Implementing a more reliable toolholding system for its milling machine operation has yielded major benefits for a global aerospace product provider. In 2000, the company integrated the first ThermoLock® Shrink-Fit toolholder, from Command Tooling Systems in Ramsey, MN, into the facility. Now, over 250 are in use, with more than 80% of the company's airfoil milling machine processes performed using ThermoLock technology.

Since then, productivity has increased and ergonomics have improved for its milling machine operators. In addition, ThermoLock's superior gripping strength and balance performance, compared to hydraulic and/or colleted toolholders, have saved thousands of dollars in time and money on maintenance and replacement parts, the company reports.

Loading and unloading tools is simplified with ThermoLock's Shrinker® technology. Machine operators simply heat the tools using a Command ThermoLock toolchanger; once they cool, the tools are held in place by metal-to-metal contact, directly in line with the spindle. Because the holder has no moving parts, set screws, collets, or nosepieces to adjust, there is virtually no runout.

Also, they never need to be retightened, which virtually eliminates physical stress to the operator -- a benefit for company operators who perform 400-600 tool changes each day. This is a significant advantage over colleted holders, which require a great amount of applied force to tighten.

"Our operators are more confident running multiple machines without concern of collets failing during heavy machining," said the aerospace product provider representative. "In the 6 years we've used ThermoLock, we have never had a tool pull out of the holder."

Using ThermoLock toolholders has resulted in a 30-45% toolholder cost reduction, saving more than $90,000 over 3 years in replacement tooling costs, the company reports. In addition, ThermoLock has significantly reduced scrap by upwards of 90% and increased productivity and spindle cycle time by 5-10%, with longer runs and fewer tool breaks.

"ThermoLock toolholders offer excellent balance repeatability and cut duplication for exceptional reliability at both extremes of the machining continuum," said Command sales representative Arnold Latzke, who works with the aerospace provider. "ThermoLock is an ideal solution for applications that require high speeds and tough cuts."

During its milling operation, the company also benefits from the toolholders' ability to cut at greater axial depths -- between 0.5-2 in. -- with more precision and a smoother cutting finish.

"Cutting tool life has increased over 20%, another significant improvement to the company's previous tooling system," Latzke said.

"We are thoroughly impressed with ThermoLock's outstanding performance and ease of use," stated the company representative.