Allied Maxcut Engineering Co. Limited. Making a difference. Reamers.

Transcription

1 EN Allied Maxcut Engineering Co. Limited Making a difference Reamers

2 Allied Maxcut (AMEC ) is the European Headquarters of Allied Machine & Engineering Corporation USA, a global leader in innovative high performance metal cutting technologies and solutions. Our focus on tool innovation, performance improvement and productivity gains for our customers, enables us to deliver outstanding results in a diverse range of manufacturing, production and process engineering industries. As a result, AMEC high performance tooling is helping countless businesses across the world to produce better products with greater accuracy, increased speed and higher quality. Precision, performance and productivity are core features of AMEC tooling and our commitment to innovation in all aspects of hole making technology means we continually set new industry standards in production efficiency, tool life and manufacturing cost improvements. This product catalogue provides detailed information on every product in our ALVAN range in a comprehensive, easy to use and informative single source reference guide. However, we recognise that every company s needs are unique, which is why our customer services and technical support team are always available to provide help and advice, should you need it. Whatever your need, AMEC delivers high performance tooling at the cutting edge.

3 Contents Products Overview...Page Page 7-15 Technical... Page Page 19-7 Technical... Page 8...Page 9-49 Technical... Page 50 Cerit Modular System... Page 51 IN 69871/1 B+A Shank... Page 52-5 JMTBA MAS-40 BT B+BT Shank... Page HSK-A IN 6989/1 Shank... Page ERC IN 6499-B Shank...Page Page 59 Integral Fixed & Adjustable Reamers... Page Adjustable Cutting Rings... Page Page 66 Guidelines for Troubleshooting...Page 67

4 Reamers Our comprehensive reamer range not only meets requirements of dimensional accuracy and surface finish, but also delivers high productivity. Including fixed, expandable and modular mandrel reamers, the range covers hole diameters from mm and incorporates integral coolant ports in three configurations for optimum coolant flow. All reamers use brazed carbide or Cermet cutting edges, incorporating various coatings to maintain optimum performance, accuracy and finish. Features and Benefits Reaming range mm 4 variations of tool type Integral reamers, straight or helical cutting edges Cutting rings available from diameter 17.6 mm Interchangeable expanding or fixed-head system, straight or helical, cutting edges TSA system, solid carbide or Cermet interchangeable head Available in carbide or Cermet with a choice of coating such as TiN, TiAlN, TiNAlox, etc High feed reaming due to multiple cutting edges 2

5 AMEC Services and support AMEC s success, is not just about the quality of our products and the high performance results they deliver; but also the level of technical support and expertise we provide on a constant basis to all our customers through a range of dedicated services. Technical Our technical department is staffed by AMEC engineers who have years of experience in helping customers meet demanding applications challenges with high performance AMEC tooling. They are also able to provide technical support on a wide range of industry sectors via our technical helpline, which can help customers save time and money when a solution is needed quickly. We also have an excellent and unique reference library of technical case studies and cutting data, which is compiled from information and experience gained from our global applications base. The chances are that if you have an application issue or problem we ve probably already solved it, somewhere in the world. Our technical department can be contacted on: Tel: +44 (0) option 4 Fax: +44 (0) engineering@alliedmaxcut.com External Support In addition, our field based sales and applications engineers provide a constant on-the-ground support network, helping solve manufacturing problems on site and provide the most effective solutions. The constant drive to improve productivity, reduce manufacturing costs and seek new higher performance systems means that our engineers are always conversant with the latest manufacturing technology to help customers achieve their objectives. To arrange a visit by one of our engineers, contact our customer service department on: Tel: +44 (0) option 4 Training AMEC hold regular technical education seminar (TES) programmes at our dedicated training and education facility in the UK, enabling customers to experience advanced AMEC hole making solutions and gain more detailed knowledge on their applications. The seminars cover technical data, cutting technology and tool application and benefits of all AMEC products as well as extensive and detailed on-machine training to demonstrate the tools in action. etails on all our technical education seminar programmes can be obtained from or by calling our technical department. Online Services AMEC s website hosts a number of key features one being our online ordering service which simplifies and speeds up the ordering process and can also be used for checking inventory and prices. Alongside this service, our fast response Insta-Quote provides quotations and drawings for special purpose tooling online in a matter of minutes. All our case studies, product brochures, industry sector information and a wealth of other data is also available through our website which is constantly updated with the latest details to ensure up to date information is always available for download. Customer Service The most important parts of our business are our customers. This is why our customer care processes and support operations are vital and integral parts of our commitment to customers. Sometimes, all that s needed is a helpful voice at the end of a telephone to check an order, answer a query or just point you in the right direction and our fully trained team are all available to help. No matter what your requirement, we ll have someone who can deal with your question quickly and efficiently. Our dedicated customer service department can be contacted on: Tel: +44 (0) option Fax: +44 (0) enquiries@alliedmaxcut.com

6 Summary iameters mm Short series Long series Central though tool coolant Without through tool coolant Radial through tool coolant Central & Radial through tool coolant Series Page Integral Expanding Reamers W 14 Integral Expanding & Fixed Reamers for High Feeds W Indicates the reamers without through tool coolant. Indicates the reamers with central through tool coolant. Indicates the reamers with radial through tool coolant. Indicates the reamers with both through tool coolant. istinguishes the common sizes pertinent to the series on the same page. 4

7 Integral Expanding & Fixed Heads Summary iameters mm Short series Long series Central though tool coolant Radial through tool coolant Central & Radial through tool coolant Series Page Expanding Reamers with Cutting Ring A A A Expanding Reamers with cutting Ring Composit Modular System 4555A iameters mm Series Page Expanding Reamers with Cutting Ring 7000-MC ML MM

8 Expanding Reamers Cutting Geometry Straight Flutes Single Lead-In Code G Single Lead-In Code V Lead-in 45 for standard speed Lead-in 45 for high speed Frontal Lead-In Code L Frontal Lead-In Code F Negative Lead-In Code N L lead-in to reduce the feed of 40% compared with the values on pages F lead-in to reduce the feed of 40% compared with the values on pages N lead-in ideal for through hole. It is possible to increase the feed up to 100% of the values on pages Titanium Lead-In Code T ouble Lead-In Code A Expanding Reamers Cutting Geometry Helical Flutes Single Lead-In Code P 6

9 Integral Expanding & Fixed Reamers Contents Page How to order information 8 Series to 2.10 mm 9 Series to 2.10 mm 10 Series to 2.10 mm 10 Series to 2.10 mm 11 Series to 2.10 mm 12 Series to 2.10 mm 12 Series to 2.10 mm 1 Series to 2.10 mm 1 Series 161W 9.60 to 2.10 mm 14 Series 162W 9.60 to 2.10 mm 14 Series to 2.10 mm 15 Features & Benefits iameter range mm Available with central or radial through coolant Can be used for through or blind holes Cylindrical or Weldon shanks for improved concentricity High speed reamers for improved productivity Series to 2.10 mm 15 Technical Section

