Pohits for Attent~on

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1 KLS~266CN CNC LATHE OPERATION MANUAL

2 Pohits for Attent~on 1. This machine is a product of electro-machinery integrated design. One can operate the machine only after training. Do not operate or adjust the machine without understanding it. 2. Read and understand the entire instruction manual, programming manual and CNC system operation manual before operating the machine. 3. The power supply for the machine should be three phase and four wires, one of which is a grounding wire. It must be positively grounded, otherwise electric shocks may occur because of induction electricity. Check if the voltage is of standard type. If there is a local voltage fluctuation, a stabilizer must be installed. 4. This machine is a CNC high speed precision lathe. Do not cut with overload. Otherwise the precision would be reduced and service life shortened. Pre-heat for 10 to 15 minutes before starting the machine. 5. Use the cutting speed and processing method recommended by technological manuals such as Mechanics Manual. 6. For non-conventional operations, do not operate it before you have enough jigs and fixtures. 7. Keep the working area clean. 8. Do not allow kids of access to the machine. Keep visitors a safe distance from the working area. 9. Use the right tool. Don t force a tool or attachment to do a job which it was not designed for. 10.Do not use the machine at a dangerous place, such as wet area, rain-drenched area, and places with explosive gas or spark ignited fire. The work site should be well illuminated. 11. Before starting the machine, remove adjusting wrenches and other tools from the machine. Never attempt to adjust or remove cutting tools when the machine is running. 12.Always keep cutters sharp and clean to obtain best cutting effect. 13.Cut off the power first before repairing or changing cutters, tool bits or making an adjustment. 14.Always use identical replacement parts when servicing.

3 Warn~ng! After frequent operation of the machine, one can be so familiar with it as to become commonplace but a careless fraction of a second may result in serious machine damage or human injury. 2

4 CONTENTS 1. MAIN CHARACTERISTICS AND APPLICATION OF THE MACHINE 2. MAIN SPECIFICATIONS OF THE MACHINE 3. CRANING, TRANSPORTATION, INSTALLATION AND TESTING OF THE MACHINE 4. DRIVING SYSTEM OF THE MACHINE 5. MAIN PROPERTY~ STRUCTURE AND SETTING OF THE MACHINE 6. OPERATION OF THE MACHINE 7. MAINTENANCE OF THE MACHINE 8. ELECTRIC SYSTEM OF THE MACHINE Notice to Users 1. If you local voltage is not stable or its fluctuation is more than 10 ], a stabilizer must be installed to ensure normal operation of the CNC system. 2. The machine should not work more than 16 hours a day. 3. The environmental temperature should be maintained within the range of C. 4. Relative humidity: No moisture condensation is produced when the temperature variation is less than 70%. 5. Be sure to avoid dust or corrosive gas containing acid or alkali. 3

5 Direction about spindle speeds of the CNC lathe The spindle speed of three steps is controlled by CNC system with each step being Variable from 27 to 135 rpm,55 to 270 rpm, 160 to 805 rpm and 325 to 1630 rpm respectively. The driving power is transmitted from the motor to the pulley on the spindle through gears.the ratios between program input speed and spindle speed for each step are 12:1. 6:1~ 2:1~. 1:1 respectively. For instance: If program input speed is 1000rpm; 1000±1=1000 rpm; 1000±2=500 rpm; 1000±6~167 rpm; 1000±12~83 rpm0 1. MAIN CHARACTERISTICS AND APPLICATION OF THE MACHINE The CNC lathe adopts FANUC Oi MATE TD system to control different cutting action of the machine. The longitudinal and cross feeds use servo-motors to drive. Automatic revolving tool post can be adopted for cutting. Manual or hydraulic chuck can be selected by users. The machine is especially suitable for machining step axles or sleeve workpieces. It can also machine taper, circular curve and thread automatically. When you use this machine, just work out the program according to the workpiece drawing, then put the program into the computer. After pressing the keys corresponding to the workpiece number and start button, the machine will automatically perform jobs including turning internal and external cylindrical surfaces, facing, grooving, chamfering, etc. It can also automatically turn circular curve, thread and taper. If an electric or hydraulic chuck is adopted, the workpiece can be chucked and released automatically. The tool post can raise, revolve, position, clamp and change tools automatically. 2. MAIN SPECIFICATIONS OF THE MACHINE 1) Max. swing over bed ~660 mm(26 ) 2) Max. longitudinal travel 960 mm(37.8 ) 3) Max. swing over slide c1430 mm(17.3 ) 4) Max. cross travel 365mm(13.4 ) 5) Spindle bore size c1 105 mm(4.1 ) 4

