instructions - future technologiesa1-tools technical data 5 2. a1-tools . 2.1. technical data ....
TRANSCRIPT
INSTRUCTIONS FOR USE
A1 & A2KNURLING 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 10. 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
General Tool Construction
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
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
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.
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
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
5
2. A1-Tools 2.1 Technical Data
A1/KF Types of knurl Cross and diamond Working range Ø 3-50 mm Shaft dimension 10x16, 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
A1/FL Types of knurl Straight and spiral Working range Ø 3-50 mm Shaft dimension 10x16, 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
10/1
2/1
6
35
36
115
16
80
36
10/1
2/16
26
32
16
106
80
34
A1-Tools Overview: Main Components
6
8
2
2
3
3
4
4
5
5
12
67 1
13
14
1
11
11
10
10
9
9
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 10 Eccentric bolt 11 Spindle screw 12 Hexagonal socket head screws - tool correction
(A1/FL) 13 Adjustment gauge - A1/KF 14 Adjustment gauge - A1/FL
A1/KF
A1/FL
A1-Tools Tool Adjustment A1/KF
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
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.
a
-c
0
b
-b
c
-a
M
Pos. Application Shaft
0 conventional 10/12/16 a CNC 10 b CNC 12 c CNC 16 -a CNC 10 -b CNC 12 -c CNC 16
Adjustment:
Unscrew eccentric bolt 10
Adjust tool head 1 accordingly by way of spindle screw 11
Clamp eccentric bolt lightly
1
10
11
10
11
8
A1-Tools Tool Adjustment A1/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
8
6
7
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 bolt 10 hand-tight when alignment is finished
11
1010
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°.
Sequence:
Adjust index disc 6 slightly towards the next smaller diameter until the correct cutter setting is reached
Tighten clamping segment 8
8
6
Step 8: Start of knurl
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.
10
A1-Tools Tool Adjustment A1/KF
11
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.
NOTE: If the knurl is not accurate or is one-sided, then the knurling process may be repeated after correcting the tool.
Step 9: Knurling
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.
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
A1-Tools Optical Measurement A1/KF
2.4 Optical Measurement A1/KF
The tool may be optically measured on the pre-setting device using adjustment gauge 13 supplied. Dismantle knurl cutter 4 and bushing 5
Unscrew eccentric bolt 10 and pre-set the turning centre by means of spindle screw 11
Clamp eccentric bolt 10 lightly
4 5
11
10
Push adjustment gauge 13 onto closed
clamping segment 8 Precision adjust the turning centre under the
pre-setting device, clamp eccentric bolt 10 hand-tight and determine the X and Z values
x=0z=013
8
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 10 0.9 23 1.8 6 0.3 13 1.2 31 2.1 8 0.6 17 1.5 50 2.5
12
A1-Tools Tool Adjustment A1/FL
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.
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.
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
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.
a
-c
0
b
-b
c
-a
M
Pos. Application Shaft
0 conventional 10/12/16 a CNC 10 b CNC 12 c CNC 16 -a CNC 10 -b CNC 12 -c CNC 16
Adjustment: Unscrew eccentric bolt 10 Adjust tool head 1accordingly by way of spindle
screw 11 Clamp eccentric bolt again hand-tight
10 11
1
11
10
NOTE: Precision adjustment of the turning centre can only be carried out on the optical pre-setting device.
14
A1-Tools Tool Adjustment A1/FL
Step 4: Clamp tool in tool holder
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°.
Sequence:
Correction is achieved by turning the tool slightly in the tool holder
Step 6: Start of knurl
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
15
A1-Tools Tool Adjustment A1/FL
16
NOTE: If the knurl is not accurate or is one-sided, then the knurling process may be repeated after correcting the tool.
If the track generated does not run paraxially, this may be put right by correcting the two hexagonal socket head screws 12.
12b
12a
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
Step 7: Knurling
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.
The coarser the pitch, the smaller the feed. Feed and cutting speed have no effect on the knurl pitch.
A1-Tools Optical Measurement A1/FL
2.6 Optical Measurement A1/FL
The tool may be optically measured on the pre-setting device using adjustment gauge 14 supplied. Dismantle knurl cutter 4 and bushing 5
Unscrew eccentric bolt 10 and adjust the turning centre by means of the spindle screw 11
Clamp eccentric bolt 10 lightly again
4 5
11
10
Mount adjustment gauge 14 on tool holder 1.1 Precision adjust the turning centre under the
pre-setting device, clamp eccentric bolt 10 hand-tight and determine the X and Z values
z=0x=0
14 1.12
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.
9
16
15
Dimensions – adapter for long-turning lathes A1/KF
80
14
10/12/16
A1/FL
80
11,6
10/12/16
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
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 20/2
5
48
25
111
159
63
20/2
5
38
50
25
149
111
56 19
A2-Tools Overview: Main Components
20
8
52 3 4
13
2 3 4 5
14
1
10
10
11
9
67 1
11
10
10
9
12
A2/KF
A2/FL
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 10 Eccentric bolt 11 Spindle screw 12 Hexagonal socket head screws - tool correction
(A2/FL) 13 Adjustment gauge - A2/KF 14 Adjustment gauge - A2/FL
A2-Tools Tool Adjustment A2/KF
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" Diamond knurl:
2x 90° toothed knurl cutters
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
1.13 42 5
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 10
Adjust tool head 1 accordingly by way of spindle screw 11
Clamp eccentric bolt lightly
10
11
1
11
10
10
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
67
8
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 10 hand-tight when alignment is finished
10
1111
10
10
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°.
Sequence:
Adjust index disc 6 slightly towards the next smaller diameter until the correct cutter setting is reached
Tighten clamping segment 8
8
6
Step 8: Start of knurl
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
25
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.
