RoAd And MineRAl technologies

Transcription

1 Parts and more ComPaCt quick-change toolholder system ht22 RoAd And MineRAl technologies

2 Contents

3 AdvAntAges PAge 4 Original Wirtgen quick-change toolholder system Page 4 High-quality production Page 6 Components of the quick-change toolholder system HT22 Page 7 Lengthwise wear on the upper part Page 10 FActs PAge 12 Larger and more robust upper parts Page 12 Increased servicing intervals Page 13 Larger contact areas Page 14 Larger shaft cross-section Page 15 APPlicAtion PAge 18 Maintenance and replacement of toolholders Page 16 Specifications Page 22 3

4 original Wirtgen quick-change toolholder system Philosophy of the Wirtgen quick-change toolholder system Based on the idea of replacing worn or defective toolholder upper parts as quickly as possible directly on-site, and thereby substantially reducing machine downtimes, Wirtgen has been developing quick-change toolholder systems since They primarily consist of two parts: a housing (bottom part of toolholder), welded to the milling drum tube, and a toolholder, connected to the housing by a quick-release bolt connection. development of the Wirtgen quick-change toolholder system The development of quick-change toolholder systems is a continuous process. In order to always meet the market s high demands on quality, the most recent investigation methods and computer simulations are employed early in the development and design phase. AdvAntAges FActs ApplicAtion

5 HIGH-QUALITY PRODUCTION The finite element method (FEM) allows the physical properties of virtual prototypes to be examined on the computer. Component behaviour can be determined and optimised even at this early stage of the simulation. Long and extensive tests are performed in parallel under maximum loads and in extreme situations. Raw material billet Blank stage 1 Blank stage 2 Forging and machining production processes High-quality hardened and tempered steels are worked in the forging process. Their wear resistance, the special heat treatment and years of production expertise form the basis for the excellent toolholder quality and guarantee a long service life and fracture resistance. In order to produce component dimensions as exact as possible, extremely tight tolerances are adhered to during the machining process. 4 I 5 AdvAntAges FActs ApplicAtion

6 COmPONeNTs Of THe QUICk-CHANGe TOOLHOLDeR system HT22 1 Wear markings with 5 mm spacing 2 100% increased maximum wear path 3 Increased wear volume in the head 4 Wear-resistant head design 11 Around 67% greater upper part contact surface to the bottom part for longer bottom part service life 12 Seal between upper and bottom parts for easy and quick installation and removal of the upper part Toolholder HT22 D20 Part No.: Optimised shaft angle geometry for increased component strength Around 6% greater shaft cross section for considerably greater resistance to shaft breakage 7 Protective plugs for screw drive 8 Optimised screw geometry for simple and safe mating up 9 Optimised welded joints with increased strength, yet at the same time with enough flexibility for optimum pick rotation Toolholder HT22 D22 Part No.: Toolholder HT22 D25 Part No.: Improved protection of the bottom part thanks to complete coverage of the upper part Dummy HT22 Part No.: AdvAntAges FActs ApplicAtion

7 Lengthwise wear on the toolholder over operating hours 30 Lengthwise wear in mm HT11 High lengthwise wear HT11 Moderate lengthwise wear HT11 Low lengthwise wear HT22 High lengthwise wear HT22 Moderate lengthwise wear HT22 Low lengthwise wear Operating hours Operating hours Thanks to the 100 % increase in the maximum wear path, the service life of the toolholder can be as much as 1,000 hours under optimum conditions. Lengthwise wear on the upper part HT22 Wearing HT11 Wearing 0 mm 5 mm 10 mm 15 mm 20 mm 25 mm 30 mm The new HT22 quick-change toolholder system s maximum effective wear length is 30 mm. This means it is twice as large as the HT11 quick-change toolholder system s wear length. 7 I 10