10 How to order information A B C AL G A = Series W W 241 B C = Cutting material and coating Code AL TN TC TA TP KL KN KC KA KP AV VN VC VA VP SV SN SC SA SP PK = Lead-in (see page 6) = iameter and tolerance escription Hard metal cutting edges K10 Hard metal cutting edges K10 TiN coated Hard metal cutting edges K10 TiCN coated Hard metal cutting edges K10 TiAlN coated Hard metal cutting edges K10 TiNAlox coated Hard metal cutting edges K05 Hard metal cutting edges K05 TiN coated Hard metal cutting edges K05 TiCN coated Hard metal cutting edges K05 TiAlN coated Hard metal cutting edges K05 TiNAlox coated Cermet cutting edges P20 Cermet cutting edges P20 TiN coated Cermet cutting edges P20 TiCN coated Cermet cutting edges P20 TiAlN coated Cermet cutting edges P20 TiNAlox coated Cermet cutting edges P10 Cermet cutting edges P10 TiN coated Cermet cutting edges P10 TiCN coated Cermet cutting edges P10 TiAlN coated Cermet cutting edges P10 TiNAlox coated PC/PK 8

11 Series 620 iameter range from 5.80 to 2.10 mm L1 1 S L Series Cylindrical Shank - Short Series - Radial Through Coolant for Through Holes L1 L 1 Number of teeth S

12 Series 2440 & 2441 iameter range from 5.80 to 2.10 mm Series 2440 L1 1 S L Series 2441 L1 L 1 S Series Cylindrical Shank - Short Series - No Coolant for Through & Blind Holes Series Cylindrical Shank - Short Series - Central Through Coolant for Blind Holes L1 L 1 Number of Teeth S

13 Series 610 iameter range from 5.80 to 2.10 mm L1 L 1 S Cylindrical Shank - Long Series - Radial Through Coolant for Through Holes L1 L 1 Number of Teeth S

14 Series 240 & 241 iameter range from 5.80 to 2.10 mm Series 240 L1 L 1 S Series 241 L1 L 1 S Series Cylindrical Shank - Long Series - No Coolant for Through & Blind Holes Series Cylindrical Shank - Long Series - Central Through Coolant for Blind Holes L1 L 1 Number of Teeth S

15 Series 1610 & 1620 iameter range from 9.60 to 2.10 mm Series 1610 L1 L 1 S Series 1620 L1 L 1 S Series Cylindrical Shank - Long Series - Radial Through Coolant Series Cylindrical Shank - Short Series - Radial Through Coolant Series 1610 Series 1620 L1 L L1 L For holes with minimum tolerance ISO IT7 1

16 Series 161W & 162W iameter range from 9.60 to 2.10 mm Series 161W L1 L 1 S Series 162W L1 L 1 S Series 161W - Weldon Shank - Long Series - Radial Through Coolant Series 162W - Weldon Shank - Short Series - Radial Through Coolant Series 161W Series 162W L1 L L1 L For holes with minimum tolerance ISO IT7 14

17 Series 617 & 627 iameter range from 5.80 to 2.10 mm Series 617 L1 L 1 S Series 627 L1 L 1 S Series Cylindrical Shank - Long Series - Radial Through Coolant - Left Hand Helical Flutes Series Cylindrical Shank - Short Series - Radial Through Coolant - Left Hand Helical Flutes Series 617 Series 627 L1 L L1 L 1 Number of Teeth S 15

18 Technical Information Standard Speed Reaming Material Mild Steel Low Carbon Steel Structural Steels Hardness BHN kg N/mm 2 Up to 175 Up to 62 Up to 600 Greater than 175 Greater than 62 Greater than 600 Alloy Steel High-Strength Steel Titanium and Alloys Stainless Steel Grey Cast Iron Spheroidal Cast Iron (pearlitic) Malleable Cast Iron Spheroidal cast iron (ferritic) Copper and Alloys Brass Bronze Bronze Phosphorus Aluminium and light alloys Synthetic Materials Up to 288HB Greater than 200HB Up to 14 Up to 50 Up to 500 Up to 175 Up to 62 Up to 600 Up to 14 Up to 50 Up to 500 Reamer ø mm Stock Allowance ø mm Surface Speed m/min Feed mm/rev Up to Up to Up to Up to Up to Up to Up to < 200 HB >200 HB Up to Up to Up to Up to Up to Lubricant Emulsible Oil Cutting Oil Emulsible Oil Cutting Oil Emulsible Oil Cutting Oil Emulsible Oil Cutting Oil Emulsible Oil Cutting Oil Emulsible Oil Cutting Oil Oil Emulsible Oil Cutting Oil Emulsible Oil Cutting Oil Emulsible Oil Emulsible Oil Cutting Oil Oil Emulsible Oil Cutting Oil Compressed Air ry Emulsible Oil 16

19 Technical Information High Speed & Feed Reaming Material Mild Steel Low Carbon Steel Structural Steel Hardness Reamer Stock Surface Speed m /min ø mm Allowance BHN kg N/mm 2 ø mm H.M. Coated Cerment Up to 175 Up to 62 Up to 600 Greater than 175 Greater than 62 Greater than 600 Alloy Steel High Strength Steel Titanium and Alloys Stainless Steel Grey Cast Iron Spheroidal Cast Iron (pearlitic) Malleable Cast Iron Spheroidal cast iron (ferritic) Copper and Alloys Brass Bronze Bronze Phosphorus Aluminium and light alloys Up to 288HB Greater than 200HB Up to 14 Up to 50 Up to 500 Up to 175 Up to 62 Up to 600 Up to 14 Up to 50 Up to 500 Lead-In A,G Feed mm/rev Lead-In E, N, M Up to Over Up to Over Up to Over Up to Over Up to Over Up to Over Up to Over Up to Over Up to Over Up to Over Up to Over HIGH SPEE FOR ALUMINIUM REAMING Aluminium with silicon greater than 10% - brazed carbide with PK PK Hard Metal - Surface speed up to 1500 m/min - When using PK reamers a machine tool with high rigidity and absolute precision is a minimum requirement - Each application must be assessed by our technical department 17

