INSTRUCTIONS FOR USE A1 & A2 KNURLING TOOLS

INSTRUCTIONS FOR USE A1 & A2 KNURLING TOOLS

Contents CONTENTS 1. General... 2 1.1 Introduction... 2 1.2 Tool Construction... 3 2. A1-Tools... 5 2.1 Technical Data... 5 2.2 Overview: Main Components... 6 2.3 Tool Adjustment A1/KF... 7 2.4 Optical Measurement A1/KF... 12 2.5 Tool Adjustment A1/FL... 13 2.6 Optical Measurement A1/FL... 17 2.7 Adapter for long-turning lathes... 18 3. A2-Tools... 19 3.1 Technical Data... 19 3.2 Overview: Main Components... 20 3.3 Tool Adjustment A2/KF... 21 3.4 Optical Measurement A2/KF... 26 3.5 Tool Adjustment A2/FL... 27 3.6 Optical Measurement A2/FL... 31 4. Coolant Unit A1/A2...32 4.1 General...32 4.2 Technical Data...32 4.3 Overview: Main Components...33 4.4 Assembly/Starting up...34 4.5 Clean the Coolant Unit...35 4.6 Subsequent Machining of Shank A2...36 5. Wear Parts...37 6. Knurling of Stepped Workpieces...37 7. Knurl Cutters with Bevel...38 8. Troubleshooting...39 9. Dimensions and Pitches Available...40. Reference Values for Feeds and Cutting Speeds...41 1

General Introduction 1. General 1.1 Introduction Please read through the Instructions for Use carefully before using the Quick knurl cutting 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 the 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

1.2 Tool Construction A-series tools are flexible in use and may be employed on all lathes from the conventional to CNC-controlled dual-spindle lathes, optionally as a left-hand or right-hand tool, in front or behind the turning centre. The tools have a cutting action, are free-cutting and it is not possible to make them adopt a specific General Tool Construction 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 Knurl cutters Straight knurl RAA A/FL 30 L /30 R Spiral knurl RBL / RBR A/FL As required Cross knurl RKE A/KF 15 L + 15 R Diamond knurl RGE A/KF 2 x 90 3

General Tool Construction Tool definition Definition of the tool as left- or right-handed is determined by the position of the knurl cutters when the tool is viewed from the front in the clamped position. left right left right Perfect results may be achieved with: Correct adjustment Closely following the instructions regarding the start of the knurling process Appropriate feed and cutting speed Selection of the correct tool size. Quick knurl cutter tools with large dimensioned knurl cutters, e.g. Ø 21.5 mm instead of Ø 14.5, have a longer service life Clamping Clamping of the holder on the shaft 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 knurl cutters. Shafts and bodies may be individually assembled easily and without much effort by the customer himself. NOTE: It is imperative to ensure an abundant supply of coolant or cutting oil directly onto the knurl cutters to ensure perfect cooling and lubrication of the knurl cutters. 4

A1-Tools Technical Data 2. A1-Tools 2.1 Technical Data A1/KF Types of knurl Cross and diamond Working range Ø 3-50 mm Shaft dimension x16, 12x16 or 16x16 mm Knurl cutters Ø 14.5 mm Cross 1 x 15 L and 1 x 15 R Diamond 2 x 90 Pitches see page 40 Weight 0.3 kg 36 36 35 115 80 /12/16 16 A1/FL Types of knurl Straight and spiral Working range Ø 3-50 mm Shaft dimension x16, 12x16 or 16x16 mm Knurl cutters Ø 14.5 mm Straight 1 x 30 L / 30 R Spiral As required Pitches see page 40 Weight 0.3 kg 32 34 26 6 80 /12/16 16 5

A1-Tools Overview: Main Components 2.2 Overview: Main Components Pos. Designation 1 Tool head 2 Countersunk screw 3 Washer 4 Knurl cutter 5 Bushing 6 Index disc (diameter adjustment) 7 Index point 8 Clamping segment 9 Shaft Eccentric bolt 11 Spindle screw 2 2 3 13 3 4 4 5 8 5 A1/KF 7 6 1 A1/FL 1 11 9 12 Hexagonal socket head screws - tool correction (A1/FL) 11 13 Adjustment gauge - A1/KF 14 Adjustment gauge - A1/FL 14 9 12 6