8 THe New wirtgen HT22 IN DeTAIL Larger and more robust upper parts The upper parts have all been reinforced using considerably more wear volume in all wear-relevant areas. The maximum life is additionally ensured by robust securing in the bottom part of the quick-change toolholder and by increased fracture strength. A comparison to the precursor system HT11 makes this clear. Detailed mould Forging blank after deburring Waste trimmings Heat treating and hardening Final toolholder heat treating and hardening is particularly important, because both the great hardness and the necessary ductility represent important properties with regard to low wear. Using the most up-to-date production and testing methods, Wirtgen continuously produces toolholders in a constant quality and thus guarantees optimum service lifetimes for the quick-change toolholder systems. HT11 HT22 6 I 11 AdvAntAges FActs ApplicAtion

9 Reduced servicing requirements thanks to increased servicing intervals The occasionally extreme loads imposed during the milling process can reduce the high pretension of the thrust screw over the long service period. The thrust screw pretension can be lost due to material deformation in the quick-change toolholder system as a result of extreme loads, e.g. by accidental milling in large steel components. It is therefore advisable to check the specified torque of 500 Nm at regular intervals and thus the system s pretension. On the HT22 quick-change toolholder system these servicing intervals are now substantially reduced thanks to the system s particularly robust design. After an initial inspection following first use (approx. 10 operating hours) the specified intervals for the HT22 quick-change toolholder system have now increased from 250 h to 500 h compared to the HT11 precursor system. The next inspections then follow at 1,000 h, 1,500 h and 2,000 h. 12 I 13

10 the new Wirtgen ht22 in detail large, self-centring contact areas Thanks to the prismatic arrangement of the contact area between the upper and the bottom part, increased by nearly 70 % compared to the HT11 quick-change toolholder system, particularly high cutting forces can be reliably and durably transferred to the bottom part of the toolholder without noticeable material fatigue. Complete covering of the bottom part by the upper part prevents burr formation on the bottom part. This guarantees simple changing of the upper part without work being required on the bottom part of the toolholder. HT11 = 2372 mm 2 HT22 = 3969 mm % AdvAntAges FActs ApplicAtion

11 Highest fracture strength thanks to large shaft cross-section Wirtgen large milling machines deliver increasing milling performance. This substantially increases the demands on the quick-change toolholder system s strength parameters. The strengthened and shape-optimised shaft of the HT22 quick-change toolholder system is extremely resistant to fracture and offers increased resistance to undesirable deformation. HT11 HT22 HT11 = 924 mm 2 HT22 = 984 mm % 14 I 15

12 maintenance and replacement of toolholders damaged or worn toolholders should be replaced to minimise operating costs. Please replace carefully and always follow the instructions below. Only use the correct tools and adhere to the inspection intervals. Given adequate maintenance it is possible to correctly replace a toolholder in just a few minutes. toolholder inspection and maintenance Please note: The toolholders must be continuously kept in excellent condition. Inspection for wear is therefore recommended several times a day. Using the milling drum turning device, the milling drum is positioned such that the picks and toolholders are easily accessible. Replacing the toolholder 01 First clean the retainer screw s access bore of asphalt residues. Then remove the plug with the aid of a screwdriver. The plugs offered by Wirtgen substantially reduce cleaning effort, thus allowing faster replacement. ( Fig. 01) 1 AdvAntAges FActs ApplicAtion

13 02 The retainer screw is now carefully cleaned, loosened by hand using an Allen key and removed completely. The threads and the screw head may deform as a result of the high loads imposed during the cutting process. To prevent damage to the threads in the bottom 2 part of the toolholder, the screw should therefore not be reused. ( Fig. 02 ) Please note: the tool should reach to the full depth to prevent damage to the screw during removal. do not use worn tools! 03 Once the retainer screw has been removed, the toolholder can be pulled out of the bottom part of the toolholder. ( Fig. 03 ) 3 16 I 17

