Operating instruction for the collet holders type: Please keep this for

Operating instruction for the collet holders type: Please keep this for

Operating instruction for the collet holders type:
KSN 0/HD/ER
KSN 1/HD/ER
KSN 3/HD/ER
KSN 4/HD/ER
Date of edition:
Stage of alteration:
01.04.2009
0
Please keep this for future use!
Operating instruction for the collet holders
type KSN/HD/ER
Operating instruction for the collet holders
type KSN/HD/ER
Contents:
1
Application range, safety instructions and technical data ............................... 3
1.1
1.2
1.3
1.4
Application range, determined use......................................................................... 3
Specification .......................................................................................................... 4
Safety instructions.................................................................................................. 5
Dimensions and technical data .............................................................................. 6
2
Putting the collet holders into operation ........................................................... 7
2.1
2.2
2.3
2.4
2.5
2.5.1
2.5.2
2.5.3
2.6
2.6.1
2.6.2
Unpacking.............................................................................................................. 7
First putting into operation...................................................................................... 7
Reputting into operation ......................................................................................... 7
Assembly of the coolant-lubricant pipe for collet holders with shank type HSK
(hollow taper shank DIN 69893A) .......................................................................... 8
Collet ..................................................................................................................... 9
Application .......................................................................................................... 9
Assembly instruction for the collets and tools ...................................................... 9
Remove tool and clamping nut ...........................................................................11
Sealing disks for clamping nuts.............................................................................12
Application .........................................................................................................12
Assembly instruction for sealing disks into clamping nuts...................................12
3
Maintenance........................................................................................................13
3.1
3.2
Maintenance schedule ..........................................................................................13
External cleaning ..................................................................................................13
4
Storage when not in use ....................................................................................13
Edition: 01.04.2009
1
Operating instruction for the collet holders
type KSN/HD/ER
Warning signs, symbols
This operating instruction uses the following symbols
Marks special instructions, rules and prohibitions which are important in order to
avoid any damage.
Please observe these instructions!
Marks application instructions and other useful information.
protected
protected
protected
Sectional view: Collet holder KSN/HD/ER
2
Edition: 01.04.2009
Operating instruction for the collet holders
type KSN/HD/ER
1 Application range, safety instructions and technical data
1.1
Application range, determined use
The collet holders type KSN/HD/ER are mainly used on CNC machining centers, CNC
turning machines and conventional machining centers with internal coolant-lubricant supply.
The collet holders are marked by a red ring, see Picture 1, page 6.
Normally, the collet holders are equipped with one of the following shanks:
Cylindrical shank acc. to DIN1835 B+E
Hollow taper shank (HSK) acc. to DIN 69893 A
For the cutting range of each type, please refer to Table 1, page 6.
The tool is locked via the collets acc. to DIN6499. The collets must be chosen depending on
their type and the tool used, for more information please refer to chapter 2.5, page 9.
The collet holders type KSN/HD/ER are equipped with a length compensation on tension and
on compression and a pressure point mechanism, see chapter 1.2 page 4.
The collet holders type KSN/HD/ER are suitable for internal coolant-lubricant supply up to 50
bar, see chapter 1.2, page 4.
The non-determined use exempts the manufacturer from any liability!
Edition: 01.04.2009
3
Operating instruction for the collet holders
type KSN/HD/ER
1.2
Specification
Further features of the collet holders type KSN/HD/ER are:
•
Small and compact overhang length.
•
Length compensation in compression direction:
Compensates differences between spindle feed and the pitch of the thread to be
produced.
•
Length compensation in tension direction:
Compensates differences between spindle feed and the pitch of the thread to be
produced as well as an overrun of the spindle in the reversing point of the thread
producing cycle.
•
Pressure point mechanism:
The pressure point mechanism guarantees the safe cutting of the tool. Only when the
effective occurring axial force exceeds the allowed cutting force, the pressure point
mechanism sets the length compensation movement free.
⇒ Repeatable and regular thread depths are reached.
•
Internal coolant-lubricant supply:
Due to the special construction the coolant is guided from the spindle to the tool. The
length compensation remains – independent on the coolant-lubricant pressure – in
function.
The max. coolant-lubricant pressure is 50 bar.
Filtering of the coolant: <0,030mm.
•
Suited for right – and left-hand rotation
⇒ possible on machines with reverse from right- to left-hand rotation.
4
Edition: 01.04.2009
Operating instruction for the collet holders
type KSN/HD/ER
1.3
Safety instructions
For all works, ie putting into operation, production or maintenance, please observe the details
given in the operating instruction.
All relevant safety regulations as well as local instructions are to be observed when working
with the collet holders.
Below please find some basic rules:
-
Please wear gloves during tool change to avoid injury.
-
Basically change the tool yourself to avoid the sudden start of the spindle
caused by mis-operating.
-
Hold the tool when loosening the tool clamping to avoid it falling down and
damaging the tool and workpiece.