2.3 Tool Adjustment A1/KF Preliminary work: Clamp workpiece and turn Maximum out-of-roundness 0.03 mm Step 1: Cutter selection Cross knurl: 1x 15 left-hand spiral toothed knurl cutter on cutter holder "L" 1x 15 right-hand spiral toothed knurl cutter on cutter holder "R" Diamond knurl: 2x 90 toothed knurl cutters A1-Tools Tool Adjustment A1/KF Step 2: Install knurl cutters Clean the contact surface of bushing 5 and cutter holder 1.1. Coat bushing 5 and the face ends as well as the hole of knurl cutter 4 with a little Molykote G paste With knurl cutter 4 and washer 3 pushed on, insert bushing 5 into the cutter holder Screw in countersunk screw 2 and only tighten enough to allow knurl cutter 4 to rotate free of play 2 3 4 5 1.1 7

A1-Tools Tool Adjustment A1/KF Step 3: Pre-adjust turning centre For centring of the tool, the mark M on the shaft 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. Pos. Application Shaft 0 conventional /12/16 a CNC b CNC 12 c CNC 16 -a CNC -b CNC 12 -c CNC 16 c b a 0 -a -b -c M Adjustment: Unscrew eccentric bolt Adjust tool head 1 accordingly by way of spindle screw 11 Clamp eccentric bolt lightly 1 11 11 8

Step 4: Set diameter Measure off workpiece diameter Unscrew clamping segment 8 by two turns Turn index disc 6 until the required diameter aligns with index point 7 Only clamp clamping segment 8 lightly for subsequent adjustment of cutter 7 6 Step 5: Clamp tool in tool holder A1-Tools Tool Adjustment A1/KF Step 6: Re-align turning centre Carefully bring into contact with the workpiece Both cutters must be in contact simultaneously. Precision adjustment is carried out using spindle screw 11 Tighten eccentric bolt hand-tight when alignment is finished 11 8 11 9

A1-Tools Tool Adjustment A1/KF Step 7: Adjust cutter The ideal position of the knurling cutters is when they lie parallel on the workpiece and still cut very slightly, i.e. the cutting edge of the cutters can be pressed in somewhat deeper (approx. 1-2 ). In the case of materials which are hard to machine, the knurling cutters may be inclined up to max. 3-4. 6 8 Step 8: Start of knurl Sequence: Adjust index disc 6 slightly towards the next smaller diameter until the correct cutter setting is reached Tighten clamping segment 8 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 without interruption. The feed on infeeding should be approx. 0.05 0.1 mm. The knurling depth corresponds to the pitch of the knurling cutter being used, e.g. 1.0 mm pitch requires 1.0 mm infeed with reference to the diameter. The depth is measured from the knurling cutter's point of contact with the workpiece.

A1-Tools Tool Adjustment A1/KF After an idle time of 2-3 seconds, the workpiece is knurled by using the longitudinal feed. 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. max 1,5 mm NOTE: Note that the protective bevel at the beginning of the workpiece may not be applied until knurling is complete. The coarser the pitch, the smaller the feed. Feed and cutting speed have no effect on the knurl pitch. Step 9: Knurling NOTE: If the knurl is not accurate or is onesided, then the knurling process may be repeated after correcting the tool. ATTENTION: Under no circumstances knurl with longitudinal feed into the face edge of the workpiece. Starting the knurl within the workpiece can be done only in certain circumstances. 11

