INSTRUCTIONS FOR USE B2 FORM KNURLING TOOL

Transcription

1 INSTRUCTIONS FOR USE B2 FORM KNURLING TOOL

2 Contents CONTENTS 1. General Introduction Tool Construction B2 Tools Technical Data Overview: Main components Tool adjustment B2/KF Tool adjustment B2/FL Wear Parts Troubleshooting Dimensions and pitches Available Reference Values for Feeds and Cutting Speeds Coolant unit General Overview: Main components Assembly/Starting up

3 General Introduction 1. General 1.1 Introduction Please read through the Instructions for Use carefully before using the QUICK knurling tools! The instructions have been written for operators with qualified training in the field of machining and cutting. Compliance with the Instructions for Use increases reliability in use, increases the service life of tools, and prevents downtimes. We reserve the right to make alterations to the technical details of the tools by comparison with the information and illustrations contained in these Instructions for Use. Symbols in these instructions ATTENTION: This Symbol warns that operating procedures carried out without paying attention to the measures specified may lead to damage to the tool and/or the machine tool. NOTE: This Symbol refers to further information and provides additional information for using the QUICK knurling tools. Text markups: This symbol identifies lists This symbol identifies an action sequence 2

4 1.2 Tool Construction B-series tools are flexible in use and may be employed on all lathes from the conventional to CNC-controlled multiple-spindle lathes, optionally as a left-hand or right-hand tool, in front or behind the turning centre. The tools press the corresponding knurling shape by cold forming on the workpiece, thus providing chipless machining. General Tool Construction It is not possible to make them adopt a specific speed ratio to the diameter of the workpiece by means of sustained forcing. As a result the number of teeth of the knurl produced may differ. The difference is approx. +/- 1-3 teeth depending on the pitch. Type of knurl DIN 82 Tool Knurling wheel Straight knurl RAA B2/FL 90 Spiral knurl RBL / RBR B2/FL As required Cross knurl RKE B2/KF 45 L + 45 R Diamond knurl RGE B2/KF 30 L + 30 R 3

5 General Tool Construction Applications Machining of cold formable materials All knurling shapes and knurling profiles are possible with a single tool Knurling is possible as far as the flange or workpiece shoulder The tool can be applied to any point on the workpiece Tool definition Definition of the tool as left- or right-handed is determined by the position of the knurling wheels when the tool is viewed from the front in the clamped position. left right left right Clamping Clamping of the tool body on the shank is effected by means of an eccentric chuck. The surface clamping generated as a result reduces the vibrations arising due to machining and increases the service life of the knurling wheels. Shanks and bodies may be individually assembled easily and without much effort by the customer himself. 4

6 General Tool Construction Perfect results may be achieved with: Correct adjustment Closely following the instructions regarding the start of the knurling process Appropriate feed and cutting speed NOTE: It is imperative to ensure an abundant supply of coolant or cutting oil directly onto the knurling wheels to ensure perfect cooling and lubrication of the knurling wheels. Supplied with Pos. Description 1 Tool holder with shank 2 Wheel holder (x 2) 3 Washer(x 2) 4 Knurling wheels (as required) 5 Coolant hose 6 Blanking plug 7 Tool key - Torx 25 8 Paste Molykote G 9 Instructions for Use 9 5

7 B2 Tools Technical Data 2. B2 Tools 2.1 Technical Data B2/KF Types of knurl Cross and diamond Working range Ø mm Shank dimension 20x25 or 25x25 mm Knurling wheel Ø 25 mm Cross 1 x 45 L and 1 x 45 R Diamond 1 x 30 L and 1 x 30 R Pitches see page 20 Weight 1.1 kg B2/FL Types of knurl Straight and spiral RAA / RBL / RBR Working range Ø mm Shank dimension 20x25 or 25x25 mm Knurling wheel Ø 25 mm Straight 1 x 90 Spiral As required Pitches see page 20 Weight 1.1 kg 6

8 2.2 Overview: Main components B2 Tools Overview: Main components Pos. Description 1 Tool head 2 Wheel holder with wheel flat 3 Knurling wheel 4 Washer 5 Cover plate 6 Terminal strip 7 Clamping segment 8 Index point 9 Coolant nozzles 10 Shank 11 Eccentric bolt 12 Spindle screw 7

9 B2 Tools Tool adjustment B2/KF 2.3 Tool adjustment B2/KF Preliminary work: Clamp workpiece and turn. Maximum out-of-roundness: 0.03 mm Step 1: Cutter selection Cross knurl: 1x 45 left-hand spiral toothed knurling wheel on wheel holder "L" 1x 45 right-hand spiral toothed knurling wheel on wheel holder "R" Diamond knurl: 1x 30 left-hand spiral toothed knurling wheel on wheel holder "L" 1x 30 right-hand spiral toothed knurling wheel on wheel holder "R" Step 2: Install knurling wheels Clean contact surface 1.1 for washer 4 on cover plate 5 Apply Molykote G paste lightly to wheel holder 2 and washer 4 Loosen clamping segment 7 by turning counterclockwise Insert wheel holder 2 into knurling wheel 3 and slide on washer 4 Align flat 2.1 of wheel holder to clamping strip 6 and insert wheel holder Tighten clamping segment 7 again, causing the terminal strip to lock the wheel holder into position. Check that the knurling wheel is able to turn with no play 8

