operating instruction for the quick-change tap holders type tension...operating instruction for the...

Operating instruction for the quick-change tap holders type: KSN 1/HD KSN 3/HD KSN 4/HD

Date of edition: 15.02.2008 Stage of alteration: 1

Please keep this for future use!

Operating instruction for the quick-change tap holders type KSN/HD


Edition: 15.02.2008 1

Contents:

1 Application range, safety instructions and technical data................................ 3

1.1 Application range, determined use......................................................................... 3 1.2 Specification .......................................................................................................... 4 1.3 Safety instructions.................................................................................................. 5 1.4 Dimensions and technical data .............................................................................. 6

2 Putting the quick-change tap holders into operation........................................ 7

2.1 Unpacking.............................................................................................................. 7 2.2 First putting into operation...................................................................................... 7 2.3 Reputting into operation ......................................................................................... 7 2.4 Assembly of the coolant-lubricant pipe for quick-change tap holders with shank

type HSK............................................................................................................... 8 2.5 Use and choice of the quick-change adapters........................................................ 9 2.6 Insert tool ..............................................................................................................11 2.6.1 Quick-change adapters EM, EM/IKZ, EM-U, EM-U/IKZ, EM-L, EM-UL...............11 2.6.2 Quick-change adapters EM-E-Lock....................................................................12 2.7 Insert quick-change adapter..................................................................................13 2.8 Remove quick-change adapter .............................................................................14 2.9 Remove tool..........................................................................................................15

3 Maintenance ........................................................................................................16

3.1 Maintenance schedule ..........................................................................................16 3.2 External cleaning ..................................................................................................16

4 Storage when not in use.....................................................................................16


Edition: 15.02.2008 2

Warning signs, symbols This operating instruction uses the following symbols Marks special instructions, rules and prohibitions which are important in order to

avoid any damage. Please observe these instructions!

Marks application instructions and other useful information.

Sectional view: Quick-change tap holder KSN/HD

Protected

Protected

Protected

Protected


Edition: 15.02.2008 3

1 Application range, safety instructions and technical data

1.1 Application range, determined use

The quick-change tap holders type KSN/HD are mainly used on CNC machining centers, CNC turning machines and conventional machining centers with internal coolant-lubricant supply. The quick-change tap holders are marked by a red ring at the grip sleeve, see Picture 1, page 6. Normally, the quick-change tap holders are equipped with one of the following shanks: � Cylindrical shank acc. to DIN 6327 or ASME B 5.11 � Cylindrical shank acc. to DIN ISO 10889 (correspond to DIN 69880 or VDI 3425) or

DIN1835 B+E or ASME B 94.19 � Hollow taper shank (HSK) acc. to DIN 69893 A or DIN 69893 C � Taper shank acc. to DIN 69871 AD or B � ABS-clutch (System KOMET)

For the cutting range of each type, please refer to Table 1, page 6. The locking of the tool is executed via quick-change adapters type EM. The quick-change adapters must be chosen according to the size and the tool used, for more information please refer to chapter 2.5, page 9. The quick-change tap holders type KSN/HD are equipped with a length compensation on tension and on compression, pressure point mechanism and front release, see chapter 1.2 page 4. The quick-change tap holders type KSN/HD are suitable for internal coolant-lubricant supply up to 50 bar, see chapter 1.2, page 4. The non-determined use exempts the manufacturer from any liability!


Edition: 15.02.2008 4

1.2 Specification

Further features of the quick-change tap holders type KSN/HD are: • Small and compact overhang

• Length compensation in compression direction:

Compensates differences between spindle feed and the pitch of the thread to be produced. When using a quick-change adapter with overload clutch, the length compensation on compression compensates the spindle feed as soon as the overload clutch starts working.

• Length compensation in tension direction: Compensates differences between spindle feed and the pitch of the thread to be produced as well as an overrun of the spindle in the reversing point of the thread producing cycle.

• Front release: The front release protects the quick-change tap holder, the used quick-change adapter and the tool as well as the workpiece against damage caused by excessive axial tension. Such tension may occur if the length compensation path is exceeded due to afterrunning of the spindle at the point of reversal, or when the fast-feed function is activated before the tool has come free from the workpiece. In these situations the quick-change adapter disengages automatically from the quick-change tap holder and avoids expensive damages.

• Pressure point mechanism: The pressure point mechanism guarantees the safe cutting of the tool. Only when the effective occurring axial force exceeds the allowed cutting force, the pressure point mechanism releases the length compensation movement free.

⇒ Repeatable and regular thread depths are reached.

• Internal coolant-lubricant supply: Due to the special construction the coolant is guided from the spindle to the tool. The length compensation remains – independent from the coolant-lubricant pressure – in function. The max. coolant-lubricant pressure is 50 bar. Filtering of the coolant: <0,030mm

• High-quality surface protection against corrosion.

• Suited for right – and left-hand rotation

⇒ applicable on machines with reversion of rotation


Edition: 15.02.2008 5

1.3 Safety instructions

For all works, ie 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 quick-change tap holders. 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 workpiece.

- Keep the tool adaptation clean.

