Thread Rolling Head Stationary RS27-56 EN

Transcription

Operating Instructions
Thread Rolling Head
Type:
RS 27/56
Contents
01.0 Preface
02.0 Safety Instructions
2
03.0 Product Specification
5
04.0 Roll Holders
6
05.0 Thread Rolls
7
06.0 Assembly
9
2
4
5.1 Inscriptions
5.2 Bearing
5.3 Quality
6.1 Assembly of the thread rolls
6.2 Assembly of the roll holders
6.3 Adjustment of the thread diameter
6.4 Adjustment of the thread length
6.5 Mounting on the machine
7
8
8
9
10
11
12
12
07.0 Initial Operation
14
7.1 Rollable materials
7.2 Pre-machining of the workpiece
14
14
08.0 Operation
16
8.1 Thread rolling against a collar
8.2 Thread run-out
8.3 Feed for thread rolling
8.4 Rolling speed
8.5 Power output requirement
8.6 Cooling - lubrication
8.7 Tool life
16
16
16
17
17
18
18
9.1 Service intervals
9.2 Disassembly of the rolling head
9.3 Reassembly of the rolling head
19
19
20
Roll Holder Table
32
09.0 Care and Maintenance
19
10.0 Troubleshooting
22
11.0 Technical Specification
27
12.0 Component Parts
29
13.0 Annex
32
Thread Rolling Head RS 27/56
1
A. Preface
Dear customer,
congratulations on the purchase of this WAGNER® product! You
bought a high-quality commodity, which facilitates effective and
economic operation. Our Thread Rolling Heads are known for
their high quality and long-life cycle. We hope that you are fully
satisfied with our products.
This manual is made to help you taking the first steps with your new
WAGNER® product, explain the operation and point out possible
hazards.
After-Sales Service:
If you need further advice, training or ulterior help or if you are not
satisfied with your WAGNER® product, please contact us!
Our sales team is at your disposal.
CAUTION: Please implicitly read the operating instructions before initial operation
and follow the safety instructions!
The contents of this manual should be read, understood and
followed in every aspect by everybody involved. This is especially
true for the safety instructions and notes on hazards found
throughout this manual (see chapter B. »Safety instructions«).
Following these instructions will help avoid accidents, mistakes
and malfunctioning.
This documentation includes all information necessary for using
and maintaining your WAGNER® Thread Rolling Head. The documents are up-to-date at the time the product was manufac-tured.
Use only these documents when working with the Thread Rolling
Head.
WAGNER® WERKZEUGSYSTEME MÜLLER GmbH reserves the
right to make technical changes to improve the product, if and
when appropriate.
If the instructions in this manual are not followed, and this negligence results in mistakes, damages, loss of production, etc.,
WAGNER® WERKZEUGSYSTEME MÜLLER GmbH will not be responsible for any subsequent damages.
Due to copyrights, we must point out that this manual is for internal
use only. Providing this manual to third parties is prohibited.
»Regulations for the prevention of
industrial accidents«
02
During operation, maintenance and repair the respective national
and international »regulations for the prevention of industrial accidents« apply in addition to the previously listed instructions. The
operating instructions, particularly the chapter »Safety instructions«, has to be read in any case. Following the safety instructions
and legal regulations helps to prevent doing damage to persons,
machines and our product.
Warranty
Limited liability:
CAUTION: Do not use this product for any
other purpose than its designated use!
Follow the safety instructions and notes on
hazard!
Using the product only by trained specialists, otherwise its use may constitute a risk
to life and limb of the user and cause damage to material property. For such cases,
the manufacturer declines all responsibility.
In case of buying and using original WAGNER® spare parts and
accessories, we guarantee proper operation of the Thread Rolling
Head.
We exclude any warranty for damage of persons, machines and
our products, in case of:
 improper mounting and operating
 using no original spare parts
 removing components and assemblies
 arbitrarily modifying our products
 using broken rolling heads.
