaws were made, as well as their sizes for specific parts;
• nominal pressure on the part when fastening;
• maximum propeller stroke at full extension;
• the mass of the vice is selected in accordance with the dimensions of the machine’s work table;
• type of drive mechanism.

Advantages and disadvantages

The benefits include:

• high force allows you to hold large workpieces during processing;
• the body, made of high-quality steel, can withstand maximum loads;
• the frame is protected from corrosion;
• with the help of a milling vice they perform high-precision work;
• processing soft material without damaging it.

The disadvantages include:

• use of pads under the jaws to prevent the part from jamming;
• vertical distortion of the jaws;
• the use of a complex drive for movement.

Manufacturers and cost

Milling rotary vices are made as an additional accessory for machine tools. Produced by domestic and foreign companies. The price range starts from 2,000 rubles and reaches 30,000 rubles.

Double machine vice for machinist

By spreading three or four vises across the router table, you've taken advantage of the X axis pretty well. But there's an opportunity to better utilize the Y axis with a double vise:

Double vice

A typical two-station vise is like two vises in one: you can put two parts in instead of one. By using double vises wisely, you can really increase the number of parts that can be processed on your machine table at one time.

Competitors of machine rotary vices

The only competitor to such a device is a fixed vice , which, based on its name, does not have such an extremely important function.
However, such a device, without a rotating mechanism, costs much less, so when purchasing them you can save up to 10% of the cost of a manual vice or up to 35% of the cost of hydraulics. There is also little competition between manual and hydraulic devices. Here you need to decide what would be better - significant savings or the opportunity to completely abandon adjusting the vice manually.

Special milling vice

By using multiple vises, double vises, moving jaws, and even using jaws spanning multiple vises, quite a lot is possible. In fact, you can even use a vice to attach other fastening devices. A very common trick is to place small ones in a machinist's vice to turn the jaws in a different direction:

Small vices in big ones

You can also create small plate fixtures that are designed to fit in a vise, creating what is often called a "vice tray" since individual plate fixtures can be pulled out of the vise in the same way as pallets.

Vise Pallets are simply small insert attachments designed to be held in the jaws of a router vise.

In general, solutions such as pallet vises are designed to allow the vise to be left on the machine in shops where the flexibility and ease of clamping of the vise is ideal for most of their jobs.

Tormah made a great suggestion on his blog which was to use a Sine (Toolmaker) vise as a vise tray.

Purpose

In metal-cutting machines, basically all movements are carried out by the working tool. Performing work on the opposite side makes the task more difficult, and the action of the tool falls out of the worker’s field of vision.

Milling vices are used in the following situations:

• to move the workpiece during processing with the front side facing the master, while it can quickly identify shortcomings in the operation of the equipment;
• when making a part in the shape of a perfect circle;
• when moving the workpiece 90°.

Fixation devices are used:

• in a private workshop in the manufacture of various accessories, for fitting plastic windows;
• In industrial production, vices for milling machines are used in the manufacture of parts of complex shapes.

Custom soft and hard jaws increase clamping flexibility in the vise

Soft jaws on a router vise are a very popular form of clamping. The idea is to create aluminum vise jaws (since aluminum is softer than ferrous metals, hence the name) that are tailored to specific applications. Sometimes it is preferable to use a more durable material, in which case we use Hard Jaws.

Here are some examples:

Sponges for round parts

Use soft sponges to find and hold the large round part. You can often see a "V" shape, but it doesn't support the piece as well as soft jaws.

Dovetail

As mentioned above, we don't want to grab the entire height of the part with the jaws. A particularly fine grip can be achieved with dovetail jaws. The small red circle indicates the dovetail, which prevents the workpiece from sliding upward during heavy cutting.

Special soft sponges

Here's a typical setup. The part is cut from the block on the left (these are the same Carvesmart dovetail cams). The part is then turned over in a set of special soft jaws on the right, which are a mirror image of the part. The end mill then removes some of the flat stock left from the original material (this has already happened in this photo).

