GR 1 GR 2 GR 3 GR 1-S GR 2-S GR 3-S Tapping attachment GR / GR-S Operating instruction
Contents: 1 Application range, safety instructions and technical data... 4 1.1 Application range, determined use, specifications... 4 1.2 Safety instructions... 5 1.3 Proprietary rights... 5 1.4 Dimensions and technical data... 6 1.4.1 1.4.2 Tapping attachment type GR... 6 Tapping attachment type GR-S... 7 2 Putting the tapping attachment into operation... 8 2.1 Unpacking... 8 2.2 Prepare tapping attachment... 9 2.2.1 2.2.2 2.2.3 Mount shank on types GR1/GR1-S and GR2/GR2-S... 9 Mount shank on types GR3/GR3-S... 10 Mount holding bar... 11 2.3 Putting the tapping attachment into operation... 12 2.4 Clamp tap with tapping attachment... 13 2.4.1 2.4.2 2.4.2.1 2.4.2.2 Clamp collet and tap with type GR... 13 Clamp quick-change adapter and tap with type GR-S... 15 Inset tap... 15 Insert the quick-change adapter... 16 2.5 Detach tap from tapping attachment... 17 2.5.1 2.5.2 2.5.2.1 2.5.2.2 Detach tap from type GR... 17 Detach tap from type GR-S... 18 Detach quick-change adapter... 18 Detach tap... 19 2.6 Adjustment of overload clutch... 20 3 Mainenance... 21 3.1 Maintenance schedule... 21 3.2 External cleaning... 21 4 Storage when not in use... 21 5 Course of a thread producing cycle... 22 2 Operating instruction edition: 01.02.2017
Warnings, symbols In this operating instruction the following symbols are used: Marks special instructions, rules and prohibitions, which are important in order to avoid any damage. Please observe these instructions! Note Marks application instructions and other useful information. Sectional view: Tapping attachment GR Operating instruction edition: 01.02.2017 3
1 Application range, safety instructions and technical data 1.1 Application range, determined use, specifications The tapping attachments type GR and GR-S are mainly used on pillar drilling machines. The reverse of the rotation direction can be executed via the integrated turning gear mechanism by reversing the machine spindle (left-hand running). There is no change of the turning direction of the machine spindle. The resulting advantages are: Saving time by shorter cycle times Protection of the machine (engine) Saving energy by almost constant power consumption The tapping attachment can only be used if it is adapted in a driven machine spindle. Being inserted in the machine, the holding bar must be secured against twisting in both turning directions. Our GR series is available in the following designs: Type GR with tool adaptation by means of collets type Rubber-Flex. The torque is transferred by adjustable driving cams, see chapter 2.4, page 13. Type GR-S with tool adaptation by means of quick-change adapters of our EM series, see chapter 2.4.2, page 15. Further characteristics are: Integrated length compensation on compression and tension for compensating differences between spindle feed and pitch of the thread to be produced Integrated overload clutch, see chapter 2.6, page 20 Transmission ratio advance/reversal is 1:1,6 1:1,75, depending on the size Normally, the tapping attachments are provided with morse taper shanks which must be ordered separately. For information regarding the assembly of the shank please refer to chapter 2.2, page 9. The tapping attachments type GR and GR-S are not designed for internal coolantlubricant supply. The tapping attachments type GR and GR-S are only designed for producing right hand threads. For the cutting range of each type please refer to table 1 and table 2. The non-determined use exempts the manufacturer from any liability. 4 Operating instruction edition: 01.02.2017
1.2 Safety instructions For all works, i.e. 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 tapping attachments. 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 the work piece. Keep the tool adaptation clean. There are maximum values for cutting speeds and feeds for every kind of machining. Please observe such data. Please observe the maximum tool dimensions. Furthermore, the instructions of the tool manufacturers are valid! 1.3 Proprietary rights The entire contents of these operating instructions are subject to German proprietary rights legislation. Any form of multiplication, processing, broadcasting, passing on to third parties - also in the form of extracts - and any kind of use outside the boundaries of proprietary rights requires the written consent of EMUGE GmbH&Co.KG. Operating instruction edition: 01.02.2017 5
1.4 Dimensions and technical data 1.4.1 Tapping attachment type GR C: Length compensation on compression G: Disengaging distance H: Free wheel T: Length compensation on tension D2 D Holding bar Torque adjusting ring D1 Shank adaptation Universal clamping head L Picture 1: Dimension of tapping attachment GR Table 1: Technical of tapping attachment GR Type Article number Cutting change Clamping range D 1 Collet size 1 Shank adaptation GR 1 F0401999 M2 M7 Nr. 2-1/4 2,5-6,5 J116 J117 B16 (DIN) ISO 239 GR 2 F0402999 M4 M12 Nr. 8-7/16 3,5-10 J421 J422 B16 (DIN) ISO 239 GR 3 F0403999 M8 - M20 5/16-3/4 6-16 R30 R32 M20 Type D D 2 L C G H T Max. Speed/rpm [min -1 ] GR 1 23 55 130 5 3,5 1,5 7 1500 GR 2 28 75 156 5 4 1,5 8,5 1000 GR 3 40 91 204 6 6 1,5 11,5 600 1 These Rubber-Flex-collets are part of the delivery 6 Operating instruction edition: 01.02.2017