-
Keep the tool adaptation clean.
-
There are maximum values for cutting speeds and feed. Please observe such
data.
-
Please observe the maximum tool dimensions.
-
Furthermore, the instructions of the tool manufacturers are valid!
Edition: 01.04.2009
5
Operating instruction for the collet holders
type KSN/HD/ER
Dimensions and technical data
T
ØD1
ØD3
C
ØD
1.4
Red ring
Picture 1: Dimensions of the collet holders type KSN/HD/ER
Table 1: Technical data of the collet holders type KSN/HD/ER
Type
KSN 0/HD/ER
KSN 1/HD/ER
KSN 3/HD/ER
KSN 4/HD/ER
Cutting range
M2 – M8
5
Nr.2 – /16
M4 – M12
7
Nr.8 – /16
M4 – M20
3
Nr.8 – /4
M7 – M30
1
1
/4 – 1 /8
Clamping
range
ØD1
[mm]
Collet
1
size
2,5 – 7
2
T
3
∅D
∅D3
C
[mm]
[mm]
[mm]
[mm]
max.
Coolant
pressure
[bar]
ER11 (GB)
29
16
6
6
50
4,5 – 10
ER20 (GB)
38
28
5
7,5
50
4,5 - 16
ER32 (GB)
52
50
7
10
50
7 - 22
ER40 (GB)
73,5
63
15
15
50
Further outer dimensions depend on the required shank. These dimensions and data are
indicated in the EMUGE main catalogue or may be given by your EMUGE representative.
1
Nominal size acc. to DIN 6499
Length compensation in compression direction
3
Length compensation in tension direction
2
6
Edition: 01.04.2009
Operating instruction for the collet holders
type KSN/HD/ER
2
2.1
-
Putting the collet holders into operation
Unpacking
Take the collet holder from the plastic case
Clean the collet holder with a duster to remove any conservation oil
Do not use any aggressive solvents.
Do not use any fibrous materials, ie steel wool.
⇒ The collet holder is now ready for operation!
Exception:
Type with hollow taper shank (HSK). Please refer to chapter 2.4, page 8, for how to put
this collet holder into operation.
2.2
First putting into operation
For collet holders with HSK-shank (hollow taper shank) the coolant-lubricant pipe
must be mounted prior to putting into operation, see chapter 2.4, page 8.
When working with internal coolant supply:
The tap holders KSN/HD/ER are made for coolant pressure up to 50 bar.
Filtering of the coolant: <0,030mm.
The collet holders are inserted into the machine manually or – if provided – by the tool
exchanger.
The tool exchange must not be executed while the machine spindle rotates!
-
Only use tool shanks and tightening bolts suitable for the specific machine.
Make sure the tool is correctly clamped.
⇒ Risk of accident by spinning of the tool!
Please see also the indications in the operating instruction of your machine
tool!
2.3 Reputting into operation
In case the collet holder is reput into operation – as described in chapter 4, page 13 – please
carry out the following working steps:
1. Clean the collet holder with a duster to remove any conservation oil
Do not use any aggressive solvents.
Do not use any fibrous materials, ie steel wool.
2. Check function of the length compensation:
Stretch and compress the collet holder at the clamping nut, let go off the clamping nut →
the collet holder must independently return to its initial position
3. Exchange the collet holder into the machine as described in chapter 2.2
Edition: 01.04.2009
7
Operating instruction for the collet holders
type KSN/HD/ER
2.4
Assembly of the coolant-lubricant pipe for collet holders with shank type HSK
(hollow taper shank DIN 69893A)
a) Components
Coolant-lubricant
pipe
O-ring small
cross-section
O-ring big
cross-section
Thread nut
b) Prepare coolant-lubricant pipe
O-ring small cross-section
1. Move on the two O-rings.
O-ring big cross-section
2. Move on thread nut.
c) Mount coolant-lubricant pipe in the shank
Required tool:
Assembly wrench, choose appropriate size for the shank size
(For the assembly wrench please refer to the EMUGE main catalogue, category
accessories)
Groove
Pins
1. Put assembly wrench on
the coolant-lubricant pipe
Watch the position of
the pins against the
grooves!
2. Screw coolant-lubricant
pipe in the shank
8
Edition: 01.04.2009
Operating instruction for the collet holders
type KSN/HD/ER
2.5
Collet
2.5.1 Application
The adaptation of the tool is executed via collets type ER and/or ER/GB. With collets type ER
the tool is centred and clamped via the clamping diameter. With collets type ER/GB the
torque - arising during the thread producing operation - is additionally transferred via the
square, integrated in the collet.
Owing to the better torque transmission, we would recommend the use of collets
type ER/GB.
The collet sizes for the according collet holders may be taken from table 1, page 6. The
clamping diameter is indicated by the tool used.
2.5.2
Assembly instruction for the collets and tools
If you work with internal coolant supply, the sealing disk must first be inserted into
the clamping nut, see chapter 2.6.