When using accessories which are not made by WAGNER® or
explicitly approved by us, we exclude any warranty.
Generally, we are not liable for damages of all kind caused by
removing safety equipment on the machine. We imply that our
products are only set up on technically proper operating machines.
Specified operation
CAUTION: Do not use this product for any other purpose than
its designated use! Follow the »safety instructions and notes on
hazards«!
This product should only be used by trained specialists, otherwise
its use may constitute a risk to life and limb of the user and cause
damage to material property. For such cases, the manufacturer
declines all responsibility.
Do not use force when mounting, demounting and operating. You
could otherwise damage the rolling head or the machine.
Initial Operation
Please carry out an operational check before initial operation of
the Thread Rolling Head.
3
B. Safety instructions
Following the safety instructions and the
notes on hazard makes sure that the
Thread Rolling Heads are used securely.
Persons in charge of operating, maintaining and repairing
always have to read and understand the manual and the safety
instructions. People who are under the influence of alcohol and/
or drugs may cause accidents!
When mounting, please bear in mind the weight of the thread
rolling attachment and, if necessary, lift by means of a lifting
equipment.
Take care that the cutting sides between the attachment and the
machine are clean. Dirt may affect the precision of the workpiece.
Generally, shut down the machine at the main switch when
mounting the attachment. Make sure that the spindle cannot
start unexpectedly when exchanging the rolls.
Remove all tools and inspection equipments from the working
chamber of the machine before setting into operation. There is a
risk of injury by centrifuging tools and euipment!
Close the safety gate or protection cover before operating!
Hurtling chips and broken heads or workpieces may cause
damage to people and machines.
Make sure that the Thread Rolling Head cannot disengage
during operation.
When closing the Thread Rolling Head do not touch the head, do
not touch rotating tools: risk of injury!
Please check and handle the thread rolls extremely carefully. The
rolls have square edges. If necessary, wear safety gloves!
Please make sure the Thread Rolling Head is protected and
fastened approprietly when transporting.
04
3.0 Product Specification
Function
The roll holders act as a mounting for the thread rolls. They are
mounted in the body unit and lie up against the inside of the cam
ring.
The thread diameter is adjusted by manually turning the cam ring
by means of the adjusting screws.
Opening and closing of the roll holder system is effected by turning
the body unit relative to the guide ring which is screwed together
with the cam ring.
It is closed by radially turning via the closing handle or closing roll.
The locking plates engage and keep the head closed.
The head opens by pulling the entire rolling head out and away
from the flange. This way the locking plates are unlocked and the
cam ring turns back again: The roll holders are able to swing
outwards. The thread rolls release the thread, and the head can be
retracted without any contact on the work piece.
Manual pullout of the rolling head: The head can be pulled out
manually by means of two bolts Ø 6 mm and two boreholes which
are attached to the cam ring [300].
Applications
All kinds of threads with a broad range of both right- and lefthanded profile sections can be produced using a variety of roll
holders and thread rolls.
Moreover, forming work such as knurling, crimping of beading
and burnishing can be performed.
If you have any such applications, please inquire!
Adjusting screws Thrust bushings
Roll holders with
thread rolls
Cam ring
Body unit with
Guide ring
Closing roll
Locking plates
Flange
Shank
Fig 1: Main components of Thread Rolling Head RS 27/56
5
4.0 Roll Holders
Holder Table:
see page 32
Inscription
The roll holders (3 pieces per set) hold the thread rolls. They differ
with respect to their diameter ranges and the integrated holder
angle which is adapted to the thread to be rolled.
Refer to the holder tables on page 32 for the exact applications,
produceable threads and the relative roll sizes.
We request you to inquire with us for any threads which are not
listed.
The roll holder designations are engraved in the front face,
e.g.
RA 27/56 – 4 – 1.5
Whereby
RA 27/56 indicates
4
1.5
suitability for head type RS 27/56
diameter range
holder angle in degrees
Furthermore, the sequential number (1-2-3) is engraved in order
to make sure the thread rolls are inserted in the right sequence.