- There are maximum values for cutting speeds and feed. Please observe such data.

- Please observe the maximum tool dimensions.

- Furthermore, the instructions of the tool manufacturers are valid!


Edition: 15.02.2008 6

1.4 Dimensions and technical data

Picture 1: Dimensions of the quick-change tap holders type KSN/HD

Table 1: Technical data of the quick-change tap holders type KSN/HD

Type Cutting range

Quick-change adapter size

∅D

[mm]

∅D1

[mm]

C1

[mm]

T2

[mm]

ZA3

[mm]

max. coolant

pressure [bar]

KSN 1/HD M3 – M14

(No.4 – 9/16) EM01 40 19 5 7,5 2,5 50

KSN 3/HD M4,5 – M24 (No.10 – 1)

EM03 56 31 7 10 3 50

KSN 4/HD M14 – M36 (9/16 – 13/8)

EM04 80 48 15 20 5 50

Further outer dimensions depend on the required shank. These dimensions and data may be taken from the EMUGE main catalogue or refer to our EMUGE representative.

1 Length compensation in compression direction

2 Length compensation in tension direction

3 Front release

ØD

ØD

1

C TZA

red ring

grip sleeve


Edition: 15.02.2008 7

2 Putting the quick-change tap holders into operation

2.1 Unpacking

- Take the quick-change tap holder from the plastic case - Clean the quick-change tap holder with a duster to remove any conservation oil Do not use any aggressive solvents.

Do not use any fibrous materials, ie steel wool.

⇒ The quick-change tap holder is now ready for operation! Exception: Type with hollow taper shank (HSK). Please refer to chapter 2.4, page 8, for how to put this quick-change tap holder into operation.

2.2 First putting into operation

For quick-change tap holders with HSK-shank (hollow taper shank) the coolant-

lubricant pipe must be mounted prior to putting into operation, see chapter 2.4, page 8. When working with internal coolant supply: The tap holders KSN/HD are made for coolant pressure up to max. 50 bar. Filtering of the coolant: <0,030mm.

The quick-change tap holders are inserted into the machine manually or – if provided – by the tool exchanger. The tool exchange 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.

⇒ Risk of accident by spinning of the tool! - Please see also the indications in the operating instruction of your machine

tool!

2.3 Reputting into operation

In case the quick-change tap holder is reput into operation – as described in chapter 4, page 16 – please carry out the following working steps:

1. Clean the quick-change tap holder with a duster to remove any conservation oil

Do not use any aggressive solvents. Do not use any fibrous materials, ie steel wool.

2. Check function of the length compensation: Tear and compress the quick-change tap holder at the grip sleeve, let go off the grip sleeve

→ the quick-change tap holder must return to its initial position

3. Exchange the quick-change tap holder into the machine as described in chapter 2.2


Edition: 15.02.2008 8

2.4 Assembly of the coolant-lubricant pipe for quick-change tap holders with shank type HSK (hollow taper shank DIN 69893A)

a) Components

b) Prepare coolant-lubricant pipe

1. Slide on the two O-rings.

2. Slide on thread nut.

c) Mount coolant-lubricant pipe in the shank Required tool:

Assembly wrench, choose appropriate size for the shank size (For the assembly wrench please refer to the EMUGE main catalogue, category accessories)

1. Plug assembly wrench on

the coolant-lubricant pipe

Watch the position of the pins against the grooves!

2. Screw coolant-lubricant pipe in the shank

Coolant-lubricant pipe

O-ring smallcross-section

O-ring bigcross-section

Thread nut

O-ring small cross-section

O-ring big cross-section

Groove

Pins


Edition: 15.02.2008 9

2.5 Use and choice of the quick-change adapters

The adaptation of the tool is executed via quick-change adapters. The following quick-change adapters are available: Type EM.. Rigid type, without overload clutch.

Application range: Production of through hole threads

Type EM../IKZ Rigid type, without overload clutch, coolant-lubricant supply through channels along the tool shank. Application range: Production of through hole threads with internal coolant-lubricant supply

Type EM..-E-Lock Rigid type, without overload clutch, locking of the tool is secured by form-fitting. The tool must be provided with a groove at one square face. Application range: Clamping of hard metal tools, with high coolant-lubricant pressures and in high-speed machining

Type EM..-U With adjustable overload clutch. Application range: Production of blind hole threads

Type EM..-U/IKZ With adjustable overload clutch, with internal coolant supply through channels along the tool shank. Application range: Production of blind hole threads with internal coolant-lubricant supply

Type EM..-L With length adjustment, without overload clutch. Serves for pre-adjusting the tools in the quick-change adapters out of the machine. Application range: on multi-spindle heads and transfer lines

Type EM..-UL With adjustable overload clutch and length adjustment. Application range: Production of blind hole threads on multi-spindle heads

Type EM..-Z Rigid type with adaptation for collets type ER (GB) Application range: Clamping of hard metal tools, with high coolant-lubricant pressures and in high-speed machining

Type EM-L/ER/IKZ With length adjustment and adaptation for collets type ER (GB) Application range: multi-spindle heads and transfer lines, for clamping hard metal tools, with high coolant-pressures and in high-speed machining