10 Step 3: Pre-adjust turning centre For centring of the tool, the mark M on the shank must be aligned with the mark on the head. The mark in the middle of the head should be selected for use in conventional machines The outer marks should be selected for use in CNC machines depending on the shaft dimensions. B2 Tools Tool adjustment B2/KF Adjustment: Unscrew eccentric bolt 11 Adjust tool head 1 accordingly by way of spindle screw 12 Clamp eccentric bolt again hand-tight Pos. Use Shank 0 conventional 20/25 a CNC 20 b CNC 25 -a CNC 20 -b CNC 25 Step 4: Clamp tool in tool holder 9

11 B2 Tools Tool adjustment B2/KF Step 5: Adjust turning centre Carefully bring into contact with the workpiece Both cutters must be in contact simultaneously. Precision adjustment is carried out using spindle screw 12 Tighten eccentric bolts 11 hand-tight when alignment is finished Step 6: Adjust knurling wheels Infeed in X-direction Groove knurling: Adjust the tool so that it is axially parallel with the workpiece. X Longitudinal knurling Tool tilt of approx Z X 1-2 Z X Infeed in the x-direction until a sharp knurl pattern occurs on the workpiece. Usually approx. ½ the pitch of the inserted knurling wheels. The material application is usually ½ the pitch. 10

12 Step 7: Start of knurl TIP: Longitudinal knurling The start of the knurl should be in a width no greater than 1.5 mm. With this width, now move the tool to the full depth (X-axis) without interruption. The feed on infeeding should be approx. 0.1 mm. The knurling depth corresponds to the pitch of the knurling cutter being used, e.g. 1.0 mm pitch requires 0.5 mm infeed with reference to the diameter. The infeed is measured from the knurling cutter's point of contact with the workpiece. max 1,5 mm B2 Tools Tool adjustment B2/KF The surface deformation of the workpiece cannot be determined exactly as this is different from material to material. The knurling depth, however, should be sufficient to ensure that the knurl is only just sharp. NOTE: Please ensure that the protection facing on the start of the workpiece can only be applied after knurling has taken place. The coarser the pitch, the smaller the feed. Feed and cutting speed have no effect on the knurl pitch. Z X After an idle time of 2-3 seconds, the workpiece is knurled by using the longitudinal feed. For feed rate values, see table on page 21. Z X Step 8: Knurling NOTE: If the knurl is not accurate or is onesided, then the knurling process may be repeated after correcting the tool. 11

13 B2 Tools Tool adjustment B2/FL 2.4 Tool adjustment B2/FL Preliminary work: Clamp workpiece and turn. Maximum out-of-roundness: 0.03 mm Step 1: Cutter selection Straight knurl RAA: 1x 90 knurling wheel Spiral knurl: Depending on the spiral tilt desired, knurling wheels with spirals of 30, 45 or a special tooth pitch angle must be installed Because of the large number of possible variations it is advisable to consult your dealer and/or the manufacturer. Step 2: Install knurling wheel Clean contact surface 1.1 for washer 4 on cover plate 5 Apply Molykote G paste lightly to wheel holder 2 and washer 4 Loosen clamping segment 7 by turning counterclockwise Insert wheel holder 2 into knurling wheel 3 and slide on washer 4 Align flat 2.1 of wheel holder to clamping strip 6 and insert wheel holder Tighten clamping segment 7 again, causing the terminal strip to lock the wheel holder into position. Check that the knurling wheel is able to turn with no play 12

14 Step 3: Adjust turning centre For centring of the tool, the mark M on the shank must be aligned with the mark on the head. The mark in the middle of the head should be selected for use in conventional machines The outer marks should be selected for use in CNC machines depending on the shaft dimensions. B2 Tools Tool adjustment B2/FL Adjustment: Unscrew eccentric bolt 11 Adjust tool head 1 accordingly by way of spindle screw 12 Clamp eccentric bolt again hand-tight Pos. Use Shank 0 conventional 20/25 a CNC 20 b CNC 25 -a CNC 20 -b CNC 25 Step 4: Clamp tool in tool holder 13