In addition, a set designation, e.g. K 69, is inscribed;only holder
sets with the same designation are usable.
Roll holders for left-handed threads have the suffix »L« in addition
to the above mentioned designations (e.g. RA 27/56-4L-1.5).
Roll holder
designation
-4
2
RA
1.5
6
7/5 3
Sequential number
Fig 2:
Roll holder inscription
06
K
69
Set designation
5.0 Thread Rolls
The thread roll is the actual form tool. The thread profile to be
rolled is worked into the roll in the form of parallel grooves. A set
consists of 3 thread rolls. Thread rolls for cylindrical threads with a
symmetrical profile are normally insertable on both sides; i. e. rolls
can be reversed and used at both ends.
The first tooth of the roll has a lower profile than the final profile;
the forming of the workpiece is effected in this section of the roll.
Further forming grades are:
A3
3rd tooth of the roll = full profile. The thread run out is one
third shorter than at the standard forming grade. It should
only be used for well formable materials.
A7
7th tooth of the roll = full profile. The thread run out is one
thread pitch (1P) longer than at the standard forming
grade. It is recommended for heavily formable materials.
Thread roll dimensions which partially differ may be necessary for
various types of roll holders. Refer to the roll holder tables on page
32 for more detailed specifications.
5.1 Inscription
Roll dimension
Sequential number
The roll designation is engraved in the front side. The designation
contains form of the thread, thread pitch or threads per inch, roll
size and manufacturing number. In addition to this the roll's sequential number 1-2-3 is engraved. On reversable rolls there is
another engraving A-B-C on the opposite side of the roll.
Example:
I 35 R 27 M 2.0
Type of
thread
I 35
R 27
M 2.0
Set / manufacturing number; hence all 3 rolls in
a set must have the same number.
Roll dimension. Dimensions are specified in mm
in the roll holder tables.
Type of thread
(here: metric thread, Pitch 2.0 mm)
Set number
Fig 3: Designation of thread rolls
7
Further possible designations for thread form and pitch or threads
per inch are for example:
UN 32
W 14
thread form as per US standard ASA B1.1,
with 32 threads per inch
Whitworth thread as per DIN 11, DIN 259 and
British Standards, with 14 threads per inch.
The roll size, thread form and pitch are also the specifications
for ordering rolls.
5.2 Bearing
The thread rolls are mounted on the roll bolt by means of carbide
bushes or needles.
Carbide bushes offer the lowest cost bearing since they themselves are subject to only slight wear and the roll bolts are also
given a longer service life.
Carbide bushes are utilizable with thread lenghts of up to 4 times
the diameter. Furthermore, they can only be used if oil is being
used as coolant/lubricant. They cannot be used in case of high
deforming forces (e.g. Acme threads).
Bearing needles can always be utilized, however, the needles
should be renewed each time the thread rolls are replaced. Special
attention must be paid in this case to the wear of the roll bolt, since
such wear can jam the bearing.
5.3 Quality
08
The standard material for our thread rolls is high quality tool steel.
For rolling threads on stainless steels we recommend nitrified rolls.
For steels with a tensile strength of 1200 N/mm² or higher we offer
rolls made of high-alloyed and specially heat treated tool steel.
6.0 Assembly
6.1 Assembly of the thread rolls
When assembling, care must be taken that the set designations
(e.g. I 35) of the three thread rolls correspond with one another.
The thread rolls are assembled in the roll holders so that either the
sequential number 1-2-3 is fitted towards the front in the respective
roll holder or with the designation A-B-C towards the front in roll
holders 1-2-3.
The roll designation 1-2-3 is not identical with the opposite side
A-B-C. Indeed roll 1 is designated on the rear face with an A, roll 2
with C and roll 3 with B. Special attention must be paid to this, if
the rolls are inserted by their secondary ends.
