V-Cut Tool - VCT

Operating Manual
V-Cut Tool - VCT
Keep it in a safe place for future use!
Original operating manual
Software/Firmware version: FW1.61
Creation date: 03-2015
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Contents
Contents
1 Product description......................................................................................................................... 5
1.1 Technical description........................................................................................................................ 5
1.2 Technical information........................................................................................................................5
1.3 VCT................................................................................................................................................... 6
2 Safety requirements......................................................................................................................... 7
2.1 Intended use..................................................................................................................................... 7
2.2 Examples of improper use............................................................................................................... 7
3 Controls and operation....................................................................................................................9
3.1 Important menu items.......................................................................................................................9
3.2 Inserting the blade.......................................................................................................................... 10
3.3 Setting the cutting angle.................................................................................................................11
3.4 Inserting a tool................................................................................................................................12
3.5 Setting the infeed angle................................................................................................................. 12
3.6 Initialization process....................................................................................................................... 13
3.7 Material-dependent settings............................................................................................................15
3.8 Carrying out a test cut....................................................................................................................15
3.9 X/Y correction................................................................................................................................. 16
4 Maintenance.................................................................................................................................... 19
5 Examples of application................................................................................................................ 21
5.1 Producing the through-cut.............................................................................................................. 21
5.2 Grooving..........................................................................................................................................21
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Contents
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Product description
1 Product description
1.1 Technical description
The "V-cut tool" is used for cutting materials up to a thickness of 16 mm. In this process, the blade
is inserted into the material at a defined angle (45°, 30°, 22.5°, 15°, 0°) and therefore a V-cut is
produced.
Tip:
Keep a spare tool ready in order to avoid cutter downtime.
1.2 Technical information
Name
Measurement Unit
Weight
Maximum cutting depth
0.29 kg
1)
16 mm
Restriction of the working area
X
2)
40 mm
Y
2)
40 mm
1)
2)
Depending on the material and blade Depending on the set Up Z pos
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Product description
1.3 VCT
6
1
Sleeve
2
Holder
3
Blade holder 16 mm cutting depth, trapezoid blade
4
High-carbon steel trapezoid blade
5
Blade holder 10 mm cutting depth, carbide blade
6
Carbide blade
7
Blade holder 16 mm cutting depth, carbide blade
8
Adjusting gauge
9
Allen screwdriver, 2.5 mm
Safety requirements
2 Safety requirements
2.1 Intended use
Safe operation is guaranteed when the equipment is used solely for its intended purpose.
The equipment provided determines the possible uses of the tool.
The VCT is intended for cutting various materials with Zünd blades and blade holders in combination
with Zünd modules.
Any other use which does not meet this description shall be classed as improper use. The user bears
sole liability for any damage arising as a result of improper use.
The tool is deemed to be used as intended under the following conditions:
• all national safety regulations are observed
• The safety instructions listed in this operating manual are observed
• The operating conditions are observed and the recommended materials are used
2.2 Examples of improper use
•
•
•
•
•
•
•
•
•
•
•
Use of unsuitable blades
Incorrect clamping of the blade/blade holder
Use outside of the intended module
Improper or non-intended use
Incorrect mounting of the tool in the module
Incompatible sizes of blade and blade holder
Failure to clean the tool at regular intervals
Structural alterations to the equipment without the permission of Zünd
Non-observance of maintenance instructions
Non-adherence to safety requirements
Failure to react to signs of wear and damage
Risks arising from improper use
• Risk of damage to tool and cutter system
• Cut injuries
• Blade breakage
• Blade may unintentionally slip out of shank
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Safety requirements
8
Controls and operation
3 Controls and operation
3.1 Important menu items
Tip:
The VCT is completely integrated into the Zünd Cut Center. The Zünd Cut Center helps you
select the right parameters for your processing material.
General settings
Menu
Setting/function
1-1-1-2-1 Define Z init pos
Define the zero point manually
1-1-1-2-2 Auto init
Define the zero point automatically with the ITI
1-1-1-2-3 Up Z pos
Set the upper position (outside the material)
1-1-1-2-4 Down Z pos
Set the cutting depth
1-1-1-2-5 Test cut
Perform test cut
Speed and acceleration
Menu
Setting/function
1-1-1-3-2-1 Up X+Y
Movement speed in up position
1-1-1-3-2-2 Down X+Y
Movement speed in down position
1-1-1-3-2-3 Lift Z
Lifting speed
1-1-1-3-2-4 Lower Z
Lowering speed
1-1-1-3-3-1 Up X+Y
Tool acceleration in upper position
1-1-1-3-3-2 Down X+Y
Tool acceleration in lower position
V-cut settings
Menu
Setting/function
1-1-1-3-1-1 Infeed angle
Selection of the cutting angle(45°, 30°, 22.5°, 15°,
0°)
1-1-1-4-2 Correct X
Entry of a value for X correction
1-1-1-4-3 Correct Y
Entry of a value for Y correction
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Controls and operation
3.2 Inserting the blade
Note:
Clamping the blade without adjusting gauge leads to reduced output quality and can also lead to
collisions with the ITI.