15 B2 Tools Tool adjustment B2/FL Step 5: Adjust knurling wheels Infeed in X-direction Groove knurling: Adjust the tool so that it is axially parallel with the workpiece. X Longitudinal knurling Tool tilt of approx. 1-2 Step 6: Start of knurl TIP: Longitudinal knurling The start of the knurl should be in a width no greater than 1.5 mm. With this width, now move the tool to the full depth (X-axis) without interruption. The feed on infeeding should be approx. 0.1 mm. The knurling depth corresponds to the pitch of the knurling cutter being used, e.g. 1.0 mm pitch requires 0.5 mm infeed with reference to the diameter. The infeed is measured from the knurling cutter's point of contact with the workpiece. max 1,5 mm Z Z Z X 1-2 Infeed in the x-direction until a sharp knurl pattern occurs on the workpiece. Usually approx. ½ the pitch of the inserted knurling wheels. The material application is usually ½ the pitch. Z X X After an idle time of 2-3 seconds, the workpiece is knurled by using the longitudinal feed. For feed rate values, see table on page 21. X 14

16 The surface deformation of the workpiece cannot be determined exactly as this is different from material to material. The knurling depth, however, should be sufficient to ensure that the knurl is only just sharp. Step 7: Knurling B2 Tools Tool adjustment B2/FL NOTE: If the knurl is not accurate or is onesided, then the knurling process may be repeated after correcting the tool. NOTE: Please ensure that the protection facing on the start of the workpiece can only be applied after knurling has taken place. The coarser the pitch, the smaller the feed. Feed and cutting speed have no effect on the knurl pitch. 15

17 Coolant unit General 3. Coolant unit 3.1 General This integrated cooling system enables targeted cooling and lubrication of the knurling wheels and/or workpieces and thus increases the service life of the tools/knurling wheels. Coolant pressure max. 8 bar 3.2 Overview: Main components Pos. Description 1 Coolant unit integrated into the tool head 2 Adjustable nozzles 3 Push-in connection 4 Coolant hose 5 Blanking plug 16

18 3.3 Assembly/Starting up Step 1: Connect coolant supply Clamp tool in tool holder Insert coolant hose 4 into the top push-in connector 3 until it stops Route hose with corresponding bending radius to connection on tool holder, cut to length as necessary and connect On the second coolant connection, insert blanking plug 5 until limit stop is reached Coolant unit Assembly/Starting up Step 2: Activate cooling system Activate the cooling system before commencing knurling ATTENTION: The coolant unit is designed for a max. pressure of 8 bar. Step 4: Precision adjustment of the ball nozzles on coolant unit To ensure optimal cooling for B2 tools, direct the two nozzles at the knurling wheels NOTE: To remove the hose and the blanking plug, push in the push-in connector slightly. 17

19 Wear Parts 4. Wear Parts The fixing elements for the knurling wheels of the QUICK B2-series tools are wear parts and must be replaced frequently. Pos. Description 1 Wheel holder 2 Washer 18

20 Troubleshooting 5. Troubleshooting B2/KF tool Overlapping of the knurl (double knurl) Approach to knurl depth too slow as a result of which too little guidance of knurling wheels in track Look at start of knurl Teeth of knurling wheel knocked off Knurling wheel has been overloaded feed too great, cutting depth too great Unevenly deep knurl track Re-align position of head using spindle Seizing of knurling wheels on wheel holder Reduce cutting speed Use Molykote paste Coolant jet directly onto the knurling wheels B2/FL tool Knurl trailing spirally Look at start of knurl Look at knurling depth Clearance of tool too positive or too negative Teeth of knurling wheel knocked off Knurling wheel has been overloaded feed too great, cutting depth too great Seizing of knurling wheels on wheel holder Reduce cutting speed Use Molykote paste Coolant jet directly onto the knurling wheels 19

21 Dimensions and pitches Available 6. Dimensions and pitches Available Technical Description Material: Powder metallurgy tool steel Heat treatment: Hardened to HRC Designs: ground Order numbers and designation Ident. no. Ø A Ø B C /12 8 Dimensions and pitches C t A B Ø Tooth pitch angle Pitches (t) toothed 0.5 / 0.6 / 0.8 / 1.0 / 1.2 / L / 30 R toothed 0.5 / 0.6 / 0.8 / 1.0 / 1.2 / L / 45 R toothed 0.5 / 0.6 / 0.8 / 1.0 / 1.2 / 1.5 Pos. Description 1 Production date MM/YY 2 Tooth pitch angle 3 Tooth pitch direction R (right) L (left) 4 Tooth pitch 5 Material 6 Tooth tip angle 7 Production process G (ground) / M (milled) 8 Coated with QDUR / TiCN / TIN 20

22 Reference Values for Feeds and Cutting Speeds 7. Reference Values for Feeds and Cutting Speeds Knurling wheel Ø 25 Material V m/min s mm/rev Steel up to 600 N/mm² Steel up to 900 N/mm² Stainless steels Ms Ms Bronze Cast steel

23 QUICK Tooling GmbH Brunnenstraße Aldingen Germany Tel.: Fax: / Edition. Technical details are subject to change. Printing errors excepted. No part of these document may be copied or disclosed for any purposes without the written approval of QUICK Tooling GmbH. All rights reserved.