A1-Tools Optical Measurement A1/KF 2.4 Optical Measurement A1/KF The tool may be optically measured on the presetting device using adjustment gauge 13 supplied. 8 Dismantle knurl cutter 4 and bushing 5 Unscrew eccentric bolt and pre-set the turning centre by means of spindle screw 11 13 z=0 x=0 Clamp eccentric bolt lightly 4 5 Push adjustment gauge 13 onto closed clamping segment 8 Precision adjust the turning centre under the pre-setting device, clamp eccentric bolt hand-tight and determine the X and Z values 11 The measured Z value is the start of the knurl not the collision measurement. The measured X value is adopted without a correction value for a workpiece diameter of 5 mm. The radius values shown in the table must be added to the X values depending on the workpiece diameter. With this measurement the knurl cutters are positioned approximately 0.2-0.3 mm above the diameter to be knurled. Precise adjustment of the tool must be carried out on the machine. Ø X+ Ø X+ Ø X+ 5 0 0.9 23 1.8 6 0.3 13 1.2 31 2.1 8 0.6 17 1.5 50 2.5 12

2.5 Tool Adjustment A1/FL Preliminary work: Clamp workpiece and turn Maximum out-of-roundness 0.03 mm Step 1: Cutter selection Straight knurl - right-hand tool: 1x 30 right-hand spiral toothed knurl cutter Straight knurl - left-hand tool: 1x 30 left-hand spiral toothed knurl cutter NOTE: Right-hand tool requires the workpiece to rotate in a clockwise direction. Left-hand tool requires the workpiece to rotate in an anti-clockwise direction. A1-Tools Tool Adjustment A1/FL Step 2: Install knurl cutters Clean the contact surface of bushing 5 and cutter holder 1.1. Coat bushing 5 and the face ends as well as the hole of knurl cutter 4 with a little Molykote G paste With knurl cutter 4 and washer 3 pushed on, insert bushing 5 into the cutter holder Screw in countersunk screw 2 and only tighten enough to allow knurl cutter 4 to rotate free of play 2 3 4 5 1.1 Spiral knurl: Knurl cutters are to be mounted with 15, 30 or 90 spirals depending on the pitch of the spiral desired on the workpiece. It is advisable due to the large number of possible variations to consult your dealer or the manufacturer. 13

A1-Tools Tool Adjustment A1/FL Step 3: Adjust turning centre For centring of the tool, the mark M on the shaft 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. c b a 0 -a -b -c M Pos. Application Shaft 0 conventional /12/16 a CNC b CNC 12 c CNC 16 -a CNC -b CNC 12 -c CNC 16 Adjustment: Unscrew eccentric bolt Adjust tool head 1accordingly by way of spindle screw 11 Clamp eccentric bolt again hand-tight 1 11 11 NOTE: Precision adjustment of the turning centre can only be carried out on the optical pre-setting device. 14

Step 4: Clamp tool in tool holder Step 6: Start of knurl A1-Tools Tool Adjustment A1/FL Step 5: Adjust cutter The ideal position of the knurling cutters is when they lie parallel on the workpiece and still cut very slightly, i.e. the cutting edge of the cutters can be pressed in somewhat deeper (approx. 1-2 ). In the case of materials which are hard to machine, the knurling cutters may be inclined up to max. 3-4. 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 without interruption. The feed on infeeding should be approx. 0.05-0.1 mm. The knurling depth corresponds to the pitch of the knurling cutter being used, e.g. 1.0 mm pitch requires 1.0 mm infeed with reference to the diameter. The depth is measured from the knurling cutter's point of contact with the workpiece. After an idle time of 2-3 seconds, the workpiece is knurled by using the longitudinal feed. 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. max 1,5 mm Sequence: Correction is achieved by turning the tool slightly in the tool holder 15

A1-Tools Tool Adjustment A1/FL ATTENTION: Under no circumstances knurl with longitudinal feed into the face edge of the workpiece. Starting the knurl within the workpiece can be done only in certain circumstances. NOTE: Note that the protective bevel at the beginning of the workpiece may not be applied until knurling is complete. Step 7: Knurling If the track generated does not run paraxially, this may be put right by correcting the two hexagonal socket head screws 12. When adjusting by way of screw 12a, first loosen screw 12b and vice versa Tighten the opposing screw again hand-tight when adjustment is complete The coarser the pitch, the smaller the feed. Feed and cutting speed have no effect on the knurl pitch. 12a 12b NOTE: If the knurl is not accurate or is one-sided, then the knurling process may be repeated after correcting the tool. 16