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Controls and operation
A
B
C
D
E
F
G
H
Loosen the blade holder clamp with the Allen key (2.5 mm).
Insert the desired blade into the knife holder clamp.
Place the blade holder into the adjusting gauge and fold it down.
Screw in the blade holder with the adjusting gauge.
Align the blade in the adjusting gauge.
Tighten the clamp of the blade holder.
Unscrew the blade holder from the adjusting gauge.
Fold the blade holder upwards and remove from the adjusting gauge.
Results
The blade is correctly fixed in the blade holder.
3.3 Setting the cutting angle
Blade positions
The holder allows the blade holder to be assembled in five different positions. The cutting angle is
different depending on the position:
45°
30°
22.5°
15°
0°
Procedure
A Guide the blade holder into the desired holding fixture on the holder.
B Tighten the blade holder with the Allen key (4 mm).
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Controls and operation
3.4 Inserting a tool
The UM is assembled on the required slot.
A Select 1-5-1 Change module/tool in the cutter menu.
The module carriage moves to the module change position.
B
C
D
E
Insert the VCT into the tool holder. Align the red mark on the tool with the red mark on the module.
Lower the shank of the tool into the module opening until it stops.
Press the module lock and latch the bayonet catch.
Place the blade holder with inserted blade into the sleeve opening (from below) and screw it in.
Results
The VCT is inserted. Follow the instructions on the cutter operating unit if you want to insert a new
VCT or select an already existing VCT. Further information can be found in chapter Tool handling of
the cutter operating instructions.
3.5 Setting the infeed angle
The setting of the infeed angle ensures that the blade automatically penetrates into the material at
the correct angle. The penetration point can be optimised using the 1-1-1-4-2 Correct X or 1-1-1-4-3
Correct Y (see section 'X/Y correction on page 16' in this chapter). The X/Y value depends on the
infeed angle and is selected automatically.
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Controls and operation
Note:
Risk of damage to the cutter.
• Ensure that the set value 1-1-1-3-1-1 Infeed angle always matches the value set on the VCT.
A Switch to the 1-1-1-3-1-1 Infeed angle setting.
B Select the set infeed angle of the VCT and confirm with OK .
3.6 Initialization process
Caution:
Risk of injury during tool initialization!
The front light barriers are not active during manual initialization!
• Do not touch the operating area of the tool during initialization
• Define the zero point with the ITI.
Note:
Clamping the blade without adjusting gauge leads to reduced output quality and can also lead to
collisions with the ITI.
Note:
It is not possible to initialize using the AKI!
Tip:
Initialization can be carried out manually or automatically with the permanently installed ITI.
1-1-1-2-1 Define Z init pos
1-1-1-2-2 Auto init
Using ITI or manually, adjust the tip of the tool
insert exactly to the height of the working surface
(cutting/routing underlay). The value determined
is used as the starting point for the settingsUpper
positionandLower position.
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Controls and operation
1-1-1-2-3 Up Z pos
1-1-1-2-4 Down Z pos
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TheUpper positiondefines the distance between
the zero point and the raised tool. Select this
value according to the material and its folding
properties. A short distance between processing
material and raised tool generally means a shorter
processing time.
TheLower positiondefines the cutting depth of
the tool into the cutting/routing underlay. This
is necessary in order to cut completely through
the processing material. TheLower positionis
dependent on the processing material and the
processing method.
Controls and operation
3.7 Material-dependent settings
Tip:
To prepare your machining data, use theZCCsoftware. The tool is completely integrated into
theZCC. A large number of materials and the optimal processing parameters have already been
created. This reduces tedious processing tests to a minimum and increases processing efficiency.
The setting of processing parameters is material-dependent. Prior to processing, perform tests to
check your settings.
3.8 Carrying out a test cut
•
•
•
•
•
The tool has been initialised.
The machine is in the 'OFFLINE' operating status
Material-specific settings have been made
The tool is active
The value of the menu function 1-1-1-3-1-1 Infeed angle corresponds to the angle of the blade
used
Testing cutting quality
A
B
C
D
Place the material to be processed on the working surface.
1-1-1-4-4 Test cut Select.
Use the travel keys to position the tool over the material.Press OK to start the test cut.
Check the test cut. If the quality of the test cut is insufficient then carry out X/Y correction (see
section 'X/Y correction on page 16' in this chapter).
Checkig cutting depth
A
B
C
D
Place the material to be processed on the working surface.
1-1-1-2-5 Test cut Select.
Use the travel keys to position the tool over the material.Press OK to start the test cut.
Check the test cut. If necessary, correct or redefine the zero point on the Z axis via the 1-1-1-2-4
Down Z pos function.
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Controls and operation
3.9 X/Y correction
Carry out X/Y correction under the following circumstances:
• The quality of the test cut is not sufficient
• The blade cannot be set using the adjusting gauge
In the case of VCT, the cutting centre does not lie in the turning centre of the module and therefore
it has to be aligned. The correction values are stored in the menu under 1-1-1-4-2 Correct X and
1-1-1-4-3 Correct Y .
