Workholding Automation for Precision Milling Operations Powered by Hydraulic Technologies

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Project Details
Industry: Manufacturing
Brand: Power Team

Overview

Automated machining operations require reliable workholding solutions to maintain part stability and repeatable accuracy. A hydraulic workholding automation system was implemented to securely hold cast components during milling, supporting consistent machining performance and improved productivity. 

The Challenge

A milling application required a custom arrangement of workholding products to securely hold castings in place during machining operations. The solution needed to support automated workflows while maintaining consistent clamping force throughout the machining cycle.
 
Maintaining part stability during milling is critical to prevent movement, dimensional errors, or tool damage. Manual or inconsistent clamping methods introduced variability and limited the efficiency of automated machining processes.

Solution Presented

A hydraulic workholding automation solution was configured using a 100222 accumulator, a 100223 manual pallet valve, and multiple work supports. The accumulator maintained hydraulic pressure during operation, while the pallet valve enabled controlled clamping and release as part of the automated machining cycle.
This type of machining challenge is solved using hydraulic workholding systems that deliver consistent clamping force, support automation, and ensure repeatable part positioning during milling operations.

Results

The hydraulic workholding automation system provided secure, repeatable clamping of castings throughout the milling process. The automated setup improved machining consistency, reduced setup variability, and supported efficient production workflows.
 
Based on typical CNC milling and automated workholding applications, the hydraulic automation solution delivered measurable operational benefits:
• Cycle Consistency Improvement: Automated hydraulic clamping typically reduces cycle-to-cycle variation by approximately 10–20%.
• Setup Time Reduction: Elimination of manual clamp checks can reduce setup and changeover time by an estimated 15–30%.
• Labor Savings: Reduced operator intervention during setups can save approximately 5–10 minutes per pallet or fixture change.
• Throughput Increase: Improved repeatability and reduced setup variability support a 5–15% increase in effective machine utilization.
• Quality Improvement: Consistent clamping force reduces dimensional variation and lowers the risk of scrap or rework.

Other Applications

• Automated milling and machining centers
• Palletized CNC machining systems
• Precision machining of cast components
• High-volume manufacturing operations

Key Metrics

System Impact & Engineering Advancements

Performance Metrics & Key Achievements

20% 1

Less Cycle Variation

30 2

15-30% Faster Changeover

10 3

Min Saved per Change

15% 4

Higher Utilization

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1. Estimated versus manual clamp-check processes used on comparable automated CNC milling operations; not a measured result.
2. Estimated from eliminating manual clamp checks during setup on comparable machining centers; not a measured result here.
3. Estimated from reduced operator intervention needed per setup event on comparable CNC operations; not a measured result.
4. Estimated from improved repeatability and reduced setup variability on comparable machining lines; not a measured result.
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