1.4.2 Tapping attachment type GR-S C: Length compensation on compression G: Disengaging distance H: Free wheel T: Length compensation on tension D2 D Torque adjusting ring Holding bar D1 Quick change adaptation Shank adaptation L Picture 2: Dimension of tapping attachment GR-S Table 2: Technical data of tapping attachment GR-S Type Article number Cutting range Adapter size Shank adaptation GR 1-S F0411999 M2 M7 Nr. 2-1/4 EM00 B16 (DIN) ISO 239 GR 2-S F0412999 M4 M12 Nr. 8-7/16 EM01 B16 (DIN) ISO 239 GR 3-S F0413999 M8 - M20 5/16-3/4 EM03 M20 Type D D 2 L C G H T Max. Speed/rpm [min -1 ] GR 1-S 25 55 139 5 3,5 1,5 7 1500 GR 2-S 32 75 157 5 4 1,5 8,5 1000 GR 3-S 50 91 204 6 6 1,5 11,5 600 Operating instruction edition: 01.02.2017 7
2 Putting the tapping attachment into operation Note Treat the tapping attachments very careful. Protect the tapping attachments against moisture and high temperature differences. The tapping attachment is supplied without shank. The required morse taper shank has to be ordered separately. Details are given in the EMUGE main catalogue, category GR / GR-S. 2.1 Unpacking Take the tapping attachment and accessories from the packing case Clean the tapping attachment with a duster to remove any conservation oil Note Do not use any aggressive solvents. Do not use fibrous materials i.e. steel wool. 8 Operating instruction edition: 01.02.2017
2.2 Prepare tapping attachment 2.2.1 Mount shank on types GR1/GR1-S and GR2/GR2-S Note Required tool: Plastic hammer 1. Clean the adaptation in the tapping attachment and the shank 2. Insert shank into the adaptation, see picture 3 3. Fix the shank with a soft punch using a plastic hammer, see picture 4 Shank Shank adaptation Picture 3: Picture 4: Insert shank Fix shank Operating instruction edition: 01.02.2017 9
2.2.2 Mount shank on types GR3/GR3-S Note Required tool: Open ended spanner SW 30 1. Screw shank into the adaptation, see picture 5 2. Tighten the shank using the open ended spanner, see picture 6 Shank Shank adaptation Picture 5: Picture 6: Screw in shank Tighten shank 10 Operating instruction edition: 01.02.2017
2.2.3 Mount holding bar Note Required tool: Hexagon socket wrench (part of the delivery) Put the supplied holding bar into the adaptation and tighten with the thread pin The holding bar has a countersink. Position of countersink and position of the thread pin must match. Adaptation Holding bar Thread pin Countersink Picture 7: Fix holding bar Operating instruction edition: 01.02.2017 11
2.3 Putting the tapping attachment into operation 1. Insert the tapping attachment into the adaptation of the machine spindle The tool change 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. Otherwise: Risk of accident by spinning of the tool! Please see also the indications in the operating instruction of your machine tool! 2. Secure the holding bar against twisting in both directions, see picture 8. Detail X Detail X Make sure the spindle is guided over its complete movement! Picture 8: Tapping attachment secured against twisting The tapping attachment is now ready for operation. 12 Operating instruction edition: 01.02.2017
2.4 Clamp tap with tapping attachment 2.4.1 Clamp collet and tap with type GR The locking of the tap is executed via adjustable and floating-mounted driver cams, centering is carried out via a Rubber-Flex-collet, see picture 9. Thread spindle Driver cam Clamping nut Hexagon socket wrench Rubber-Flex-collet Picture 9: Set-up of the universal clamping head Note Choose the appropriate Rubber-Flex collet for the required tap!! Required tool: Open ended spanner Hexagon socket wrench (part of the delivery) (part of the delivery) Clampingnut Ruber-Flex colet 1. Insert Rubber-Flex-collet into the clamping nut. Make sure the collet is flush with the clamping nut Clamping head 2. Screw the clamping nut with collet on to the thread of the clamping head Clamping nut with collet Operating instruction edition: 01.02.2017 13
Clamping nut Driver cam 3. Push tap into the collet and slightly tighten the clamping nut so that the tap does not fall out but may still be turned Tool Tap Thread spindle Driver cam Tool 4. Clamp tap square via driver cam and thread spindle. Correct Wrong!! Check and eventually correct the position of the square through the visual control window in the clamping head 5. Tighten the clamping nut using the open ended spanner In order to avoid the damage of parts, please support the clamping nut, when tightening with the wrench, with the open ended spanner. 14 Operating instruction edition: 01.02.2017