Type EM-PGR Rigid type with adaptation for collets type PGR (GB) Application range: clamping of hard metal tools, with high coolant-pressures and in high-speed machining

Type EM..-SE Rigid type with adaptation for dies acc. to DIN 223 Application range: Production of external threads

Type EM..-ELSE Rigid type for adaptation of Elastic dies Application range: Production of external threads


Edition: 15.02.2008 10

Type EM..-R Reducing adaptation for all EM types Application range: for the extension of the clamping range downwards

Working with internal coolant-lubricant supply:

For the following quick-change adapters it is necessary to use tools with oil channel:

EM, EM E-Lock, EM-U, EM-L, EM-UL, EM-Z, EM-L/ER/IKZ, EM-PGR

For the following quick-change adapters, tools without oil channel are used:

EM-IKZ, EM-U/IKZ The adaptation of the tool is carried out via a quick-change ball clamping system, except for EM-Z, EM-L/ER/IKZ , EM-PGR. The torque arising during the thread producing operation is transferred via the square integrated in the quick-change adapter. The adaptation of the dies is executed via mechanical locking. All quick-change adapters are suited for producing right- and left-hand threads. The quick-change adapter sizes for the appropriate quick-change tap holder may be taken from Table 1, page 6. The clamping diameter is defined by the used tool. Each diameter requires a separate quick-change adapter.


Edition: 15.02.2008 11

2.6 Insert tool

2.6.1 Quick-change adapters EM, EM/IKZ, EM-U, EM-U/IKZ, EM-L, EM-UL

Choose the appropriate quick-change adapter for the tool used!

1. Press guiding bush back

and hold it.

2. Push tool into the guiding bush. Bring the square into the correct position by turning the tool.

3. Let go of the guiding bush.

The instruction is valid for all quick-change adapters types:

EM, EM-IKZ, EM-U, EM-U/IKZ, EM-L, EM-UL.

For quick-change adapters type EM-E-Lock, please observe chapter 2.6.2, page 12.

Quick-change adapter

Guiding bushTool


Edition: 15.02.2008 12

2.6.2 Quick-change adapters EM-E-Lock

Choose the appropriate quick-change adapter for the tool used! The tool must be provided with a groove in one square face!

1. Press guiding bush back and hold it.

2. Push tool into the guiding

bush.

Position of holding pin and groove in the tool must match!


The instruction is valid for all quick-change adapters type:

EM-E-Lock. The tool may only be changed if the quick-change adapter is not fixed in the

quick-change tap holder. If the quick-change adapter with tool is fixed in the quick-change tap holder, the holding pin in the quick-change adapter stops the tool from being taken out.


Guiding bush

Tool

Holding pin

Groove in the tool

Tool


Edition: 15.02.2008 13

2.7 Insert quick-change adapter

The quick-change adapter must not be changed while the machine spindle

rotates!

1. Fix shank ie by adapting the holder in the machine spindle

2. Put in quick-change adapter Watch position of driver and groove!

3. Push grip sleeve in direction of the shank and hold it

4. Push quick-change adapter back

5. Pull the grip sleeve forward, let go Check, whether grip sleeve is in front position.

Fixing of the shank

ShankGrip sleeve


Tool

Groove

Driver


Edition: 15.02.2008 14

2.8 Remove quick-change adapter

The quick-change adapter must not be changed while the machine spindle rotates!

1. Push grip sleeve in direction of shank and hold it.

2. Remove quick-change adapter.


Fixing of the shank

Shank

Grip sleeve


Tool


Edition: 15.02.2008 15

2.9 Remove tool

1. Press guiding bush back and hold it

2. Remove tool

3. Let go of the guiding bush

The instruction is valid for all quick-change adapters types:

EM, EM-IKZ, EM-U, EM-U/IKZ, EM-L, EM-UL, EM-E-Lock. EM-E-Lock:

The tool may only be released if the quick-change adapter is not fixed in the quick-change tap holder.


Guiding bushTool


Edition: 15.02.2008 16

3 Maintenance

3.1 Maintenance schedule

What?

When? Who?

External cleaning Periodically, depending on the degree of dirt. Operator

3.2 External cleaning

Clean the quick-change tap holder at periodic intervals with a duster depending on how dirty the holder is. Do not use any aggressive solvents.

Do not use any fibrous materials, ie steel wool.

4 Storage when not in use

If the quick-change tap holder is taken out of service, please go through the following steps:

1. Clean the holder with a duster.

Do not use any aggressive solvents. Do not use any fibrous materials, ie steel wool.

2. Spray the quick-change tap holder with a preservation oil to avoid rusting and to preserve the easy running of the holder.

Before storage all evidence of coolant-lubricant and machining residues must be

removed!


Edition: 15.02.2008 17

Notes:


EMUGE-Werk Richard Glimpel GmbH & Co. KG · Fabrik für Präzisionswerkzeuge Nürnberger Straße 96-100 · 91207 Lauf · GERMANY · Tel. +49 (0) 9123 / 186-0 · Fax +49 (0) 9123 / 14313 [email protected] · www.emuge-franken.com

ZB

10022.G

B

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