20 Technical Approach Angles Hardness Material Approach Angle* BHN KG N/mm² Iron and mild steel (C<0,2%) G - A - E Mild steel (C 0,2 < 0,%) N - A - E Mild steel (C 0, < 0,4%) N - A - E Mild steel (C 0,4 < 0,5%) N - A - E Alloy Steel < 222 < 80 < 784 G - N - A - E Alloy Steel G - N - E Alloy Steel G - N - M Alloy Steel >278 > 100 > 980 G - N - M Stainless Steel G - N - M Grey, Spheroidal and Malleable Cast Iron V - N - E Titanium and Titanium Alloy Pure Copper Electrolytic Copper T - E G - N - E G - N - E Brass / Bronze Aluminum Alloy < 10% Si Aluminum Alloy > 11% Si Magnesium Alloy Thermoplastic Material G - N - E V - A - E V - E G - A - E V - E Thermosetting Resins Stiffened Synthetic Material * o not use negative lead-in on blind holes Negative lead-in N can be used on a large range of materials - Please contact our technical department. V - E V - E 18

21 Expanding Cutting Rings Contents Page How to order information 20 Cutting Rings to mm 21 Series to mm 22 Series to mm 2 Series 4550A to mm 24 Features & Benefits iameter range mm Asymmetric cutting edges to ensure best roundness of hole Holes with restricted tolerances of ISO 5 and ISO 6 are achievable Cycindrical shanks with or without flats and modular composit shanks available for improved concentricity Can be used for through or blind holes Radial through coolant and radial and central through coolant combination available Series 4555A to mm 25 Series to mm 26 Series to mm 27 Series 4500A to mm 28 Series 4505A to mm 29 Series to mm 0 Series to mm 1 Series to mm 2 Series to mm Series to mm 4 Series to mm 5 Series to mm 6 Series to mm 7 Technical Section 8 19

22 How to order information A B C 2000-CT X A B C = Cutting material and coating Code 2000-CT 2TIN-CT 2TIC-CT 2TIA-CT 2TLP-CT 2000-KT 2TIN-KT 2TIC-KT 2TIA-KT 2TLP-KT 2AVC-CT 2ANC-CT 2ACC-CT 2AAC-CT 2APC-CT 2AVC-ST 2ANC-ST 2ACC-ST 2AAC-ST 2APC-ST 2PK-CT = Lead-in (See Page 6) = iameter and tolerance escription Hard metal cutting edges K10 Hard metal cutting edges K10 TiN coated Hard metal cutting edges K10 TiCN coated Hard metal cutting edges K10 TiAlN coated Hard metal cutting edges K10 TiNAlox coated Hard metal cutting edges K05 Hard metal cutting edges K05 TiN coated Hard metal cutting edges K05 TiCN coated Hard metal cutting edges K05 TiAlN coated Hard metal cutting edges K05 TiNAlox coated Cermet cutting edges P20 Cermet cutting edges P20 TiN coated Cermet cutting edges P20 TiCN coated Cermet cutting edges P20 TiAlN coated Cermet cutting edges P20 TiNAlox coated Cermet cutting edges P10 Cermet cutting edges P10 TiN coated Cermet cutting edges P10 TiCN coated Cermet cutting edges P10 TiAlN coated Cermet cutting edges P10 TiNAlox coated Multicrystal diamond cutting edges 20

23 Cutting Rings iameter range from to mm L L Straight flutes Helical flutes L L Number of Teeth The ALVAN cutting rings are modular and compatible with all the reamers on pages 22 to 7. A regrinding and re-brazing service is available for damaged and worn cutting edges (please contact our technical department). The asymmetric design of the cutting edges ensures the best roundness of the hole (see page 60). Holes with restricted tolerances (ISO 5 and 6) can be achieved and expansion allows the reaming diameter to be maintained. The ALVAN cutting rings are manufactured to the middle limits of the hole tolerance so they must be assembled and adjusted to the required diameter. This is important for maximum performance and tool life. Left hand helical flutes cutting rings from diameter 2.60 to mm are available on request. 21

24 Series 4550 iameter range from to mm 1 2 L L4 L1 Series Cylindrical Shank with Flat - Short Series - Radial Through Coolant for Through Holes 1 2 L1 L L4 L L5 Number of Teeth Complete Mandrel without Cutting Ring Conical Ring 1 Ring Nut 5 rive Pin Number of rive Pins MC AC A CO MC AC A CO MC AC A CO MC AC A CO MC AC A CO MC AC GH CO MC AC GH CO MC AC GH CO MC AC GH CO MC AC GH CO MC AC GH CO = Cutting Ring 22

25 1 L4 2 Series 4555 iameter range from to mm L L1 Series Cylindrical Shank with Flat - Short Series - Radial Through Coolant for Blind Holes 1 2 L1 L L4 L L5 Number of Teeth Complete Mandrel without Cutting Ring Key 6 Conical Ring 1 Conical Ring Second Expansion Conical Ring Third Expansion rive Pin 2 = Cutting Ring MC CH AC AC CO MC CH AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO Number of rive Pins 2

26 Series 4550A iameter range from to mm 1 2 L L4 L1 L5 Series 4550A - Cylindrical Shank - Short Series - Radial Through Coolant for Through Holes 1 2 L1 L L4 L5 Number of Teeth Complete Mandrel without Cutting Ring Conical Ring 1 Ring Nut 5 rive Pin Number of rive Pins A-MC AC A CO A-MC AC A CO A-MC AC A CO A-MC AC A CO A-MC AC A CO A-MC AC GH CO A-MC AC GH CO A-MC AC GH CO A-MC AC GH CO A-MC AC GH CO A-MC AC GH CO = Cutting Ring 24

27 Series 4555A iameter range from to mm 1 L4 2 L L1 L5 Series 4555A - Cylindrical Shank - Short Series - Radial Through Coolant for Blind Holes 1 2 L1 L L4 L5 Number of Teeth Complete Mandrel without Cutting Ring Key 6 Conical Ring 1 Conical Ring Second Expansion Conical Ring Third Expansion rive Pin 2 = Cutting Ring A-MC CH AC AC CO A-MC CH AC AC CO A-MC CH AC AC AC CO A-MC CH AC AC AC CO A-MC CH AC AC AC CO A-MC CH AC AC AC CO A-MC CH AC AC AC CO A-MC CH AC AC AC CO A-MC CH AC AC AC CO A-MC CH AC AC AC CO A-MC CH AC AC AC CO A-MC CH AC AC AC CO A-MC CH AC AC AC CO A-MC CH AC AC AC CO A-MC CH AC AC AC CO Number of rive Pins 25

28 Series 4500 iameter range from to mm 1 L4 2 L L1 Series Cylindrical Shank with Flat - Long Series - Radial Through Coolant for Through Holes 1 2 L1 L L4 L L5 Number of Teeth Complete Mandrel without Cutting Ring Conical Ring 1 Ring Nut 5 rive Pin Number of rive Pins MC AC A CO MC AC A CO MC AC A CO MC AC A CO MC AC A CO MC AC GH CO MC AC GH CO MC AC GH CO MC AC GH CO MC AC GH CO MC AC GH CO = Cutting Ring 26