Before assembly, we recommend that the sliding surfaces of the
bushes be smeared with Molykote-D-Paste or equivalent.
Sequential number
Carbide bush
Fig 4:
Roll holder and thread rolls
Assembly with carbide bushes:
Roll bolt
Thread roll
2
Sequential number
1. Please push the bush into the roll.
2. Hold the roll with inserted bush between the holder's recess and
fix the roll with the roll bolt.
Fig 5:
Assembly with carbide bushes
9
Assembly with bearing needles:
For this purpose the provided assembly bolt is required. Place the
thread roll on a flat surface and put the assembly bolt into the roll
bore. Insert the bearing needles individually. The right number of
needles must be adhered to (see roll holder table on page 32)
The roll prepared in this way is then fitted together with the
assembly bolt into the holder (as described above, »Assembly with
carbide bushes«). Push the roll bolt through the bore. In doing so
the assembly bolt is pressed out forward (see fig. 6b).
In special cases double rows of needle bearings are inserted.
Thereby a bronze spacing disc is placed between the two rows of
needle bearings. A bush is used to facilitate assembly, this being
placed on the base when the first row of needles is being inserted,
and the spacer disc being laid on the bush. The roll is then turned
over for the purpose of assembling the second row of needles, and
likewise the needles inserted on the base.
Fig 6a: Assembly with bearing needles
2
Fig 6b:
Assembly with bearing needles
6.2 Assembly of the roll holders
Please assemble the roll holders only in the »closed« head position.
Adhere to the sequence of roll holders:
Right-handed threads:
Left-handed threads:
1-2-3 in clockwise direction
1-2-3 in counter-clockwise direction
Thinly smear the sliding surfaces of the roll holders with Molykote
D paste before assembly.
The roll holders are fastened by a screw, the appropriate holding
disc is integrated in the head and engages with a toothing in the
holder stud.
When inserting the holders, please mind that the toothing easily fits
into each other. Please make sure that the holders are squeezed
outwards by the spring force when releasing the holders. This is to
ensure that the toothing is engaged.
10
After that please tighten the fastening screw.
Finally please check the free movement of the holders as well as
the function of the thrust bushings, by which the holders are
squeezed towards the curves of the cam ring:
1. Turn the cam ring out of position and make sure that the roll
holders slide tangentially along the curve planes during and
after the turning.
2. Swing the single roll holders inwards manually. The holders
must swing back outwards due to the spring force.
Threaded bush
Spring pressure
Locking screw
Holding disc
Fig 7:
Components for assembly of the roll holders
6.3 Adjustment of the thread diameter
Roll holder
Adjustment of the head is effected most simply by means of a
sample thread. The head must only be adjusted in closed condition
until the sample workpiece is no longer turnable. Adjustment of the
head is effected by means of the two set screws [301], after having
loosened the Allen screws [305] and hence cam ring [300].
A graduation is provided on the cam ring. Twisting in the »+«
direction results in an enlargement of the thread diameter to be
adjusted, and in the »-« direction in a reduction. After the loose
screws have been tightened a trial thread can be rolled.
Inspection of the latter using an Aggra gauge, flank micrometer,
ring gauge or other measuring device will show whether readjustment is necessary. If no sample threads are available, a bolt
can also be used whose diameter corresponds with the core
diameter of the thread.
} CAUTION:
The two set screws [301] may not be tightened excessively,
otherwise distortion of the guide ring may occur, which will
hinder its movability.
11
6.4 Adjustment of the thread length
The thread length is limited by the opening of the rolling head. The
opening process is initiated by feed stop. The opening stroke is 3
mm.
Feed stop can be achieved by:
a) Limitation of the machine's feed stroke,
(e.g. by means of a positive stop or by stopping a ball screw)
b) Internal stop on the thread rolling head
In both settings take note of the fact that the greatest length is
achieved when the rolling head is opened.
When rolling up to a collar the possible thread length is determined by the front edge of the holder or roll.
The feed stop must ensure that a feed movement will no longer
take place.