14 maintenance and replacement of toolholders 4 04 The threaded bore and the cylindrical guide of the bottom part of the toolholder welded onto the milling drum must then be carefully cleaned and inspected for damage. Cleaning ensures that no milled material is located in the bottom part and the contact areas between the upper and bottom part fit tightly together after assembly without any gaps. ( Fig. 04) There is a danger of fracture if the surface of the bottom part of the toolholder is not even and undamaged. 05 Once a perfect contact area has been produced, push the bottom part seal over the shaft of the new toolholder. ( Fig. 0 5) 06 The toolholder shaft is then coated with a temperature-resistant grease (up to 100 C) and placed in the bottom part of the toolholder. ( Fig. 06) 5 6 AdvAntAges FActs ApplicAtion

15 The grease assumes a sealing function, protects the toolholder against corrosion and allows easier removal when necessary. 07 The new retainer screw is also coated with a temperature-resistant grease and screwed in 7 approx. three turns by hand. If the retainer screw can only be screwed in using great effort, the thread in the bottom part must be recut using a thread cutter. ( Fig. 07) Please note: never use used retainer screws! 08 The retainer screw is now tightened to a torque of 500 Nm using a torque wrench. ( Fig. 08) Please note: only use a hand-operated torque wrench to tighten the hexagon socket screws I 19

16 maintenance and replacement of toolholders 09 A ring test should be performed after tightening the retainer screw. Applying a hammer blow to the toolholder s contact area, check whether it settles further. Use a 1 kg copper hammer to do this. ( Fig. 09) 9 10 After this, the torque (500 Nm) on the retainer screw must be checked again. ( Fig. 10) 11 The plug is now fitted in the retainer screw. ( Fig. 11) Please note: Following first use (approx. 10 operating hours) the hexagon socket screws must be retightened to a torque of 500 nm; then at regular 500 operating hour intervals (500 h, 1,000 h, 1,500 h). if conspicuous AdvAntAges FActs ApplicAtion

17 rotation is noted, the bottom part of the toolholder must be inspected. 12 Finally, the new pick is fitted. Use a copper hammer to do this. ( Fig. 12) I 21

18 specifications Specifications Weight of upper part D20 Tightening torque First servicing interval, check torque Second servicing interval, check torque Third servicing interval, check torque Fourth servicing interval, check torque Additional servicing intervals, check torque Delivery range of system HT22 series Toolholder HT22 D20 Upper parts Toolholder HT22 D22 Toolholder HT22 D25 Dummy HT22 Screw Plug Seal Lubricating grease Retainer screw HT22 M30X2 Plug HT22 (1 piece) Plug HT22 (100 pieces) Bottom part seal HT22 Bottom part seal HT22 (100 pieces) Quick-change toolholder lubricating grease Torque wrench Nm Ratchet extension 3/4" x 2 mm Tools Hexagon socket 17 mm - 3/4" Clockwise ratchet 3/4" Thread cutter M30 x 2 Thread cutter adapter AdvAntAges FActs ApplicAtion

19 HT3 HT11 Ht kg 1.70 kg 2.30 kg 500 Nm 500 Nm 500 nm 10 hours 10 hours 10 hours 250 hours 250 hours 500 hours 500 hours 500 hours 1,000 hours 750 hours 750 hours 1,500 hours Every 250 hours Every 250 hours every 500 hours Part No. Weight in kg I 23

20 WIRTGEN GMBH Reinhard-Wirtgen-Strasse Windhagen Germany Phone: +49 (0) 26 45/131-0 Fax: +49 (0) 26 45/ service@wirtgen.de JOSEPH VÖGELE AG Joseph-Vögele-Strasse Ludwigshafen Germany Phone: +49 (0) 621/ Fax: +49 (0) 621/ spareparts@voegele.info HAMM AG Hammstrasse Tirschenreuth Germany Phone: +49 (0) 9631/80-0 Fax: +49 (0) 9631/ parts@hamm.eu KLEEMANN GMBH Manfred-Wörner-Strasse Göppingen Germany Phone: +49 (0) 7161/206-0 Fax: +49 (0) 7161/ info@kleemann.info Illustrations and texts are non-binding. Subject to technical changes. Performance data depend on operational conditions. No. WG EN / /13 by Wirtgen Group 2013 Printed in Germany