2.6 Optical Measurement A1/FL The tool may be optically measured on the presetting device using adjustment gauge 14 supplied. Dismantle knurl cutter 4 and bushing 5 Unscrew eccentric bolt and adjust the turning centre by means of the spindle screw 11 Clamp eccentric bolt lightly again A1-Tools Optical Measurement A1/FL Mount adjustment gauge 14 on tool holder 1.1 Precision adjust the turning centre under the pre-setting device, clamp eccentric bolt hand-tight and determine the X and Z values 2 14 1.1 4 5 z=0 x=0 11 The measured Z value is the start of the knurl not the collision measurement. If the measured X value is programmed, the knurl cutter is positioned approximately 0.2-0.3 mm above the diameter to be knurled and precise adjustment of the tool must be carried out on the machine. 17

A1-Tools Adapter for long-turning lathes 2.7 Adapter for long-turning lathes A1 adapter for long turning lathes 15 may be mounted on appropriate A1 shaft 9 simply by means of the two screws 16. Retention in the machine is by means of the adapter. As a result the tool is aligned completely flush with the knurl cutters. Dimensions adapter for long-turning lathes A1/KF 14 9 15 A1/FL 80 /12/16 16 11,6 80 /12/16 18

A2-Tools Technical Data 3. A2-Tools 3.1 Technical Data A2/KF Types of knurl Cross and diamond Working range Ø 5-250 mm Shaft dimension 20x25 or 25x25 mm Knurl cutters Ø 21.5 mm Cross 1 x 15 L and 1 x 15 R Diamond 2 x 90 Pitches see page 40 Weight 1.2 kg 50 63 48 159 111 20/25 25 A2/FL Types of knurl Straight and spiral Working range Ø 5-250 mm Shaft dimension 20x25 or 25x25 mm Knurl cutters Ø 21.5 mm Straight 1 x 30 L / 30 R Spiral As required Pitches see page 40 Weight 1.0 kg 50 56 38 149 111 20/25 25 19

A2-Tools Overview: Main Components 3.2 Overview: Main Components Pos. Designation 1 Tool head 2 Countersunk screw 3 Washer 4 Knurl cutters 5 Bushing 6 Index disc (diameter adjustment) 7 Index point 8 Clamping segment 9 Shaft Eccentric bolt 11 Spindle screw 12 Hexagonal socket head screws - tool correction (A2/FL) 13 Adjustment gauge - A2/KF 14 Adjustment gauge - A2/FL 2 3 4 5 13 8 2 3 4 5 12 A2/KF 7 6 1 A2/FL 1 11 9 11 9 14 20

3.3 Tool Adjustment A2/KF Preliminary work: Clamp workpiece and turn Maximum out-of-roundness 0.03 mm Step 1: Cutter selection Cross knurl: 1x 15 left-hand spiral toothed knurl cutter on cutter holder "L" 1x 15 right-hand spiral toothed knurl cutter on cutter holder "R" A2-Tools Tool Adjustment A2/KF Step 2: Install knurl cutters Clean the contact surface of bushing 5 and cutter holder 1.1. Coat bushing 5 and the face ends as well as the hole of knurl cutter 4 with a little Molykote G paste With knurl cutter 4 and washer 3 pushed on, insert bushing 5 into the cutter holder Screw in countersunk screw 2 and only tighten enough to allow knurl cutter 4 to rotate free of play Diamond knurl: 2x 90 toothed knurl cutters 2 3 4 5 1.1 21

A2-Tools Tool Adjustment A2/KF Step 3: Pre-adjust turning centre For centring of the tool, the mark M on the shaft 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. b a 0 -a -b M Pos. Application Shaft 0 conventional 20/25 a CNC 20 b CNC 25 -a CNC 20 -b CNC 25 Adjustment: Unscrew eccentric bolt Adjust tool head 1 accordingly by way of spindle screw 11 Clamp eccentric bolt lightly 1 11 11 22