6.5 Mounting on the machine
Rolling Head
Type
RS 27/56
Shank size
Incline
a
NC 30
NC 40
NC 50
18.5°
16.5°
16.5°
Stationary thread rolling heads are normally clamped in the tool
mounting by means of a shank, whereby care must be taken that
they are precisely centred. WAGNER® supplies shanks in various
diameters, both cylindrical and in NC-versions. The shanks are
interchangeable. A device on the machine must be available for
closing the rolling head.
Several illustrations of the principles of mounting and closing facilities on lathes are shown on page 13.
Special closing devices are obtainable for thread rolling heads
from several manufacturers of turning machines.
When making the closing cams take care of the fact that there must
be not only a cam rise for the closing movement, but also a fall
(approx. 5°) in order that the rolling head locks.
The closing roll is mounted in a fixed position on the rolling head
and is re-adjustable in the case of the NC-shank in 60° increments
by remounting the shank. If these 60°-increments are insufficient,
infinite adjustment is made possible by means of an additional
closing ring with a closing roll.
When remounting to a different position, remove the driver [78].
The output necessary for the thread rolling process may in this case
not exceed 10 kW and the speed should be in excess of 800 min-1.
Ensure that the fixing screws [501] are tightened evenly with a
torque of 10 Nm.
Fig 8: Normal position of the closing roll with a
closed rolling head and NC shank.
12
Feed direction
When used on radial turrets the thread rolling head is
closable by means of a closing cam into the position
opposite the work spindle while the tool inserted there
is advancing.
Closing direction
Closing roll
Closing cam
fixed
This version is utilizable on multi-spindle automatic
turning machines. This type is also possible on CNC
machines with tool turrets, whereby the closing cam is
firmly clamped on the tailstock/ sleeve spindle or is
fixed in another way to the machine bed.
Closing direction
Closing
during retract movement
Closing cam fixed
Tool carrier or
turret
Closing roll
One possibility on CNC machines.
In this case the rolling head is closed by moving the
rolling head's closing roll onto the stop via the X- and
Z-axis.
X
Z
Closing direction
Stop for closing
closing by means of
revolver which moves
onto the stop via the
X- or Z-axis.
13
7.0 Initial Operation
7.1 Rollable Materials
The material must be cold-formable. The necessary elongation of
the material is dependent on the volume of the deformation.
For materials of up to 800 N/mm² the following applies:
tensile strength of at least 7% for vee-threads
tensile strength of at least 12% for Acme threads
Elongation must be correspondingly greater with increasing tensile strength in order to economically roll threads.
7.2 Pre-machining of the work piece
Equal in area
Blank pre-machining is depending on the peculiarity of the material flow which takes place due to cold forming during thread
rolling. The volume displaced by the crests of the thread profiles
onto the rolls in the direction of the thread core must be equal to
the volume inflowing into the thread crests. Therefore the premachining diameter required for rolling, corresponds roughly with
the thread's effective diameter.
The flowability of the material also being of significance. The precise pre-machining diameter is only determinable by trial and error. It has to be selected in a way that with the correct effective
diameter, the major diameter of the thread is not over-rolled but
only lightly rolled onto.
b
2
a
2
Fig 9: Profile displacement with thread rolling:
a
½ on the starting-Ø results in b½ on the thread-Ø
The pre-machining diameter which has been determined in this
way, is the maximum dimension. The acceptable tolerance towards minus represents about … of the thread's major diameter tolerance. If this tolerance is complied with, the major diameter will
remain within the tolerance. Changes to the pre-machining
diameter have an effect on the major diameter of the rolled thread
of 3-5 times this amount.
A change of a = 0.02 mm in the pre-machining diameter can thus
cause, e.g. a change of b = 0.1 mm in the thread's major diameter.
For the determination of the pre-machining diameter, we recommend to select the diameter equal to the desired effective diameter.
By this means, a basis is obtained for rolling threads.