2.4.2 2.4.2.1 Clamp quick-change adapter and tap with type GR-S Inset tap Note Choose the appropriate quick-change adapter for the required tap! Quick-change adapter adapter Guiding bush Guiding bush Tool Tap 1. Press guiding bush back and hold it 2. Push tap into the guiding bush. Note Bring square into correct position by turning the tool. 3. Let go of guiding bush Operating instruction edition: 01.02.2017 15
2.4.2.2 Insert the quick-change adapter The adapter must not be changed while the machine spindle rotates! Fixing Fixierung Tap Werkzeug 1. Fix tapping attachment Griffbüchse Grip sleeve Schnellwechseleinsatz Quick-change adapter i.e. by adapting in the machine spindle Driver Groove 2. Put in quick-change adapter Watch position of driver and groove! 3. Schnell Push quick-change adapter to rear end grip sleeve automatically locks the quick-change adapter 4. Check, whether grip sleeve is back in front position 16 Operating instruction edition: 01.02.2017
2.5 Detach tap from tapping attachment 2.5.1 Detach tap from type GR The tap must not be changed while the machine spindle rotates! 1. Detach the nut using the open ended spanner In order to avoid the damage of parts in the tapping attachment, please support the clamping nut, when being detached with the wrench, with open ended spanner, see chapter 2.4, point 5. 2. Detach driver cam through thread spindle 3. Remove tap 4. Screw off the nut 5. Remove collet from the nut 6. Eventually clean the parts Operating instruction edition: 01.02.2017 17
2.5.2 2.5.2.1 Detach tap from type GR-S Detach quick-change adapter The quick-change adapter must not be changed while the machine spindle rotates Fixing Fixing Grip sleeve Grip sleeve Gewindewerkzeug Tool Tap 1. Push grip sleeve in direction of shank and hold it quick-change adapter is automatically released adapter Quick-change adapter 2. Remove quick-change adapter 3. Let go of guiding bush 18 Operating instruction edition: 01.02.2017
2.5.2.2 Detach tap Quick-change adapter Schnellwechseleinsatz Guiding bush Führungsbüchse Tap Gewindewerkzeug Werkzeug 1. Press guiding bush back and hold it 2. Remove tap 3. Let go of guiding bush Operating instruction edition: 01.02.2017 19
2.6 Adjustment of overload clutch The integrated overload clutch interrupts the torque transmission between machine spindle and tool during the thread producing cycle if the adjusted torque is exceeded. This protects the tool against breakage, i.e. when cutting on block with blind hole threads. 1. Detach thread pin in the torque adjusting ring. 2. Set torque adjusting ring to the lowest possible torque value = turn left as far as possible. 3. Start thread cutting clutch slips through 4. Increase the torque via the adjusting ring and fix this adjustment by tightening the thread pin. 5. Re-start thread cutting. If there is no perfect torque driving, repeat points 1 to 4. Reduction torque Thread pin Increase torque The torque adjustment may only be carried out while the machine is switched off. Note As the required torque depends on different parameter, i.e. number of revolutions, material to be worked, lubrication, it is not possible to indicate any torque values. 20 Operating instruction edition: 01.02.2017
3 Mainenance 3.1 Maintenance schedule What? When? Who? External cleaning Periodically, depending on the degree of dirt Operator The tapping attachment does not have to be greased. 3.2 External cleaning Clean the tapping attachment at periodic intervals with a duster depending on the degree of dirt. Note Do not use any aggressive solvents. Do not use fibrous materials i.e. steel wool. 4 Storage when not in use If the tapping attachment is taken out of service, please go through the following steps: 1. Clean the tapping attachment with a duster, see chapter 3.2. 2. Spray the tapping attachment with a preservation oil to avoid rusting and to preserve the easy running Before storage, all evidence of coolant and machining residues must be removed! Operating instruction edition: 01.02.2017 21
10 GR / GR-S 5 Course of a thread producing cycle 1. Insert the tapping attachment as described in chapter 2.3 page 12. 2. Start thread cutting, adjust the torque as instructed in chapter 2.6, page 20. 3. Retract the tool spindle after reaching the thread depth the spindle of the tapping attachment turns the rotation direction. 4. After leaving the produced thread, the tapping attachment automatically switches back to right-hand running. Start position Spindle feed stop Free-wheel Reverse Picture 10: Course of a thread producing cycle When retracting the tool spindle please check that the length compensation on tension is not completely activated. Please avoid the jerky retraction of the spindle. 22 Operating instruction edition: 01.02.2017
Notes: Operating instruction edition: 01.02.2017 23
EMUGE tapping attachment GR / GR-S Operating instruction Article number: ZB10016.GB Original in German, Edition: 6, last change: 01.02.2017, change stage: 5 Please keep this for future use! EMUGE-Werk Richard Glimpel GmbH & Co. KG Fabrik für Präzisionswerkzeuge Nürnberger Straße 96-100 91207 Lauf GERMANY +49 9123 186-0 +49 9123 186-230 info@emuge-franken.com www.emuge-franken.com