29 Series 4505 iameter range from to mm 1 L4 2 L L1 Series Cylindrical Shank with Flat - Long Series - Radial Through Coolant for Blind Holes 1 2 L1 L L4 L L5 Number of Teeth Complete Mandrel without Cutting Ring Key 6 Conical Ring 1 Conical Ring Second Expansion Conical Ring Third Expansion rive Pin 2 = Cutting Ring MC CH AC AC CO MC CH AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO Number of rive Pins 27

30 Series 4500A iameter range from to mm 1 L L4 2 L1 L5 Series 4500A - Cylindrical Shank - Long Series - Radial Through Coolant for Through Holes 1 2 L1 L L4 L5 Number of Teeth Complete Mandrel without Cutting Ring Conical Ring 1 Ring Nut 5 rive Pin Number of rive Pins A-MC AC A CO A-MC AC A CO A-MC AC A CO A-MC AC A CO A-MC AC A CO A-MC AC GH CO A-MC AC GH CO A-MC AC GH CO A-MC AC GH CO A-MC AC GH CO A-MC AC GH CO = Cutting Ring 28

31 Series 4505A iameter range from to mm 1 L4 2 L L1 L5 Series 4505A - Cylindrical Shank - Long Series - Radial Through Coolant for Blind Holes 1 2 L1 L L4 L5 Number of Teeth Complete Mandrel without Cutting Ring Key 6 Conical Ring 1 Conical Ring Second Expansion Conical Ring Third Expansion rive Pin 2 = Cutting Ring A-MC CH AC AC CO A-MC CH AC AC CO A-MC CH AC AC AC CO A-MC CH AC AC AC CO A-MC CH AC AC AC CO A-MC CH AC AC AC CO A-MC CH AC AC AC CO A-MC CH AC AC AC CO A-MC CH AC AC AC CO A-MC CH AC AC AC CO A-MC CH AC AC AC CO A-MC CH AC AC AC CO A-MC CH AC AC AC CO A-MC CH AC AC AC CO A-MC CH AC AC AC CO Number of rive Pins 29

32 Series 40 iameter range from to mm 1 L L1 Series 40 - Modular Composit Shank - Short Series - Radial Through Coolant for Through Holes 1 L1 L L L4 Number of Teeth Complete Mandrel without Cutting Ring Conical Ring 1 Ring Nut 5 rive Pin Number of rive Pins MC AC A CO MC AC A CO MC AC A CO MC AC A CO MC AC A CO MC AC GH CO MC AC GH CO MC AC GH CO MC AC GH CO MC AC GH CO MC AC GH CO = Cutting Ring 0

33 Series 45 iameter range from to mm 1 L L1 Series 45 - Modular Composit Shank - Short Series - Radial Through Coolant for Blind Holes 1 L1 L L L4 Number of Teeth Complete Mandrel without Cutting Ring Key 6 Conical Ring 1 Conical Ring Second Expansion Conical Ring Third Expansion rive Pin 2 = Cutting Ring MC CH AC AC CO MC CH AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO Number of rive Pins 1

34 Series 450 iameter range from to mm 1 L L1 5 Series Modular Composit Shank - Standard Series - Radial Through Coolant for Through Holes 1 L1 L Number of Teeth Complete Mandrel without Cutting Ring Conical Ring 1 Ring Nut 5 rive Pin Number of rive Pins MC AC A CO MC AC A CO MC AC A CO MC AC A CO MC AC A CO MC AC GH CO MC AC GH CO MC AC GH CO MC AC GH CO MC AC GH CO MC AC GH CO = Cutting Ring 2

35 Series 455 iameter range from to mm 1 L L1 5 Series Modular Composit Shank - Standard Series - Radial Through Coolant for Blind Holes 1 L1 L Number of Teeth Complete Mandrel without Cutting Ring Key 6 Conical Ring 1 Conical Ring Second Expansion Conical Ring Third Expansion rive Pin 2 = Cutting Ring MC CH AC AC CO MC CH AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO Number of rive Pins

36 Series 450 iameter range from to mm 1 L Series Modular Composit Shank - Standard Series - Radial Through Coolant for Through Holes 1 L1 L L1 Number of Teeth Complete Mandrel without Cutting Ring Conical Ring 1 Nut 4 Flange 5 Mandrel 6 rive Pin 2 = Cutting Ring MC BU GH FL MA CO MC BU GH FL MA CO MC BU GH FL MA CO MC BU GH FL MA CO MC BU GH FL MA CO MC BU GH FL MA CO MC BU GH FL MA CO MC BU GH FL MA CO MC BU GH FL MA CO MC BU GH FL MA CO MC BU GH FL MA CO MC BU GH FL MA CO MC BU GH FL MA CO Number of rive Pins 4

37 Series 455 iameter range from to mm 1 L Series Modular Composit Shank - Long Series - Radial & Central Through Coolant for Blind Holes 1 L1 L Number of Teeth L1 7 (optional) Complete Mandrel without Cutting Ring Conical Ring 1 Nut 4 Flange 5 Mandrel 6 Key (optional) 7 rive Pin 2 = Cutting Ring MC AC GH FL MA CH CO MC AC GH FL MA CH CO MC AC GH FL MA CH CO MC AC GH FL MA CH CO MC AC GH FL MA CH CO MC AC GH FL MA CH CO MC AC GH FL MA CH CO MC AC GH FL MA CH CO MC AC GH FL MA CH CO MC AC GH FL MA CH CO MC AC GH FL MA CH CO MC AC GH FL MA CH CO MC AC GH FL MA CH CO Number of rive Pins 5

38 Series 400 iameter range from to mm 1 L L1 Series Modular Composit Shank - Long Series - Radial Through Coolant for Through Holes 1 L1 L Number of Teeth Complete Mandrel without Cutting Ring Conical Ring 1 Ring nut or nut 5 rive Pin MC AC A CO MC AC A CO MC AC A CO MC AC A CO MC AC A CO MC AC GH CO MC AC GH CO MC AC GH CO MC AC GH CO MC AC GH CO MC AC GH CO = Cutting Ring Number of rive Pins 6

39 Series 405 iameter range from to mm 1 L L1 Series Modular Composit Shank - Long Series - Radial & Central Through Coolant for Blind Holes 1 L1 L Number of Teeth Complete Mandrel without Cutting Ring Key 6 Conical Ring 1 Conical Ring Second Expansion Conical Ring Third Expansion rive Pin 2 = Cutting Ring MC CH AC AC CO MC CH AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO MC CH AC AC AC CO Number of rive Pins 7