Setting the workpiece in a vice at a precise angle

Machine vice. Quick replacement of jaws

I think you can see that vise routing using custom jaws can be a powerful solution for securing workpieces. So powerful that most work is done with this method alone. Manufacturers spend a lot of time creating custom jaws and often put them in a storage box to be used for other jobs or in case a customer re-orders a part.

Even though the vise spends most of its time on the table, we still have a bottleneck in setting the time it takes to change the vise jaws. You may have seen this coming, but there are also plenty of quick-change vises available. The Carvesmart jaws we pictured are one variety, but there are many more. Judicious use of an air ratchet and socket head screws can also speed up the jaw replacement job.

Hydraulic vice type

Hydraulic vices provide the greatest clamping value. Their operating principle is the same as that of pneumatic ones, only water is used instead of air. If it is necessary to develop particularly high force, a viscous liquid is poured. Such devices are connected to a reservoir where the liquid used is filled. The container is not open.

Vices are expensive. Therefore, they are used in enterprises manufacturing high-tech products. They can be located on automated machines.

Review and comparison of models

JET MMV/SP-50 GR35010

JMD-3 Jet 50000058

JMD-1 Jet 50000025 Jet 385021

Features and purpose

Any vice, including a bench vice, is a mechanical device, the main purpose of which is to ensure reliable fixation of various workpieces and workpieces. They are also designed to free the master's hands during work, which ensures precise execution of actions (drilling, making cuts). The vice promotes worker safety and reduces physical and energy costs to a minimum.

Since the design of the vice is simple, the scope of its application seems quite wide: the vice is used by both professionals in production workshops and amateurs for repair work in home workshops.

The parts are fixed in a vice between 2 parallel plates by rotating the handle, which adjusts the degree of clamping. In turn, the bench vice is securely mounted on a special stable workbench or work table.

A special feature of this device is its great strength, since intense impact force is used when performing work such as forging, chopping and riveting. Vices can come in a variety of sizes, from lightweight small models to huge fixtures used in factory production.

Design and principle of operation of clamping devices

Since machine vices are necessary to securely hold the workpiece during processing, they are made of durable steel elements. Depending on the type and purpose of the machine vice, their design can vary significantly.

The mid-price category includes rotary models, the functionality of which allows drilling operations to be performed more efficiently. The advantages of vices of the first and second types are combined in universal devices for a drilling machine, which, naturally, makes the cost of such devices quite high.

Even vices of the same type, but produced by different companies, may have certain design differences. This is explained by the fact that each manufacturer tries to provide their products with additional options, to make them more reliable and convenient to use.

Professional machine vices can be equipped with various clamping bars

Whatever functionality the machine vice has, the basis of its design is made up of mandatory elements, which include:

• strips that act as the base of the vice;
• two jaws that provide clamping of the workpiece;
• a screw with a handle, which ensures the movement of the movable clamping jaw;
• plates that serve as working elements of the clamping jaws;
• a number of additional details.

The device of the simplest machine vice

The bar, which acts as a base, is the supporting element on which all other parts of the vice are fixed. It is on the bar, which is made of hard and wear-resistant metal, that a hole for the screw is drilled and the movable and fixed jaws are mounted. To ensure precise movement, there is a rectangular shank on the bottom of the movable jaw, which is inserted into a cutout made on the fixed jaw.

Shank responsible for the parallel movement of the jaws

The screw responsible for moving the movable jaw is connected to it, which is ensured by a special locking ring. Rotating in the threaded hole of the base plate, the screw moves the movable jaw, thereby ensuring clamping of the workpiece processed on the drilling machine. To understand how a vice works, you can watch the corresponding video.

Both serial models and homemade vices for a drilling machine can be made according to different patterns of screw action on the movable jaw. In the simplest models of a vice, which are easy to make with your own hands, the screw is directly connected to a movable jaw, which it either pulls (unclamps the jaws) or pushes (compresses the jaws), which depends on the direction of its rotation. In more complex models, which may include both fixed and rotary vices, rotation of the screw is transmitted through gear drives, which makes the work of the drilling machine operator easier. Thanks to the gear drives, very little force is required to compress or unclench the jaws of the vice.