Make sure that the following requirements are fulfilled:
• The VCT is clamped in the module according to instructions
• The blade is properly clamped
• The cutter is configured in accordance with the instructions
• The Z-axis is initialised in accordance with the instructions
Correction values, general
The penetration point and/or the cut direction of each test cut act as measuring points for the
calculation of the correction values. You should therefore observe exactly where the blade penetrates
when cutting the 4 lines and mark the penetration points.
1 Start of cut (penetration point)2
End of cut
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Cutting diagram with all correction
values set to 0.
Cutting diagram once the alignment
process has been successfully
completed.
Controls and operation
Options for calculating the Y correction.
During Y-correction, the cuts are moved until the respective parallel cuts are on one line. There are
two options for calculating the required correction value:
Option 1: line 1 has to be moved
to the left and/or line 2 has to be
moved to the right to lie along the
same line.
Y = existing Y-correction value a/2
Option 2: line 1 has to be moved
to the right and/or line 2 has to be
moved to the left to lie along the
same line.
Y = existing Y-correction value +
a/2
Result: The cuts lie along one line.
Performing Y correction
A
B
C
D
Start the 1-1-1-4-4 Test cut function.
Insert the determined Y value in the 1-1-1-4-3 Correct Y field.
Perform a test cut and recalculate the correction value if necessary.
The Y-correction is complete when the cuts lie on the same line (tolerance: ± 0.1 mm). Where
necessary, check this using a magnifying glass.
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Controls and operation
Options for calculating the X correction.
During the X-correction, the cuts are moved until each penetration point is exactly in the centre. There
are two options for calculating the required correction value:
Option 1: The distance between the
penetration points is greater than the
distance between the ends of the
cuts
X = existing X-correction value b/2
Option 2: The distance between the Result: The penetration points are
penetration points is smaller than the positioned precisely in the centre.
distance between the ends of the
cuts
X = existing X-correction value +
b/2
Perform X correction
A
B
C
D
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Start the 1-1-1-4-4 Test cut function.
Insert the determined X value in the 1-1-1-4-2 Correct X field.
Perform a test cut and recalculate the correction value if necessary.
The X-correction is complete when each penetration point is precisely in the centre (tolerance: ±
0.1 mm). Where necessary, check this using a magnifying glass.
Maintenance
4 Maintenance
Note:
Risk of damage to the tool.
Never clean the tool using ultrasound, a steam jet, compressed air, etc.
Never use cleaning products (cleaning spray, grease solvents, etc.) on the machine.
The tool does not require maintenance. Simply remove dirt residues on a regular basis.
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Maintenance
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Examples of application
5 Examples of application
The V-cut tool can be used for lots of different materials. The correct selection of the blade and the
cutting parameters are important. For information about blades, refer to the Zünd product catalogue.
5.1 Producing the through-cut
1
Material
2
Cutting underlay
3
Oblique cut
4
VCT
A
B
C
D
E
Insert the blade.
Set the desired cutting angle.
1-5-1 Change module/tool Select and insert the VCT into the module.
Enter the selected infeed angle via 1-1-1-3-1-1 Infeed angle .
Initialisation (see section "Initialization process on page 13" in this chapter).
F Select material-specific cutting parameters (speed, acceleration) and enter them.
G Use 1-1-1-2-5 Test cut to carry out a test cut in order to check the cutting depth.
H If necessary, in the menu 1-1-1-2-4 Down Z pos adjust the cutting depth until a clean through-cut
is produced (0.4-0.8 mm depending on the material thickness).
5.2 Grooving
The term grooving is used to describe the detachment of a splinter of material from a thick cardboard
or sandwich material in order to make it possible to shift/bend the material.
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Examples of application
Preparing cutting file
A vector is travelled in two directions in order to produce a V-groove. In this case, the blade tip when
lowered corresponds to the vector of the cutting file (zero point + Down Z pos). The implementation of
the vector is dependent on the processing software. Be aware that the overlap needed due to the tilted
position of the blade is provided at the same time.
ACutting path, possible cutting depths
BMovement 1, first oblique cut of the V-groove
CMovement 2, second oblique cut of the V-groove
DResult: complete V-groove
1 Example: V-groove, Down Z pos: -5 mm
2 Example: V-groove, Down Z pos: -2 mm
3 Example: V-groove, Down Z pos: 0 mm
(intersection)
4 Vector of the cutting file
5 Cutting material
6 Cut during movement 1
7 Vector of the cutting file during movement 1
8 Cut during movement 2
9 Vector of the cutting file during movement 2
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Examples of application
Producing the V-groove
A
B
C
D
E
Insert the blade.
Set the desired cutting angle.
1-5-1 Change module/tool Select and insert the VCT into the module.
Enter the selected infeed angle via 1-1-1-3-1-1 Infeed angle .
Initialisation (see section "Initialization process on page 13" in this chapter).
F Select material-specific cutting parameters (speed, acceleration) and enter them.
G Use 1-1-1-2-5 Test cut to carry out a test cut in order to check the cutting depth.
H If necessary, in the menu 1-1-1-2-4 Down Z pos adjust the cutting depth until the desired turning of
the material is possible.
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Examples of application
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