40 Technical Information Material Mild Steels Low Carbon Steel Structural Steel Uncoated Coated Hardness Reamer Reamer Vf M/min Reamer Vf Feed Reamer iameter Coolant iameter BHN kg N/mm 2 ø mm M/min mm/u ø mm ø mm ø mm H.M. Cermet Coated Up to 175 Greater than 175 Up to 62 Greater than 62 Up to 600 Greater than 600 Alloy Steel High Strength Steel Titanium and Alloys Stainless Steel Grey Cast Iron Spheroidal Cast Iron (Pearlitic) Malleable Cast Iron Spheroidal Cast Iron (Ferritic) Copper and Alloys Brass Bronze Bronze Phosphorus Aluminium and Light Alloys Synthetic Materials Up to 200HB Greater than 200HB Up to 14 Up to 175 Up to 14 Up to 50 Up to 62 Up to 50 Up to 500 Up to 600 Up to 500 Lead-In A,G Lead-In E, N, M Up to Up to Coolant Cutting Oil Over Up to Up to Coolant Cutting Oil Over Up to Up to Coolant Cutting Oil Over Up to Up to Coolant Cutting Oil Over Up to Up to Coolant Cutting Oil Over Up to Up to Coolant Cutting Oil Over Up to Up to Oil < 200 HB Coolant >200 HB Over Cutting Oil Up to Up to Coolant Cutting Oil Over Up to Up to Coolant Over Up to Up to Coolant Cutting Oil Over Up to Up to Oil Coolant Over Cutting Oil Up to Compressed Air ry Emulsible Oil 8

41 Interchangeable Heads CONTENTS Page How to order information 40 Series 7000-MC to mm 41-4 Series 7000-ML to mm Series 7000-MM to mm Technical Section 50 Features & Benefits iameter range mm Heads are either fixed or expanding for improved productivity Straight, left, or right hand helical flutes making through or blind holes achievable Cylindrical or composit shanks for improved concentricity 9

42 How to order information A B C KL G A = Series 7400 Fixed head straight flutes 7405 Expanding heads straight flutes 7600 Fixed heads right hand helical flutes 7605 Expanding heads right hand helical flutes 7700 Fixed heads left hand helical flutes 7705 Expanding heads left hand helical flutes B C = Cutting material and coating Code KL KN KC KA KP SV SN SC SA SP = Lead-In (See page 6) = iameter and tolerance escription Hard metal cutting edges Hard metal cutting edges, TiN coated Hard metal cutting edges, TiCN coated Hard metal cutting edges, TiAlN coated Hard metal cutting edges, TiNAlox coated Cermet Cermet, TiN coated Cermet, TiCN coated Cermet, TiAlN coated Cermet, TiNAlox coated 40

43 Series 7000-MC iameter range from to mm L1 1 Mandrel Code without Head & Screw 7000-MC MC MC MC MC MC L1 Locking Screw Fixed Heads Locking Screw Expanding Heads Through Holes Blind Holes Through Holes Blind Holes Number of Teeth VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI All mandrels are provided with radial through tool coolant. 1st note through hole reaming - order adjustment screw to suit through holes 2nd note blind hole reaming - order adjustment screw to suit blind holes. That drilled screw allows central through tool coolant. 41

44 Series 7000-MC iameter range from to mm L1 1 Series 7000-MC - Cyclindrical Shank - Short Series - Radial & Central Through Coolant Mandrel Code without Head & Screw 7000-MC MC MC L1 Locking Screw Fixed Heads Locking Screw Expanding Heads Through Holes Blind Holes Through Holes Blind Holes Number of Teeth VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI All mandrels are provided with radial through tool coolant. 1st note through hole reaming - order adjustment screw to suit through holes 2nd note blind hole reaming - order adjustment screw to suit blind holes. That drilled screw allows central through tool coolant. 42

45 Series 7000-MC iameter range from to mm L1 1 Series 7000-MC - Cyclindrical Shank - Short Series - Radial & Central Through Coolant Mandrel Code without Head & Screw 7000-MC L1 Locking Screw Fixed Heads Through Holes Blind Holes Number of Teeth VI VI All heads are provided with radial through tool coolant 4

46 Series 7000-ML iameter range from to mm L1 1 Series 7000-ML - Cyclindrical Shank - Long Series - Radial & Central Through Coolant Mandrel Code without Head & Screw 7000-ML ML ML ML ML ML L1 Locking Screw Fixed Heads Locking Screw Expanding Heads Through Holes Blind Holes Through Holes Blind Holes Number of Teeth VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI All mandrels are provided with radial through tool coolant. 1st note through hole reaming - order adjustment screw to suit through holes 2nd note blind hole reaming - order adjustment screw to suit blind holes. That drilled screw allows central through tool coolant. 44

47 Series 7000-ML iameter range from to mm L1 1 Series 7000-ML - Cyclindrical Shank - Long Series - Radial & Central Through Coolant Mandrel Code without Head & Screw 7000-ML ML ML L1 Locking Screw Fixed Heads Locking Screw Expanding Heads Through Holes Blind Holes Through Holes Blind Holes Number of Teeth VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI All mandrels are provided with radial through tool coolant. 1st note through hole reaming - order adjustment screw to suit through holes 2nd note blind hole reaming - order adjustment screw to suit blind holes. That drilled screw allows central through tool coolant. 45

48 Series 7000-ML iameter range from to mm L1 1 Series 7000-ML - Cyclindrical Shank - Long Series - Radial & Central Through Coolant Mandrel Code without Head & Screw 7000-ML L1 Locking Screw Fixed Heads Through Holes Blind Holes Number of Teeth VI VI All heads are provided with radial through tool coolant 46

49 Series 7000-MM iameter range from to mm 1 L1 5 Series 7000-MM - Modular Composit Shank - Radial & Central Through Coolant Mandrel Code without Head & Screw 7000-MM MM MM MM MM MM L1 Locking Screw Fixed Heads Locking Screw Expanding Heads Through Holes Blind Holes Through Holes Blind Holes Number of Teeth VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI All mandrels are provided with radial through tool coolant. 1st note through hole reaming - order adjustment screw to suit through holes 2nd note blind hole reaming - order adjustment screw to suit blind holes. That drilled screw allows central through tool coolant. 47