A2-Tools Tool Adjustment A2/KF Step 4: Set diameter Measure off workpiece diameter Unscrew clamping segment 8 by two turns Turn index disc 6 until the required diameter aligns with index point 7 Only clamp clamping segment 8 lightly for subsequent adjustment of cutter 7 6 Step 5: Clamp tool in tool holder Step 6: Re-align turning centre Carefully bring into contact with the workpiece Both cutters must be in contact simultaneously. Precision adjustment is carried out using spindle screw 11 Tighten eccentric bolts hand-tight when alignment is finished 8 11 11 23

A2-Tools Tool Adjustment A2/KF Step 7: Adjust cutter The ideal position of the knurling cutters is when they lie parallel on the workpiece and still cut very slightly, i.e. the cutting edge of the cutters can be pressed in somewhat deeper (approx. 1-2 ). In the case of materials which are hard to machine, the knurling cutters may be inclined up to max. 3-4. 6 8 Step 8: Start of knurl Sequence: Adjust index disc 6 slightly towards the next smaller diameter until the correct cutter setting is reached Tighten clamping segment 8 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 without interruption. The feed on infeeding should be approx. 0.05-0.1 mm. The knurling depth corresponds to the pitch of the knurling cutter being used, e.g. 1.0 mm pitch requires 1.0 mm infeed with reference to the diameter. The depth is measured from the knurling cutter's point of contact with the workpiece. 24

A2-Tools Tool Adjustment A2/KF After an idle time of 2-3 seconds, the workpiece is knurled by using the longitudinal feed. 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. max 1,5 mm NOTE: Note that the protective bevel at the beginning of the workpiece may not be applied until knurling is complete. The coarser the pitch, the smaller the feed. Feed and cutting speed have no effect on the knurl pitch. ATTENTION: Under no circumstances knurl with longitudinal feed into the face edge of the workpiece. Starting the knurl within the workpiece can be done only in certain circumstances. Step 9: Knurling NOTE: If the knurl is not accurate or is onesided, then the knurling process may be repeated after correcting the tool. 25

A2-Tools Optical Measurement A2/KF 3.4 Optical Measurement A2/KF The tool may be optically measured on the presetting device using adjustment gauge 13 supplied. Dismantle knurl cutter 4 and bushing 5 Unscrew eccentric bolt and pre-set the turning centre by means of spindle screw 11 13 8 z=0 x=0 Clamp eccentric bolt lightly 11 4 5 Push adjustment gauge 13 onto closed clamping segment 8 Precision adjust the turning centre under the pre-setting device, clamp eccentric bolt hand-tight and determine the X and Z values 11 The measured Z value is the start of the knurl not the collision measurement. The measured X value is adopted without a correction value for a workpiece diameter of 8 mm The radius values shown in the table must be added to the X values depending on the workpiece diameter. With this measurement the knurl cutters are positioned approximately 0.2 0.3 mm above the diameter to be knurled. Precise adjustment of the tool must be carried out on the machine. Ø X+ Ø X+ Ø X+ 8 0 27 1.9 80 3.2 11 0.3 35 2.2 120 3.5 14 0.6 45 2.5 150 3.6 16 0.9 55 2.8 200 3.7 19 1.2 65 3.0 250 3.8 26

3.5 Tool Adjustment A2/FL Preliminary work: Clamp workpiece and turn Maximum out-of-roundness 0.03 mm Step 1: Cutter selection Straight knurl - right-hand tool: 1x 30 right-hand spiral toothed knurl cutter Straight knurl - left-hand tool: 1x 30 left-hand spiral toothed knurl cutter NOTE: Right-hand tool requires the workpiece to rotate in a clockwise direction. Left-hand tool requires the workpiece to rotate in an anti-clockwise direction. A2-Tools Tool Adjustment A2/FL Step 2: Install knurl cutters Clean the contact surface of bushing 5 and cutter holder 1.1. Coat bushing 5 and the face ends as well as the hole of knurl cutter 4 with a little Molykote G paste With knurl cutter 4 and washer 3 pushed on, insert bushing 5 into the cutter holder Screw in countersunk screw 2 and only tighten enough to allow knurl cutter 4 to rotate free of play 2 3 4 5 1.1 Spiral knurl: Knurl cutters are to be mounted with 15, 30 or 90 spirals depending on the pitch of the spiral desired on the workpiece. It is advisable due to the large number of possible variations to consult your dealer or the manufacturer. 27