6 6) 7) 8) Spindle bore and taper Steps of spindle speeds Range of spindle speed 9) Rapid feed 10) Min.input(XIZ) 11) Feed rate (stepless) 12) Range of threads 13) Tool station number 14) Main motor power 15) Coolant pump motor power 18) V-belt model number 19) Overall dimensions (mm) 20) Machine net weight (kg) ~113mm 1:20 stepless rpm rpm rpm rpm Z: lom/min X: 8m/min Z: 394inch/min X: 3l5inch/min mm( ) mm/min( inch/min) mm(0.006-~1.181 ) KW 75W A X1 250X /3100/3700/4300/ CRANING,TRANSPORTATION AND TESTING OF THE MACHINE 3.1 Craning and Transportation of the Machine When craning the whole machine, be sure to crane one package at a time to avoid shocking. When rollers are used for moving the machine, their diameter should be 70 80mm, and the ground slant should be less than 15. Before craning, first remove the protecting housing. Use a steel rope to tire it on the bed, the contact surface should be lined with cotton yarn or linen or wood. Be sure not to scratch handles or other surfaces. To keep balance of the machine, be sure to move the tailstock and apron to the right end of the machine and lock the tailstock tightly to the bed so as to prevent it from sliding (See Fig. 1). 5

7 Fig. I Craning the machine 3.2 Installation of the Machine Installation of the machine The machine should be mounted on a solid foundation where no vibration will be caused when it is working. Put an adjusting block near each foot screw hole and fasten the machine with foot screws (See Fig. 2). ~ : uth uth ~D ~D 6 M24X2 ~ ~ Size I L

8 um Lr m ~ ~D SC 8 M24X2 ~. L _._.._. _.._..: (for 3000mm lathe) Figure 2 Drawing of Foundation When the machine is to be installed on a concrete foundation, considerable deep foot screw holes should be prepared in advance. If the foundation is a concrete floor, the holes must be through. For the installation of the machine, a level gauge must be used to set the levelness of the machine. Fix the foot screws with concrete. After the cement has become dry and solid, tighten the screw nuts evenly, if not, the machine parts may deform to affect machine accuracy. After re-checking the machine level, pour cement down under the bed stands and seal them Leveling of the machine (Fig. 3) Move the carriage to the middle of the bed length. Then adjust the foot screws and the adjusting blocks to make both ends of the two bed ways at a horizontal level. The torsion of the bed should also be checked, therefore a level gauge should be put in longitudinal and cross position. The longitudinal reading should not exceed (the precision of the gauge being 0.02/1 000 for each scale). ±3 scales and cross 2 scales Fig. 3 Leveling of the machine Adjustment of machine accuracy After leveling the machine, the machine installation accuracy can be adjusted. Put the level gauge on the carriage and adjust the iron block to reach the required accuracy. Then 7

9 tighten the foot screws and the machine installation is finished. The measuring of machine accuracy can be carried out as follows: a) Put the level gauge on the slide carriage transversally. Move the carriage from the left to the middle and then to the right end of the bed. Put down the readings of the gauge. Set the bed stand supports so that linear error of the guide ways in the same plane is less than 0.04 mm/i 000mm for the entire inspected length. b) Put the level gauge longitudinally on the carriage near the contact surface with the front guide way. Move the carriage from the left end to the middle and then to the right end of the bed. Take down the readings of the gauge. Draw a diagram of motion curves of the carriage. The linear error of the guide ways in the vertical plane should be less than 0.02 mm for the whole bed length. 3.3 Try Running of the Machine Before starting the machine, you must understand the structure, operation procedure and lubrication of the machine. First manually check the working condition of each part. Before turning on the power, check if the electric and CNC system is in good order, if the motor is wet. Turn on the power and observe the motor running direction. If everything is ok, then proceed to idle running test. The machine must run with stability, full lubrication and reliable braking. Then check the chuck by tightening and loosening it. Check the actions of the revolving tool post and longitudinal and cross feed. If each action is correct and reliable, the machine can be put into operation. 4. DRIVING SYSTEM OF THE MACHINE 4.1 Main Drive of the Machine The spindle speed of three steps is controlled by CNC system with each step being variable from 27 to 135 rpm, 55 to 270 rpm, 160 to 805 rpm and 325 to1630 rpm respectively. The driving power is transmitted from the motor to the pulley on the spindle through gears. 4.2 Feed System of the Machine Longitudinal feed (Fig.4) Longitudinal feed of the carriage is effected by a ball screw which is driven by a servo-motor through an elastic coupling. 8