It should be borne in mind that the presence of a gear mechanism is not at all a criterion that should be emphasized when choosing clamping fixtures for a drilling machine. Many well-known manufacturers, whose products are popular with specialists all over the world, produce devices whose operating principle is implemented according to a standard scheme, which does not make them less effective or inconvenient to use

Hydraulically reinforced vice provides stable compression, independent of shock and vibration

Important structural elements of any type of vice, which experience significant loads during operation and ensure reliable fixation of the workpiece, are pressure plates, or strips. Such elements, made of durable metal, are attached to the working surfaces of the clamping jaws using screw connections.

In the standard version, the clamping bars have a flat working surface, on which a cross notch is applied. More specialized types of planks are also used, which are necessary for processing workpieces of a certain shape. The working surfaces of such planks can be made in various shapes (angular, concave, etc.). In some modern vise models, the clamping bars may be spring-loaded. This design makes it possible to slightly increase the convenience of fixing parts in the clamping fixture of a drilling machine.

Vise with prismatic jaws

Vise. Types and device. Operation and application. How to choose

A vice is a mechanical device that provides reliable fixation of workpieces for processing. They are used in plumbing and carpentry.

The instrument is made of metal or wood. It can be either compact or massive, depending on its purpose.

Using a vice, you can provide rigid temporary fastening for processing parts when sawing, drilling or planing.

What are vices made of?

The design of the vice is quite simple. The most common mechanism is two flat jaws with an adjustment knob that moves a clamping screw. With its help, the sponges diverge and contract. By placing the workpiece between them, you can ensure its reliable fixation. One jaw of the mechanism is fixedly fixed to the body, and the second slides along a guide, moved by a screw.

The locking adjustment mechanism itself consists of a lead screw that passes through the entire structure of the vice. Regardless of what the device body is made of, the screw is always metal. There is a handle at the end for easy adjustment without using a wrench. Vise jaws often have soft pads.

They can be made of hard rubber or non-ferrous metals. Their use makes it possible to reduce cutting into the workpiece being fixed. If a delicate part is installed, it is additionally wrapped in fabric or various pads to prevent deformation.

This primarily applies to soft wood, as well as plastic and workpieces that can be scratched.

The base of the vise is secured to the surface by tightening screws or clamping a clamp. Some varieties of small vises commonly used by jewelers are magnetically attached.

In order to use a vice, you need to rotate the screw handle counterclockwise to expand the jaws to sufficient clearance. After this, the part that needs to be fixed is inserted into it.

Next, the screw is screwed in clockwise and securely tightens the workpiece. When using a massive device, it should be taken into account that its compression force is very large. As a result, the workpiece may become deformed.

First of all, it swings thin-walled tubes, as well as wood.

Types of vices

A vice is a multi-functional tool that is used for various purposes. In this regard, its design was modified to perform certain tasks.

Vices have several varieties:

• Locksmiths.
• Machine tools.
• Carpentry.
• Manual.

Each variety has its own advantages and disadvantages. Vise types are designed specifically to perform specific tasks, so using them in the right way allows for maximum ease of use.

Locksmith

The bench vice type is a metal tool that does not have parts made of soft materials. It is mounted on a workbench, table or other stand.

This device can be fixed either stationary or rotated, which allows you to work at different angles. Locksmith models are characterized by jaw widths ranging from 45 to 200 mm.

On average, they provide clearance to grip parts up to 140 mm thick.

A bench vise is characterized by a small anvil on the body, which can be used to trim workpieces using a hammer. This tool has a slight play when the jaws move, but since it is used for rough work, this is not critical.

If we consider the advantages of a bench vice, we can note their fairly reliable design with good fixation. They have relatively small dimensions, although there are also quite large devices. Their body is made of metal or cast iron, so they are resistant to mechanical stress. The workpiece clamped in them can be hit with a hammer.