A2-Tools Tool Adjustment A2/FL Step 3: Adjust turning centre For centring of the tool, the mark M on the shaft 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. Pos. Application Shaft 0 conventional 20/25 a CNC 20 b CNC 25 -a CNC 20 -b CNC 25 Adjustment: Unscrew eccentric bolt Adjust tool head 1 accordingly by way of spindle screw 11 Clamp eccentric bolt again hand-tight b a 0 -a -b M 1 11 11 NOTE: Precision adjustment of the turning centre can only be carried out on the optical pre-setting device. 28

Step 4: Clamp tool in tool holder Step 6: Start of knurl A2-Tools Tool Adjustment A2/FL Step 5: Adjust cutter The ideal position of the knurling cutters is when they lie parallel on the workpiece and still cut very slightly, i.e. the cutting edge of the cutters can be pressed in somewhat deeper (approx. 1-2 ). In the case of materials which are hard to machine, the knurling cutters may be inclined up to max. 3-4. 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 without interruption. The feed on infeeding should be approx. 0.05-0.1 mm. The knurling depth corresponds to the pitch of the knurling cutter being used, e.g. 1.0 mm pitch requires 1.0 mm infeed with reference to the diameter. The depth is measured from the knurling cutter's point of contact with the workpiece. After an idle time of 2-3 seconds, the workpiece is knurled by using the longitudinal feed. 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. max 1,5 mm Sequence: Correction is achieved by turning the tool slightly in the tool holder 29

A2-Tools Tool Adjustment A2/FL ATTENTION: Under no circumstances knurl with longitudinal feed into the face edge of the workpiece. Starting the knurl within the workpiece can be done only in certain circumstances. NOTE: Note that the protective bevel at the beginning of the workpiece may not be applied until knurling is complete. Step 7: Knurling If the track generated does not run paraxially, this may be put right by correcting the two hexagonal socket head screws 12. When adjusting by way of screw 12a, first loosen screw 12b and vice versa Tighten the opposing screw again hand-tight when adjustment is complete The coarser the pitch, the smaller the feed. Feed and cutting speed have no effect on the knurl pitch. 12a 12b NOTE: If the knurl is not accurate or is onesided, then the knurling process may be repeated after correcting the tool. 30

3.6 Optical Measurement A2/FL The tool may be optically measured on the presetting device using adjustment gauge 14 supplied. Dismantle knurl cutter 4 and bushing 5 Unscrew eccentric bolt and adjust the turning centre by means of the spindle screw 11 Clamp eccentric bolt lightly again A2-Tools Optical Measurement A2/FL Mount adjustment gauge 14 on tool holder 1.1 Precision adjust the turning centre under the pre-setting device, clamp eccentric bolt hand-tight and determine the X and Z values 2 14 1.1 4 5 11 z=0 x=0 The measured Z value is the start of the knurl not the collision measurement. If the measured X value is programmed, the knurl cutter is positioned approximately 0.2-0.3 mm above the diameter to be knurled and precise adjustment of the tool must be carried out on the machine. 31

Coolant Unit A1/A2 General 4. Coolant Unit A1/A2 4.1 General This innovative cooling system enables targeted cooling and lubrication of the cutters or workpieces and thus increases the service life of the tools. Easy assembly and cleaning are further distinguishing features of the system. There are two versions available for A series knurling tools: Coolant unit with three adjustable ball nozzles for A/KF tools Coolant unit with a flat nozzle for A/FL tools 4.2 Technical Data Coolant pressure: max. 8 bar A1 32 11 17 A2 32 A1/A2 7 28 49 22 KF FL 32

4.3 Overview: Main Components Coolant Unit A1/A2 Overview: Main Components Pos. Description 1 Housing 2 Jet nozzle KF - 3 adjustable nozzles 3 Jet nozzle FL - flat nozzle 4 Gasket 5 Push-in connection 6 Blanking plug 7 Coolant hose 8 Cyl. head screw KF 2 4 6 5 1 8 5 7 FL 6 5 1 8 5 7 4 3 33

