Development and manufacture of hydraulically actuated clamping sleeves and clamping elements for machine and fixture construction
KOSTYRKA GmbH
Gerlingen (Dieselstraße 6, 70839) · Development and Manufacturing (Company Headquarters)New on Amplifa
Hydraulic clamping technology from Gerlingen near Stuttgart
KOSTYRKA GmbH develops and manufactures hydraulically actuated clamping elements: clamping sleeves and expansion sleeves with and without flange, clamping discs, clamping rings, clamping strips and clamping cassettes as well as support elements, pressure generators and adaptive clamping and fixture systems. The core of each sleeve is a flexible base body made of metal-plastic composite; as a rule the sleeves are made of bronze, or of steel for spindle clamping at high speeds. Clamping sleeves are manufactured with inner diameters from 6 to over 2,000 mm and lengths up to over 900 mm for operating pressures up to 600 bar. The clamping elements hold shafts, spindles, rotary tables, pallets and other machine elements firmly without reaction force and release them in a flash. Support elements stabilize workpieces with support pins from 10 to 40 mm in diameter and forces up to 28 kN. Customers include manufacturers of machine tools, fixture and assembly systems as well as companies from the optics, aviation and aerospace sectors. Development and manufacturing take place exclusively at the Gerlingen site near Stuttgart.
- Site
- Gerlingen
- Processes
- Manufacture of hydraulically actuated clamping sleeves (with/without flange, clamping systems), Manufacture of hydraulic expansion sleeves (with/without flange), Manufacture of clamping discs, clamping rings, clamping strips and clamping cassettes, Manufacture of hydraulically actuated support elements (cartridge rest pads, hydraulic rest pads), Manufacture of pressure generators (air-oil pressure intensifiers, oil-oil pressure intensifiers,, Development and manufacture of adaptive clamping and fixture systems (ram clamping system,, 3D coordinate measurement of all geometric features (stationary and mobile, measurement report), Microscopic inspection for burrs and chips (burr- and chip-freeness)
- Materials
- Bronze, Steel (steel material for flanged clamping sleeves at high speeds/spindle clamping), Metal-plastic composite (base body of the clamping/expansion sleeves), Steel material, Metal-plastic composite
- Certificates
- 3D coordinate measurement with measurement report, Microscopic inspection for burrs and chips, Casting density/leak tests, Laser measurement methods, Functional tests / customer-specific tests, Individual customer audits
- Founded
- 1969
- Industries
- Machine tool construction, Fixture construction, Mechanical engineering, Aviation and aerospace, Optics/precision mechanics, Assembly systems
- 01
Custom development
- 02
Manufacture of the clamping and tensioning elements
- 03
Complete assembly of ready-to-install clamping systems
- 04
Testing on request (e.g. leak testing)
- 05
Shipping from a single source
Materials and sizes
Bronze
Standard material for clamping and expansion sleeves.
Steel material
For flanged clamping sleeves at high speeds, e.g. spindle clamping.
Metal-plastic composite
Flexible base body of all hydraulic clamping and expansion sleeves.
Sites
Gerlingen
DEDevelopment and Manufacturing (Company Headquarters), Dieselstraße 6
- Part weight / size
- Clamping sleeves 6 to over 2,000 mm inner diameter, lengths
- Lot size
- Standard sizes ex stock; custom designs
- Materials
- Bronze, steel, metal-plastic composite
- Stationary 3D coordinate measuring machine
- Mobile coordinate measuring devices
- Laser measurement methods
- Functional test bench
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Manufacture of hydraulically actuated clamping sleeves (with/without flange, clamping systems)Engineering | – | Lengths up to over 900 mm × Diameter 6 to over 2,000 mm | – | – | Bronze, Steel (steel material for spindle clamping), Metal-plastic composite |
| Manufacture of hydraulic expansion sleeves (with/without flange)Engineering | – | Clamping diameter 8 to over 1,000 mm | – | – | Bronze, Steel (steel material for spindle clamping), Metal-plastic composite |
| Manufacture of clamping discs, clamping rings, clamping strips and clamping cassettesEngineering | – | – | – | – | – |
| Manufacture of hydraulically actuated support elements (cartridge rest pads, hydraulic rest pads)Engineering | – | Support pin diameter 10 to 40 mm | Forces up to 28 kN | – | – |
| Manufacture of pressure generators (air-oil pressure intensifiers, oil-oil pressure intensifiers,Engineering | – | – | – | – | – |
| Development and manufacture of adaptive clamping and fixture systems (ram clamping system,Engineering | – | Fixtures up to 60 m in length (BOEING × Strokes up to 800 mm | – | – | – |
| 3D coordinate measurement of all geometric features (stationary and mobile, measurement report)Testing | – | – | – | – | – |
| Microscopic inspection for burrs and chips (burr- and chip-freeness)Testing | – | – | – | – | – |
| Casting density testing/leak tests for clamping systemsTesting | – | – | – | – | – |
| Laser measurement methodsTesting | – | – | – | – | – |
| Functional tests (functional test bench, customer-specific tests)Testing | – | – | – | – | – |
| Assembly of ready-to-install clamping systems (fully assembled, delivered tested on request)Assembly | – | – | – | – | – |
4 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Stationary 3D coordinate measuring machine | – | – | – | – | Gerlingen |
| Mobile coordinate measuring devices (measurement directly on the machine) | – | – | – | – | Gerlingen |
| Laser measurement methods (metrology) | – | – | – | – | Gerlingen |
| Functional test bench (e.g. for the Zeiss periscope clamping) | – | – | – | – | Gerlingen |
Additional services
Reference customers
Quality assurance
All important geometric features of the clamping elements are inspected using a 3D coordinate measuring machine (stationary and mobile, also directly on the machine) and documented in measurement reports. In addition, microscopic inspection for burrs and chips, casting density and leak tests, laser measurement methods and functional tests are performed; every product is marked with a product, order and count number.
| Evidence | Gerlingen |
|---|---|
| 3D coordinate measurement with measurement report | |
| Microscopic inspection for burrs and chips | |
| Casting density/leak tests | |
| Laser measurement methods | |
| Functional tests / customer-specific tests | |
| Individual customer audits |
History
- 1969
Peter Kostyrka develops the KOSTYRKA clamping sleeve in a garage in Stuttgart-Botnang.
KOSTYRKA clamping elements achieve a 75 % market share in machine and fixture construction; several hundred thousand clamping sleeves have been delivered worldwide.