The disadvantages of plumbing tools include the presence of play in them, which gradually increases. The weak point of this design is the lock washers, which often wear out and need to be replaced.

Due to the rather small width of the jaws, it is not always convenient to fix long parts. If they are very heavy, then during processing one end of the workpiece may fall. To avoid this, you need to periodically tighten the screw.

A larger area of ​​the jaws, even with the same force, would provide a more reliable fixation due to the increased friction force, but there are no such models in bench vices.

Machine tools

Machine vise is a high precision tool. Their jaws have no backlash due to the fact that the screw moves along a clearly defined path in one axis with several additional fixation points. Such devices are used in production.

They are usually fixed on workbenches and other mechanisms for processing parts. Often they are not tightly attached, like most plumbing tools, but can be rotated, positioning the workpiece at the desired angle.

Often the stand has many axes of the adjustment mechanism, which allows you to turn the workpiece at any vertical and horizontal angle.

The machine type has a high pressing force, as well as fairly wide jaws, so they can be used to clamp fairly heavy and long parts.

Their body is made even more durable than that of a bench vice, so it better withstands mechanical stress and hammer blows.

An important advantage of this vice is the absence of backlash, which is very important if it is necessary to level the workpiece for precise drilling.

This tool also has disadvantages. There are practically none, except for the fact that the vice compresses really very hard, and if you overdo it a little with tightening the screw, the workpiece gets visible defects with a trace of the imprint of the jaws. Not that this is really a drawback, but you need to work carefully.

Manual

As for hand vices, they are the most compact. They are designed for processing small parts that just need to be fixed without being attached to the table.

The part is simply clamped in the jaws, and the vice is held in the hand. Often the design of this mechanism resembles a clothespin or pliers.

The jaws are directly pressed by tightening the wing nut.

This type of vise is usually used by modellers when building small replicas of ships, cars or airplanes. They are also used by jewelers. These models are very compact and can often even fit in a trouser pocket.

However, you should not confuse hand vices with very small bench vices. Mechanical ones are always fixed to some surface, but manual ones do not need this. They are simply held in your free hand as a handle that clamps the small part.

In this case, the second hand carries out processing with a file, sandpaper or other tool.

The advantages of manual vices include their very reliable design. They can be easily disassembled, cleaned and lubricated with a minimum of time.

They take up very little space, and besides this, they have virtually no play. Their handle is coated with santoprene. This ensures a secure hold in the hand, eliminating utterance.

This coating makes the tool warmer, which is especially important if you have to work in the cold.

The disadvantages of hand vises include the very small size of the jaws, which will not allow processing larger workpieces.

Often the lips have a small relief groove in order to more securely fasten the clamped part. As a result, a fingerprint may remain on it.

This is a fairly common problem, since manual models are mainly used for processing soft non-ferrous and precious metals.

Carpentry

The carpenter's vice is designed specifically for securing wooden workpieces for processing.

Its peculiarity lies in the wide jaws to increase the clamping area, which ensures minimal deformation on the surface of the fixed parts. Joinery models are often made from hardwoods. Primarily this oak, beech and ash.

They are fixed with screws to the table, or are directly part of it. Often, a carpenter's table comes with a built-in vice.

The main advantage of carpenter's vices is their ability to work with fairly soft materials. Their setting jaws have a large area and are smooth so they don't leave marks. The clamp stroke width is quite large, which allows you to fix even wide boards.

The disadvantages of such vices include the fact that they are completely unsuitable for fixing really hard parts. If you clamp metal in them, the jaws will be damaged.

What to look for when purchasing

When choosing any type of vice, you should first of all pay attention to the presence of backlash. If it is present on a new tool, then you should not take it, since over time it will turn into a big problem.

When choosing the optimal model, you should start from what workpieces will need to be clamped in the future. This is necessary in order to select the optimal working width. It is also worth paying attention to the method of attaching the pads to the jaws. They can be secured with rivets or screws.

The first option is more reliable, but does not allow you to conveniently change the linings.

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Source: https://tehpribory.ru/glavnaia/instrumenty/tiski.html