Coolant Unit A1/A2 Assembly/Starting up 4.4 Assembly/Starting up NOTE: The illustration for the following work steps show the tool A1/KF with coolant unit KF. The same manner of proceeding also applies for the other tools of the A series. Step 1: Assembly Position coolant unit 1 with alignment pin on shank. Screw in cyl. head screw 8 and tighten handtight. Step 2: Connect coolant supply Clamp tool in tool holder Press top push-in connector 5 in slightly and feed in hose 7 until limit stop is reached. Route hose 7 with corresponding bending radius to connection on tool holder, cut to length as necessary and connect. Press push-in connector 5 in slightly at second coolant connection of coolant unit and insert blanking plug 6 until limit stop is reached. 7 1 8 5 5 6 34

Step 3: 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 ball nozzles on coolant unit KF To ensure the best possible cooling for A/KF tools, direct the two outer nozzles onto the knurl cutters and the middle nozzle onto the workpiece Coolant Unit A1/A2 Clean the Coolant Unit 4.5 Clean the Coolant Unit Loosen coolant hose on tool holder Unscrew and remove cyl. head screw and detach coolant unit Press push-in connectors 5 slightly and detach coolant hose 7 as well as blanking plug 6 1 7 5 8 5 6 35

Coolant Unit A1/A2 Subsequent Machining of Shank A2 Unlatch mounting of nozzle insert 2 via the lateral slotted openings and pull out of housing 1 with gasket 4 2 4 2 1 4.6 Subsequent Machining of Shank A2 No receiving holes were provided in models A2/KF and A2/FL prior to introduction of the coolant unit. The shanks have to be machined subsequently to retrofit the coolant unit. 1x threaded hole M4 1x slot with fit for alignment pin 33 +0,1 0 12,5 +0,05-0,05 6 4,5 Clean all parts in soap solution and rinse with clear water to remove microchips. Re-insert nozzle insert 2 with gasket 4 into housing 1 and fix with snap closure Assemble remaining parts and re-attach coolant unit to shank M4 1 + 0,1-0,1 4 H11 36

Wear Parts 5. Wear Parts The fixing elements for the knurl cutters of the QUICK A-series tools are wear parts and must be replaced frequently. 1 2 3 6. Knurling of Stepped Workpieces It must be noted that with all QUICK knurl cutting tools it is not possible to knurl right up to a shoulder due to the inclined position of the knurl cutters. Please refer to the table for dimensions. a b Pos. Designation 1 Countersunk screw 2 Washer 3 Bushing Distance b corresponds to the Ø of the knurl cutters Ø 14.5 Ø 21.5 Ø 14.5 Ø 21.5 a b b a b b 1 1.3 2 5 2.8 4.5 2 1.8 2.6 6 3.1 4.7 3 2.2 3 7 5 4 2.6 3.8 8 5.3 37

Knurl Cutters with Bevel 7. Knurl Cutters with Bevel A knurl cutter's teeth may break off when knurling "hard" materials. It is possible to increase the knurl cutter's service life by cutting a 45 bevel. This is only applicable for the KF models. Arrangement for cutters with bevel Only one knurl cutter 4 with bevel may be used depending on the direction in which the workpiece rotates. 0,5xt 4 45 t 4 38

Troubleshooting 8. Troubleshooting A/KF Tools Knurl trailing spirally Look at start of knurl Look at knurling depth Tool tilted sideways -> check position Clearance of tool too positive or too negative Overlapping of the knurl (double knurl) Incorrect adjustment of diameter Approach to knurl depth too slow as a result of which too little guidance of knurl cutters in track Look at start of knurl Teeth of knurl cutters knocked off Bevel knurl cutters with hard materials Knurl cutter has been overloaded too much feed, cutting depth too great Incorrect adjustment of diameter Fixing screws of knurl cutters loose Look at adjustment of cutters Unevenly deep knurl track Re-align position of head using spindle Seizing of knurl cutters on bushing (see A/FL) A/FL Tools Knurl trailing spirally Correct position of head using precision adjustment screws Look at start of knurl Look at knurling depth Tool tilted sideways -> check position Clearance of tool too positive or too negative Overlapping of the knurl (double knurl) Approach to knurl depth too slow as a result of which too little guidance of knurl cutters in track Look at start of knurl Teeth of knurl cutters knocked off Knurl cutter has been overloaded feed too great, cutting depth too great Fixing screws of knurl cutters loose Look at direction of rotation Look at adjustment of cutters Seizing of knurl cutters on bushing Reduce cutting speed Use Molykote paste Coolant jet directly onto the knurl cutter 39