NOTE: If the knurl is not accurate or is one-sided, then the knurling process may be repeated after correcting the tool.
Step 9: Knurling
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.
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
A2-Tools Optical Measurement A2/KF
3.4 Optical Measurement A2/KF
The tool may be optically measured on the pre-setting device using adjustment gauge 13 supplied. Dismantle knurl cutter 4 and bushing 5
Unscrew eccentric bolt 10 and pre-set the turning centre by means of spindle screw 11
Clamp eccentric bolt 10 lightly
11
10
4 5
11
10
10
Push adjustment gauge 13 onto closed
clamping segment 8 Precision adjust the turning centre under the
pre-setting device, clamp eccentric bolt 10 hand-tight and determine the X and Z values
x=0z=0
13
8
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
A2-Tools Tool Adjustment A2/FL
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.
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.
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
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.
M
-b-b
-a-a
0
aa
bb
Pos. Application Shaft
0 conventional 20/25 a CNC 20 b CNC 25 -a CNC 20 -b CNC 25
Adjustment: Unscrew eccentric bolt 10 Adjust tool head 1 accordingly by way of spindle
screw 11 Clamp eccentric bolt again hand-tight
11
10
10
10
11
1
NOTE: Precision adjustment of the turning centre can only be carried out on the optical pre-setting device.
28
A2-Tools Tool Adjustment A2/FL
Step 4: Clamp tool in tool holder
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°.
Sequence:
Correction is achieved by turning the tool slightly in the tool holder
Step 6: Start of knurl
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
29
A2-Tools Tool Adjustment A2/FL
30
If the track generated does not run paraxially, this may be put right by correcting the two hexagonal socket head screws 12.
12b12a
When adjusting by way of screw 12a, first loosen screw 12b and vice versa
NOTE: If the knurl is not accurate or is one-sided, then the knurling process may be repeated after correcting the tool.
Tighten the opposing screw again hand-tight when adjustment is complete
Step 7: Knurling
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.
The coarser the pitch, the smaller the feed. Feed and cutting speed have no effect on the knurl pitch.
A2-Tools Optical Measurement A2/FL
3.6 Optical Measurement A2/FL
The tool may be optically measured on the pre-setting device using adjustment gauge 14 supplied. Dismantle knurl cutter 4 and bushing 5
Unscrew eccentric bolt 10 and adjust the turning centre by means of the spindle screw 11
Clamp eccentric bolt lightly 10 again
4 5
11
10
10
Mount adjustment gauge 14 on tool holder 1.1 Precision adjust the turning centre under the
pre-setting device, clamp eccentric bolt 10 hand-tight and determine the X and Z values
z=0x=0
2 14 1.1
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
7
KF FL
4.2 Technical Data
Coolant pressure: max. 8 bar
32
11
17
22
28
49
32
A1 A2
A1/A2
32
Coolant Unit A1/A2 Overview: Main Components
4.3 Overview: Main Components
1
1
8
8
2
3
4
4
5
5
5
5
6
6
7
7
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
FL
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 10.
Screw in cyl. head screw 8 and tighten hand-tight.
10
1
8
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.
5
5
6
7
34
Coolant Unit A1/A2 Clean the Coolant Unit
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
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
771
8
5
5
6
35
Coolant Unit A1/A2 Su
36
bsequent 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.
Unlatch mounting of nozzle insert 2 via the
lateral slotted openings and pull out of housing 1 with gasket 4
1
2
2 4
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
4.6 Subsequent Machining of Shank A2
1x threaded hole M4 1x slot with fit for alignment pin
1+ 0,1- 0,1
4 H
11
M4
6
4,5
33+0,1
0
12,5+0,05-0,05
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
P s. o Designation 1 Countersunk screw 2 Washer 3 Bushing
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.
b
a
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
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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.
0,5 x t
t45°
Arrangement for cutters with bevel
Only one knurl cutter 4 with bevel may be used depending on the direction in which the workpiece rotates.
4
4
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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°
t90°
30°15°
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 0.4/0.5/0.6/0.8/1.0/ 1.2/1.5/1.6/2.0
15°L/15°R toothed 0.4/0.5/0.6/0.8/1.0/ 1.2/1.5/1.6/2.0
30°L/30°R toothed 0.4/0.5/0.6/0.8/1.0/ 1.2/1.5/1.6/2.0
Order numbers and designation
Ident. no. Ø A Ø B C
271 14.5 5 3
272 21.5 8 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
40
Reference Values for Feeds and Cutting Speeds
10. Reference Values for Feeds and Cutting Speeds
Workpiece Ø 3-12
Workpiece Ø 12-40
Workpiece Ø 40-250
Material Cutter Ø V m/min
s mm/rev
V m/min
s mm/rev
V m/min
s mm/rev
Steel up to 600 N/mm² 14.5 45 0.07-0.09 40 0.07-0.09 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 21.5 100 0.08-0.20 100 0.08-0.20 90 0.08-0.20
Ms60 14.5 60 0.06-0.10 60 0.06-0.10 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
42
Workpiece Ø 3-12
Workpiece Ø 12-40
Workpiece Ø 40-250
Material Cutter Ø V m/min
s mm/rev
V m/min
s mm/rev
V m/min
s mm/rev
Bronze 14.5 45 0.07-0.09 40 0.07-0.09 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 0.10-0.25 110 0.10-0.25 100 0.10-0.25
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.
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.
QUICK Tooling GmbHBrunnenstraße 36
78554 Aldingen | Germany
Tel.: +49 7424 98198-0
Fax: +49 7424 98198-230
www.quick-tooling.com