10 servo-motor elastic coup Iinq adjustinq bolt lockinq nut ball screw Fig.4 Longitudinal feed Cross feed (Fig.5) Cross feed of the cross slide is effected by a ball screw which is driven by a servo-motor through synchro-belt pulleys I and 2 in the pulley box. locking nut ball screw / Fig. 5 Cross feed 5. MAIN PROPERTY, STRUCTURE AND SETTING OF THE MACHINE 5.1 Bed The assembly of machine bed consists of the bed, the front and rear bed stands joining together with bolts. The guide ways of the machine, having undergone supersonic frequency induction hardening, are high in durability. The motor is set inside the front bed stand. Behind the bed is the electric apparatus and the CNC system. There is a coolant system inside the rear bed stand. There are guard shields above and behind the bed. In 9

11 front of the bed is a sliding safety door with a plexiglass. 5.2 Headstock The headstock is mounted on the guide ways by 4 bolts and positioned by the flat guide ways and taper pins. The spindle is supported by high precision rolling bearings which are lubricated with oil. The spindle running is realized through V-belts and pulleys. (See Fig. 6) The spindle nose is standard cam lock type (D type). Manual chuck or hydraulic chuck can be used to chuck the parts. The operation is easy and reliable. Fig. 6 Structure of spindle component 5.3 Longitudinal Feed (See Fig.4) 5.4 Cross Feed (See Fig.5) 5.5 Revolving Tool Post (Fig. 7) The working principle of LD4 1 revolving tool post is as follows: The computer gives a signal for tool change. A relay in the tool post control box is activated and the motor runs forward. The upper part of the post is raised through speed reduction and elevating mechanism. The engaging disc leads the upper post to the selected tool position. A signaler gives a signal of tool position and the relay makes the motor run in reverse direction. With an preliminary positioning, the upper post falls down. The engaging discs are engaged resulting a precision positioning. The tool post is locked through worm and worm gear as well as locking nuts. When the clamping force reaches the set value, the over-current relay is activated and the power cut. The motor stops giving an answer signal to the computer for proceeding to the next program. 10

12 Fig.7a Revolving tool post Fig.7b Revolving tool post 6. OPERATION OF THE MACHINE When using this machine for the first time, an operator should first read carefully the operation manual, check the lubrication of all moving parts, check if the electric apparatus is in good order, if each plug and all screws are tightened and if the grounding is reliable. Make sure that the power is 3 phase, 220V 60Hz. Then connect the machine to the shop mains and turn on the master switch. The indicator will light. Points for attention: Be sure to know the machine property, the function and use of each button. Master the procedure of CNC system operation and programming to avoid accidental damage to the plant. As for working out of workpiece machining program, please refer to Programming Manual for FANUC Oi MATE TD CNC System. Only after reading programming manual and control operation manual as well as principal layout of electric apparatus (See electric manual) carefully and understanding them thoroughly, can the machine be used and operated correctly. The test for ready-made program can be carried out through dry running. After making sure that the program is correct, a loaded cut can be made. If some trouble happens during operation, the machine should be stopped at once. Find the cause of the trouble and remove it. Then the machine can be operated again. 11

13 7. MAINTENANCE OF THE MACHINE To ensure smooth running of the machine and its long service life, each moving part of the machine must be well lubricated. As for the lubrication requirement, please refer to lubrication diagram (Fig. 8) and Table 1.. Add oil according to the requirement. Keep the machine under normal lubrication when using it. Add lubricant to ball screws of Z axis and X axis in due course. Purified engine oil N32 (N22 in winter) should be used for the lubrication of the machine, with its viscosity being cst (40 C) (analogous to ISO VG32). This may vary a bit according to the working conditions. Figure 8 Diagram of lubrication Table I Index No. Lubricated part No. of oiler Term of refilling I Carriage and bed 4 Once a shift 2 Tailstock 1 Once a shift 3 Cross slide 2 Once a shift After each shift clean chips, wipe each exposed part of the machine and smear oil on it. Regularly check the tightness of the belts. Regularly maintain the electric cabinet, remove its dust and keep it clean. Regularly clean the dirt and chips in the coolant tank. Change the coolant in due course and keep it clean. 12

User Manual of JUNYI CKG32-S CNC Lathe

User Manual of JUNYI CKG32-S CNC Lathe Before installation and use, please read this Manual first. 1 Introduction Thanks for choosing JUNYI CNC Lathes. This manual book described JUNYI CKG32-S CNC lathe