50 Series 7000-MM iameter range from to mm 1 L1 5 Series 7000-MM - Modular Composit Shank - Radial & Central Through Coolant Mandrel Code without Head & Screw 7000-MM MM MM L1 Locking Screw Fixed Heads Locking Screw Expanding Heads Through Holes Blind Holes Through Holes Blind Holes Number of Teeth VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI VI All mandrels are provided with radial through tool coolant. 1st note through hole reaming - order adjustment screw to suit through holes 2nd note blind hole reaming - order adjustment screw to suit blind holes. That drilled screw allows central through tool coolant. 48

51 Series 7000-MM iameter range from to mm 1 L1 Series 7000-MM - Modular Composit Shank - Radial & Central Through Coolant Mandrel Code without Head & Screw 7000-MM L1 Locking Screw Fixed Heads Through Holes Blind Holes Number of Teeth VI VI All heads are provided with radial through tool coolant 49

52 Technical Information Heads Material Mild Steel Low Carbon Steel Structural Steel Hardness Head Stock ø mm Allowance BHN kg N/mm 2 ø mm H.M. Up to 175 Up to 62 Up to 600 Greater than 175 Greater than 62 Greater than Surface Speed m/min H.M. Coated Cerment Lead-In A,G Feed mm/rev Lead-In E, N, M Alloy Steel High Strength Steel Titanium and Alloys Stainless Steel Grey Cast Iron Spheroidal cast iron (Pearlitic) Malleable Cast Iron Spheroidal Cast Iron (Ferritic) Copper and Alloys Brass Up to 288HB Greater than 200HB Up to 14 Up to 50 Up to < 200 HB >200 HB Bronze Bronze Phosphorus Aluminium and Light Alloys Up to 175 Up to 62 Up to 600 Up to 14 Up to 50 Up to

53 CONTENTS Page IN 69871/1 B+A Shank 52-5 JMTBA MAS-40 BT B+BT Shank HSK-A IN 6989/ ERC IN 6499-B 58 Modular System courtesy of Features & Benefits Large range of shanks for different machine types Highly adjustable for improved concentricity All shanks are available with through coolant 51

54 IN 69871/1 B+A Shank [1] 20 n 2 Plugs UNI592 Ring Nut Screw L Item Number ISO Modular Reducer L Standard Equipment Screw Ring Nut Plugs Modular Screw Key Accessories Modular Ring Nut Key 02B TAB2808 TAB2809 M5X5TG Hexagon 10 ATR B TAB908 TAB279 M5X5TG Hexagon 12 ATR B TAB908 TAB279 M5X5TG Hexagon 12 ATR B TAB2808 TAB2809 M5X5TG Hexagon 10 ATR B TAB2795 TAB279 M5X5TG Hexagon 14 ATR B TAB2795 TAB279 M5X5TG Hexagon 14 ATR B TAB2795 TAB279 M5X5TG Hexagon 14 ATR B TAB2808 TAB2809 M5X5TG Hexagon 10 ATR B TAB2808 TAB2809 M5X5TG Hexagon 10 ATR B TAB2795 TAB279 M5X5TG Hexagon 14 ATR B TAB2795 TAB279 M5X5TG Hexagon 14 ATR B TAB2795 TAB279 M5X5TG Hexagon 14 ATR B TAB2795 TAB279 M5X5TG Hexagon 14 ATR8851 [1] Basic shanks can be converted into IN 69871/1A coolant by screwing the two plugs clockwise to the end of their stroke. 52

55 IN 69871/1 B+A Shank Modular with Lateral Clamping [ ² ] and Radial Adjustment [1] n 2 Plugs UNI592 n 2 Wedges+OR Clamping Screw Tang [] Item Number ISO Modular Reducer 20 L Wedges+OR Clamping Screw n 4 Adjusting owels UNI592 Autolocking Standard Equipment Adjusting owels L Plugs Tang [] Clamping Screw Key Accessories Tang Key 02B.40.50L ATR ATR M8x1x10G M5x5TG ATT1410 Hexagon 6 Fixed 18 02B.40.6L ATR ATR M8x1x14G M5x5TG ATT14104 Hexagon 6 Fixed 24 02B.45.50L ATR ATR M8x1x10G M5x5TG ATT1410 Hexagon 6 Fixed 18 02B.45.6L ATR ATR M8x1x14G M5x5TG ATT14104 Hexagon 6 Fixed 24 02B.50.50L ATR ATR M8x1x10G M5x5TG ATT1410 Hexagon 6 Fixed 18 02B.50.6L ATR ATR M8x1x14G M5x5TG ATT14104 Hexagon 6 Fixed 24 02B.50.80L ATR ATR M8x1x20G M5x5TG ATT14104 Hexagon 6 Fixed 24 [1] Basic shanks can be converted into IN 69871/1A coolant by screwing the two plugs clockwise to the end of their stroke. [2] The modular system has lateral clamping which enables efficient quick release of the tools. Light torque exerted on the clamping screw transmits high axial forces which provide stiffness and extreme accuracy to the assembly. [] All adaptors and tools with modular shanks require their respective tang fitted before assembly to the system with lateral clamping. 5

56 JMTBA MAS-40 BT B+BT Shank [1] 20 n 2 Plugs UNI592 Ring Nut Screw L Item Number BT Modular Reducer L Standard Equipment Screw Ring Nut Plugs Modular Screw Key Accessories Modular Ring Nut Key BTB TAB2808 TAB2809 M5X5TG Hexagon 10 ATR8851 BTB TAB908 TAB279 M5X5TG Hexagon 12 ATR8851 BTB TAB2808 TAB2809 M5X5TG Hexagon 10 ATR8851 BTB TAB2795 TAB279 M5X5TG Hexagon 14 ATR8851 BTB TAB2795 TAB279 M5X5TG Hexagon 14 ATR8851 [1] Basic shanks can be converted into MAS-40 BT coolant by screwing the two plugs clockwise to the end of their stroke. 54

57 JMTBA MAS-40 BT B+BT Shank Modular with Lateral Clamping [ ² ] and Radial Adjustment [1] n 2 Plugs UNI592 n 2 Wedge+OR Clamping Screw Tang [] Item Number BT Modular Reducer 20 Max radial adjustment: +/- 0,2mm am Ø L Wedges+OR Clamping Screw n 4 Adjusting owels UNI592 Autolocking Standard Equipment Adjusting owels L Plugs Tang [] Clamping Screw Key Accessories Tang Key BTB.40.50L ATR ATR M8x1x10G M5x5TG ATT1410 Hexagon 6 Fixed 18 BTB.40.6L ATR ATR M8x1x14G M5x5TG ATT14104 Hexagon 6 Fixed 24 BTB.50.50L ATR ATR M8x1x10G M5x5TG ATT1410 Hexagon 6 Fixed 18 BTB.50.6L ATR ATR M8x1x14G M5x5TG ATT14104 Hexagon 6 Fixed 24 BTB.50.80L ATR ATR M8x1x20G M5x5TG ATT14104 Hexagon 6 Fixed 24 [1] Basic shanks can be converted into IN 69871/1A coolant by screwing the two plugs clockwise to the end of their stroke. [2] The modular system has lateral clamping which enables efficient quick release of the tools. Light torque exerted on the clamping screw transmits high axial forces which provide stiffness and extreme accuracy to the assembly. [] All adaptors and tools with modular shanks require their respective tang fitted before assembly to the system with lateral clamping. 55