Dimensions and Pitches Available 9. Dimensions and Pitches Available Technical Description Material: Powder metallurgy tool steel Heat treatment: Hardened to HRC 62-64 Models: Ground or ground + coated with Q-Dur Dimensions and pitches 90 15 30 90 t Order numbers and designation Ident. no. Ø A Ø B C 271 14.5 5 3 272 21.5 8 5 Ø Tooth pitch angle Pitches (t) 14.5 90 toothed 0.4/0.5/0.6/0.8/1.0/1.2 15 L/15 R toothed 0.4/0.5/0.6/0.8/1.0/1.2 30 L/30 R toothed 0.4/0.5/0.6/0.8/1.0/1.2 21.5 90 toothed 15 L/15 R toothed 30 L/30 R toothed 0.4/0.5/0.6/0.8/1.0/ 1.2/1.5/1.6/2.0 0.4/0.5/0.6/0.8/1.0/ 1.2/1.5/1.6/2.0 0.4/0.5/0.6/0.8/1.0/ 1.2/1.5/1.6/2.0 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 40

Reference Values for Feeds and Cutting Speeds. Reference Values for Feeds and Cutting Speeds Workpiece Ø 3-12 Material Cutter Ø V s m/min mm/rev Workpiece Ø 12-40 V s m/min mm/rev Steel up to 600 N/mm² 14.5 45 0.07-0.09 40 0.07-0.09 V m/min Workpiece Ø 40-250 s mm/rev 21.5 60 0.07-0.14 60 0.07-0.15 55 0.07-0.15 Steel up to 900 N/mm² 14.5 35 0.06-0.08 30 0.06-0.08 21.5 50 0.06-0.12 45 0.06-0.12 40 0.06-0.12 Stainless steels 14.5 30 0.06-0.08 28 0.06-0.08 21.5 40 0.06-0.12 35 0.06-0.12 32 0.06-0.12 Ms58 14.5 70 0.08-0.12 60 0.08-0.12 21.5 0 0.08-0.20 0 0.08-0.20 90 0.08-0.20 Ms60 14.5 60 0.06-0. 60 0.06-0. 21.5 90 0.07-0.15 90 0.07-0.15 80 0.07-0.15 41

Reference Values for Feeds and Cutting Speeds Workpiece Ø 3-12 Material Cutter Ø V s m/min mm/rev Workpiece Ø 12-40 V s m/min mm/rev Bronze 14.5 45 0.07-0.09 40 0.07-0.09 V m/min Workpiece Ø 40-250 s mm/rev 21.5 60 0.07-0.14 60 0.07-0.14 55 0.07-0.14 Aluminium 14.5 80 0.08-0.18 70 0.08-0.18 21.5 120 0.-0.25 1 0.-0.25 0 0.-0.25 Grey cast iron 14.5 30 0.06-0.08 28 0.06-0.08 21.5 40 0.06-0.12 35 0.06-0.12 32 0.06-0.12 Cast steel 14.5 35 0.06-0.08 30 0.06-0.12 21.5 50 0.06-0.12 45 0.06-0.12 40 0.06-0.12 NOTE: Generally speaking the values applicable to aluminium are also valid for plastics. Test runs are imperative. 42

QUICK Tooling GmbH Brunnenstraße 36 78554 Aldingen Germany Tel.: +49 7424 98198-0 Fax: +49 7424 98198-230 mailing@quick-tooling.com www.quick-tooling.com 04/2014 1. 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.