14
For this purpose, the diameter adjustment of the rolling head (see
6.3 on page 11) must be selected in a way that the correct effective
diameter is achieved.
Depending on the achieved major diameter, the pre-machining
diameter has to be corrected. The major diameter of the thread
must not be over-rolled as this would cause overloading and
subsequently lead to the breakage of the thread rolls.
Thread crest
rolled onto
Thread crest
over-rolled
Fig 10:
Thread crests
At the beginning of the thread the work piece must be provided
with a chamfer for the purpose of the thread rolls' start-up. The
chamfer angle should be in case of vee-threads 15-20°, in case of
Acme threads 10-12°.
Chamfer angle for vee-threads:
15 - 20°
Chamfer angle for
Acme threads: 8 - 10°
Pre-turning
dimension
<Core-Ø
Fig 11:
Chamfer on the work piece
Depending on the thread pitch, the diameter at the beginning of
the chamfer must be several tenths of a millimetre smaller than the
core diameter.
Subject to these prerequisites the initial pressure force is:
Initial pressure force [N] ≈ Power output [KW] • 120
Thread rolling without a start-up on the work piece is possible with
a special start design on the thread rolls.
Please inquire for further information on this subject.
15
8.0 Operation
8.1 Rolling threads up to a collar
By mounting the thread rolls in roll holders, threads can be rolled
close to large diameter collars. Precise specifications are contained in the roll holder tables.
By grinding out the roll holders (at maximum up to the centre of the
roll bolt) it is possible to considerably enlarge the collar's clearance
diameter.
B
Fig 12:
Thread run out
max. collar-Ø
Major Ø
of thread
A
x
A: Collar diameter = external diameter of thread
B: Collar diameter > external diameter of thread
x
x = thread run out
8.2 Thread run out
The first tooth of the roll has a lower profile than the final profile;
the forming of the workpiece is effected in this section of the roll.
The standard forming grade at the start of the roll is A4. At this
grade the 4th tooth is the first tooth with the final profile. Accordingly, at a three roll tool, this is the second tooth of the first roll.
The standard forming grade of the roll has a thread run out of
approximately 2.3 • P (P = thread pitch). Rolls with the standard
forming grade A4 do not have a specific forming grade designation.
An undercut is not necessary. Precise specifications and other run
out possibilities are obtainable on request.
8.3 Feed for thread rolling
Apart from the necessary initial pressure force, the thread rolling
process must be initiated with a certain initial pressure feed rate.
The initial pressure feed rate is calculated as follows:
Initial pressure feed [m/min] = 0.001 • n • P
n = Spindle speed [1/min]
P = Thread pitch [mm]
16
Feed for thread rolling
Contact pressure as such can be effected both by hand and by
mechanical or hydraulic machinery elements.
In case of rigid mechanical structural elements (e.g. cams, ball
screws) take into account that in most cases the workpiece extends
due to the thread rolling process, and that the feed has to be reduced by this amount (5 - 10 % of the pitch).
In case of long threads it is possibly necessary to adjust the feed
during the rolling process to the actual pitch. However, the feed
rate may never be greater than the pitch. At the end of the
thread, take care that the feed is stopped by the opening stroke of
the head (3 mm) earlier than the thread length, and that it must
dwell there for an appropriate time period in order to make it
possible for the roll holder system to open.
In case of long threads or an uneven feed it might be necessary to
enlarge the opening stroke of the heads. This can be effected by
replacing the small stop plates with longer ones, which results in
the above mentioned extended opening strokes. The latter are
utilizable for the purpose of feed compensation.
8.4 Rolling speed
In order to achieve material flow during the thread rolling process,
a rolling speed of at least 30 m/min should be maintained.
Economic speeds are in the range of 50 - 80 m/min.