58 HSK-A IN 6989/1 Shank Kit Clutch for Coolant [] Ring Nut Screw Item Number HSK Modular Reducer L L Standard Equipment Screw Ring Nut Modular Screw Key Modular Ring Nut Key Accessories Key Kit Clutch for Coolant Kit Clutch for Coolant [1] HSK-A TAB2808 TAB2809 Hexagon 10 ATR8851 ATR2856 ATT2728 HSK-A TAB2795 TAB279 Hexagon 14 ATR8851 ATR2856 ATT2728 HSK-A TAB2808 TAB2809 Hexagon 10 ATR8851 ATR2856 ATT2656 HSK-A TAB2795 TAB279 Hexagon 14 ATR8851 ATR2856 ATT2656 HSK-A TAB2795 TAB279 Hexagon 14 ATR8851 ATR2856 ATT2656 [1] Coolant clutch kits are supplied separately on request Adjusting Cylindrical Shank Tang [] ø 50 Clamping Screw n 2 Wedge+OR Standard Equipment Accessories Item Number Wedge+OR Clamping Screw Adjusting owels Tang [] Tang Key Clamping Screw Key CIL ATR ATR M8x1x10G ATT1410 Hexagon 6 Fixed 18 CIL ATR ATR M8x1x10G ATT1410 Hexagon 6 Fixed 18 CIL ATR ATR M8x1x10G ATT1410 Hexagon 6 Fixed 18 56

59 HSK-A IN 6989/1 Shank Modular with Lateral Clamping [1] and Radial Adjustment n 4 Adjusting owels UNI592 Autolocking Kit Clutch for Coolant [] n 2 Wedge+OR Clamping Screw Tang [2] Item Number Max radial adjustment: +/- 0,2mm am Ø HSK Modular Reducer L Wedge+OR Standard Equipment Clamping Screw Adjusting owels L Clamping Screw Key Tang [2] Accessories Key Kit Clutch for Coolant Kit Clutch for Coolant [] HSK-A.6.50L ATR ATR M8x1x10G Hexagon 6 Fixed 18 ATT1410 ATR2856 ATT2728 HSK-A.6.6L ATR ATR M8x1x14G Hexagon 6 HSK-A L ATR ATR M8x1x10G Hexagon 6 HSK-A.100.6L ATR ATR M8x1x14G Hexagon 6 HSK-A L ATR ATR M8x1x20G Hexagon 6 Fixed 24 ATT14104 Fixed 18 ATT1410 Fixed 24 ATT14104 Fixed 24 ATT14104 ATR2856 ATR2856 ATR2856 ATR2856 ATT2728 ATT2656 ATT2656 ATT2656 [1] The modular system has lateral clamping which enables efficient quick release of the tools. Light torque exerted on the clamping screw transmits high axial forces which provide stiffness and extreme accuracy to the assembly. [2] All adaptors and tools with modular shanks require their respective tang fitted before assembly to the system with lateral clamping. [] Coolant clutch kits are supplied separately on request. 57

60 ERC IN 6499-B Collet Chuck Adaptors 0 Ring L rilled Adjusting owel Collect ERC d 1 Item Number rive Key + Screw UNI5921 Modular Shank Collect Reducer d 1 L Ring Nut Standard Equipment Ring Nut rive Key Screw C.H..M Adjusting owel CH..S 0 Ring Ring Nut Key Accessories Adjusting owel Key 0.50R ERC G25S TAB924 M4x8V M12x16GF 10 CH25S Hexagon R ERC G2S TAB924 M4x8V M16x15x18GF 10 CH2S Hexagon 8 0.6R ERC G2S TAB92.1 M6x12V M12x16GF 1400 CH2S Hexagon 6 0.6R ERC G40S TAB92.1 M6x12V M20x2x20GF 1400 CH40S Hexagon R ERC G2S TAB92.2 M6x16V M12x16GF 1400 CH2S Hexagon R ERC G40S TAB92.2 M6x16V M20x2x20GF 1400 CH40S Hexagon 10 Operating Instructions For Lateral Modular Shank Remove the tang from the lateral modular shank by loosening the clamping screw. Assemble the tang to the adaptor spigot which matches the lateral modular shank. Insert the adaptor with its tang into the reducer bore of the lateral modular shank. Lock the adaptor by tightening the clamping screw. Assembly For Radial Adjusting Note: Only adaptors with modular reducer spigot are suitable for radial adjustment. Complete the operations mentioned above then proceed as follows: Lightly tighten the clamping screw so that the tang is still able to move in a radial direction. Correct eccentricity with the 4 adjusting dowels by bringing them into contact with the tang Tighten the clamping screw to lock the tang. Re-check for eccentricity, if required use the 4 adjusting dowels to correct and restore the value. Tighten the clamping screw to lock the adaptor. n 2 Plugs UNI592 n 2 Wedge+OR Clamping Screw n 4 Adjusting owels UNI592 Autolocking L Tang [] 58

61 CONTENTS Page Guidelines for Troubleshooting 67 59

62 1) iameter Measurement The diameter of the reamers and of the cutting rings is measured with a micrometer. We recommend the use of a comparator style micrometer with a least a 2 um resolution to avoid micro chipping of the cutting edges. To allow setting of the reamer, two cutting edges are exactly 180 opposed. These are marked with a coloured dimple (see diagram below). Measurement must be taken from the front of the cutting edges only. The dimple indicates that the tool has been ground with a single lead-in angle (code G), the dimple on the body indicates a double lead-in angle (code A). imple imple iameter iameter 2) Tolerance Expandible reamer are ground to the middle of the tolerance. Fixed reamer are ground at the 2/ of the tolerance. ) Expanding Reamers Adjustment The adjustment must be made to compensate for wear to the cutting edges when the size reaches its lower tolerance. This operation can be repeated several times until the surface finish of the hole deteriorates to an unacceptable level, then the reamer must be reground. 60

63 Series from ø 5,80 to ø 2,10mm 1) Adjustment Procedure Turn the right hand threaded screw slowly clockwise, while checking the diameter setting of the reamer with a micrometer. When the required diameter is achieved, the tool is ready for use. 61