1. Insert collet into the clamping nut
2. Tilt collet.
The groove of the collet must engage in the eccentric ring of the clamping nut at the
marked position.
Tilt collet in opposite direction until it clearly engages, see Picture 2.
→ Collet is flush with the clamping nut or the sealing disk.
Groove of collet
Collet engaged in
clamping nut
Eccentric ring
Marked position
(Position depends on type of nut)
Picture 2: Assembly of the collet into the clamping nut type Hi-Q
Edition: 01.04.2009
9
Operating instruction for the collet holders
type KSN/HD/ER
3. Screw the engaged collet with the clamping nut manually onto the thread of the collet
holder.
Only mount clamping nuts with
correctly engaged collet!
4. Insert tool.
If collet and tool are provided with a square, the tool must be turned into
position in order to be inserted into the square of the collet.
5. Tighten the clamping nut with the appropriate wrench.
The tightening torques for the clamping nut may be taken from table 2, page 10.
In order to avoid damaging the collet holder it is necessary to support the
spindle with the open-ended spanner when tightening the clamping nut
with the wrench . See picture 3. Wrench see table 3.
Table 2: Tightening torques for clamping nuts
Type
Hi-Q/ERM(C) 20
Hi-Q/ER(C) 32
max. tightening torque
[Nm]
35
170
Data valid for use of ER-GB collets
We recommend a tightening torque of 80% of the max.
torque
Picture 3: Tightening the clamping nut
10
Edition: 01.04.2009
Operating instruction for the collet holders
type KSN/HD/ER
Table 3: Tool set or wrench fort he clamping nut and spanner to support the spindle
Tap holder
KSN0/HD-ER
KSN1/HD-ER
KSN3/HD-ER
KSN4/HD-ER
2.5.3
Article number of
the tool set
F323198.01
F323398.01
-
Article number of the
wrench
QB002005.0110
QB002003.0400
Article number of the
spanner
QB002002.00110
QB002002.00550
Remove tool and clamping nut
1. Loosen the clamping nut with the appropriate wrench
In order to avoid damaging the collet holder it is necessary to support the spindle
with the open-ended spanner when loosening the clamping nut with the wrench
. See picture 3. Wrench see table 3.
2. Pull out the tool
3. Screw the clamping nut off
4. Tilt collet up to the marking until it is removed from the eccentric ring, see picture 4.
Remove collet.
Marked position
(Position depends on type of nut)
Picture 4: Detach collet from the Hi-Q nut
Edition: 01.04.2009
11
Operating instruction for the collet holders
type KSN/HD/ER
2.6
Sealing disks for clamping nuts
2.6.1 Application
The sealing disks are inserted into the clamping nuts for producing threads with internal
coolant supply (max. coolant pressure: 50 bar). The sealing disks additionally avoid the
penetration of dirt and chips into the collet slots.
For the collet holders sizes 1-4:
Normally a clamping nut for sealing disks is part of the delivery. The sealing disk
must be ordered separately, suitable for the clamping nut and the clamping range.
For size 0 the clamping nuts with integrated sealing system can be used. No separate
sealing disk is required; the clamping nut is chosen depending on the used clamping
diameter. Please order required clamping nut separately.
2.6.2
Assembly instruction for sealing disks into clamping nuts
1.
Insert the sealing disk into the clamping nut as shown on picture 5.
2.
Move the sealing disk forward into the clamping nut until you clearly hear the
engagement. The sealing disk must be flush at the front with the clamping nut.
Labelling
Picture 5: Assembly of the sealing disk
12
Sealing disk engaged in the clamping nut
Edition: 01.04.2009
Operating instruction for the collet holders
type KSN/HD/ER
3
3.1
Maintenance
Maintenance schedule
What?
When?
Who?
External cleaning
Periodically, depending on the degree of dirt. Operator
3.2 External cleaning
Clean the collet holder at periodic intervals with a duster depending on how dirty the holder
is.
Do not use any aggressive solvents.
Do not use any fibrous materials, ie steel wool.
4 Storage when not in use
If the collet holder is taken out of service, please go through the following steps:
1. Clean the collet holder with a duster.
Do not use any aggressive solvents.
Do not use any fibrous materials, ie steel wool.
2. Spray the collet holder with a preservation oil to avoid rusting and to preserve the easy
running of the holder.
Before storage all evidence of coolant-lubricant and machining residues must be
removed!
Edition: 01.04.2009
13
Operating instruction for the collet holders
type KSN/HD/ER
ZB10038.GB
Notes:
EMUGE-Werk Richard Glimpel GmbH & Co. KG · Fabrik für Präzisionswerkzeuge
Nürnberger Straße 96-100 · 91207 Lauf · GERMANY · Tel. +49 (0) 9123 / 186-0 · Fax +49 (0) 9123 / 14313
[email protected] · www.emuge-franken.com