64 Series A A from ø 17,60 to ø 100,59mm Series from ø 17,60 to ø 100,59mm Series 400 from ø 17,60 to ø 100,59mm ) Assembly Insert the cutting ring (item 2) on the mandrel with the drive pins (item ) assembled. Insert the conical ring (item 1). Screw the nut (item 5) and lock in manually: the thread is left handed. We recommend lubricating the thread and the conical surface of contact between the cutting ring and the conical ring with antifriction Molycote grease. 2) Adjustment Procedure Turn the nut slowly, checking the diameter setting of the cutting ring with a micrometer, ensuring the drive pins are in traction in the opposite direction to the cutting action of the reamer. When the required diameter is achieved, the tool is ready for use. ) isassembly Unscrew the nut. Remove the components from the mandrel. 62

65 Series A A from ø 17,60 to ø 100,59mm Series from ø 17,60 to ø 100,59mm ) Assembly Mount the cutting ring (item 2) onto the mandrel with the drive pins (item ) assembled. Screw the conical ring nut onto the mandrel and lock it manually: the thread is left handed. Lubricate the thread and the conical surface of contact between the cutting ring and the conical ring with antifriction Molycote grease. 2) Adjustment Procedure Turn the conical ring nut slowly using a pin spanner (item 6) supplied with reamers from diameter 17,60 to 40,59 mm, checking the diameter setting of the cutting ring with a micrometer. When the required diameter is achieved unscrew the conical ring until there is a click and the drive pins are in traction in the opposite direction to the cutting action of the reamer. The reamer is ready for use. ) isassembly Unscrew the conical ring nut. Remove the components from the mandrel. 6

66 Series 450 from ø 100,60 to ø 200,59mm ) Assembly With the drive pins (item ) assembled, mount the flange (item 5) onto the mandrel (Item 6). Assemble the cutting ring (item 2) so that the slot on the left side of the dimple is mounted onto the drive pins. Insert the conical ring (item1). Screw the ring nut (item 4) onto the mandrel and tighten manually, so that the conical ring makes contact with the cutting ring: the thread is left handed. We recommend lubricating the thread and the conical surface of contact between the cutting ring and the conical ring with antifriction Molycote grease. 2) Adjustment Procedure Turn the ring nut slowly (using a pin spanner) checking the diameter setting of the cutting ring with a micrometer, ensuring the drive pins are in traction, in the opposite direction to the cutting action of reamer. When the required diameter is achieved, the tool is ready for use. ) isassembly Unscrew the ring nut. Remove the components from the mandrel. 64

67 Series 455 from ø 100,60 to ø 200,59mm 7 (optional) ) Assembly With the drive pins (item ) assembled, mount the flange (item 5) onto the mandrel (Item 6). Assemble the cutting ring (item 2) so that the slot on the left side of the dimple is mounted onto the drive pins. Insert the conical ring (item1). Screw the ring nut (item 4) onto the mandrel and tighten manually, so that the conical ring makes contact with the cutting ring: the thread is left handed. We recommend lubricating the thread and the conical surface of contact between the cutting ring and the conical ring with antifriction Molycote grease. 2) Adjustment Procedure Turn the ring nut slowly (using a pin spanner) checking the diameter setting of the cutting ring with a micrometer, ensuring the drive pins are in traction, in the opposite direction to the cutting action of reamer. When the required diameter is achieved, the tool is ready for use. ) isassembly Unscrew the ring nut. Remove the components from the mandrel. 65

68 imple iameter imple iameter 1) iameter Measurement The diameter of the heads is measured with a micrometer. To avoid microchipping of the cutting edges, we would recommed the use of a comparator style micrometer with at least 2 um resolution. The cutting edges are of a asymmetric design with two cutting edges exactly 180 opposed to allow setting. Measurement must be taken from the front of the cutting edges only. 2) Tolerance Expandible reamer are ground to the middle of the tolerance. Fixed reamer are ground at the 2/ of the tolerance. ) Expanding Heads Adjustment When the size reaches its lower tolerance the head can be adjusted to compensate for wear to the cutting edges. This operation can be repeated several times until the surface finish of the hole deteriorates to an unacceptable level. 66

69 Guidelines for Troubleshooting Problem Cause Solution Hole Too Large Hole Too Small a) The reamer is running eccentric to the centre line of the machine spindle b) Excessive misalignment of reamer c) Material build up on cutting edges d) The reamer diameter is too large a) Use the adjusted mandrel b) Rectify misalignment or use the adjusted mandrel c) Replace the coolant or change the cutting speed d) Use smaller reamer or regrind existing one a) The reamer diameter is too small a) Use large reamer b) The reamer diameter is worn b) Expand, regrind or replace the reamer c) The coolant is not suitable c) Replace the coolant d) Stock allowance too small d) Increase the stock allowance Tapered Hole Burr at the Entry of The Hole The Hole is Not Straight e) The cutting speed is too low e) Increase the cutting speed a) Excessive misalignment a) Excessive misalignment a) Concentricity and alignment error between the workpiece and the tool a) Correct misalignment or use the adjusted mandrel a) Correct misalignment or use the adjusted mandrel a) Correct misalignment or use the adjusted mandrel b) Asymmetrical cutting or angled surfaces b) Create a chamfer on the lead-in a) One cutting edge is chipped a) Regrind the reamer b) The lead-in is irregular b) Regrind the reamer Quality of the Work Surface Unsatisfactory The Reamer Creates Excessive Torque Loading c) Back taper on the cutting edges too great c) Regrind the reamer d) Excessive misalignment d) Correct misalignment or use the adjusted mandrel e) Cutting data not correct e) Verify cutting data f) Poor chip evacuation f) Verify coolant volume and pressure or use internal through tool coolant a) Back taper on the cutting edges too small a) Regrind the reamer b) The radially ground land is too wide b) Regrind the reamer c) The coolant is not suitable c) Replace the coolant Our technical department is available to assist in: 1) Establishing optimum cutting data 2) Verifying alignment problems ) Supply of correct regrinding data 67

70 Notes 68

71

72 Other Catalogues Available E E Allied Maxcut Engineering Co. Limited Allied Maxcut Engineering Co. Limited Making a difference Making a difference Criterion Allied Catalogue APX Catalogue Criterion Allied Catalogue Holemaking Catalogue European Headquarters: Allied Maxcut Engineering Co. Limited 9 Vantage Point, Pensnett Estate, Kingswinford, West Midlands, Y6 7FR England Tel: +44 (0) Fax: +44 (0) enquiries@alliedmaxcut.com Website: Global Headquarters: Allied Machine & Engineering Corp. 120 eeds rive - PO Box 6 over, Ohio, USA Tel: Fax: Website: *ALVen14R1*