8.5 Power output
The power output depends on the rolling speed, the material, the
profile form and the level of rolling of the thread. The power requirement can be calculated according to the following formula:
N » C • P •Rm• v • 0.000056 [kW]
C =
=
P =
Rm =
v
n
1 for vee-threads
2 for Acme threads
Thread pitch [mm]
Tensile strength [N/mm²]
= Rolling speed [m/min]
= R.p.m [1/min]
Turning moment:
M = 9550 •
N
n
[Nm]
17
8.6 Cooling - Lubrication
Ensure an ample supply of coolant/lubricant. 1:10 - 1:20 emulsions and thin bodied oils, as are also used for metal cutting, are
proven media.
High pressure additives reduce friction between the thread roll and
the work piece. They thus contribute towards an improvement in
tool life.
Good filtering of the coolant/lubricant is very important, in order
to prevent foreign materials (swarf) to be rolled into the thread or
settle in the roll bearing.
The after-sales services of the mineral oil companies are also at
your disposal for specific questions on coolants and lubricants.
You should approach them where required.
8.7 Tool Life
18
Conditions for a good and economic tool life:
Exact compliance with the pre-machining tolerances
Compliance with the rate of feed
Uniform, centrical starting chamfer
Precise concentricity between rolling head and workpiece’s axis
Clean and ample coolant/ lubricant supply
Level of rolling of the thread (avoid over-rolling)
Heed point 5.3 (page 8) for high material strengths and residue-free steels
9.0 Care and maintenance
9.1 Service intervals
A certain degree of care is required in order to maintain the functionality and functional reliability of the thread rolling head. This
means that the head ought to be cleaned and checked for possible
wear at regular intervals. We recommend the first service after
approximately 200,000 threads. Thereafter, the service intervals
depend on the operating conditions, the maximum interval is,
however, after 500,000 threads.
9.2 Disassembly of the rolling head
It is expedient for maintenance to partially dismantle the head.
Remove the roll holders and the thread rolls, before beginning to
dismantle.
1. Unscrew the locking screws [305] as well as adjusting screw
[301] and remove the cam ring [300]. Subsequently, dismantle
the opening screws [71] and the pressure springs [73] underneath. Remove the body unit [10] together with the guide ring
[30] from the flange [67].
2. Clean the contact surfaces, which are now exposed, of adhering abrasive metal particles and other contaminants. Inspect
the locking plates [37] and [69] for wear on their locking edges,
and replace them if required.
CAUTION: Take care when replacing: The locking plates
and screws [38] and [70] are glued with Loctite 638!
Excessive wear (rounding) of the locking edges can cause premature opening of the head or indeed completely prevent
closure.
3. Please check thrust bushings [16] for function. If not easy-running unscrew shank screw [17] and clean.
4. If functioning defects occur within the twisting mechanism between the body unit [10] and guide ring [30], the twisting mechanism must be demounted. Check whether a mark is present
on the flange side of the body unit and guide ring. This mark is
necessary for the subsequent assembly.
19
Before going further it is recommendable to clamp the body unit in
a vice. Please take care that the cover ring is not be damaged on
the guide ring.
5. Unscrew countersunk screws [34] and closing bolt [35]. Twist
the body unit [10] in such a way that the cheese-head screws
[13] come into view through the boreholes for screws [34], and
can be unscrewed.
Should the clamping segments [11] be impossible to loosen,
they can be pressed off using a M6-screw. A thread is cut into
one of the two boreholes. Pull the body unit [10] out of the guide
ring [30].
Remove the clamping segments [11], closing segments [32]
and pressure springs [36] from the guide ring’s groove [30].
6. Clean all parts and check for damage.
9.3 Reassambly
1. Oil all parts slightly.
2. Secure closing segments [32] by means of one screw [34] each
in the groove of the guide ring [30]. Also insert the clamping
segments [11] into the groove. Ensure that they are in the correct position in relation to the closing segments [32].
3. Insert the pressure springs [36] between the segments. Remove
screws [34] again. Twist the segments with the springs in such a
way that the boreholes for the clamping segments [11] appear
under the through holes for the closing bolt [35].
4. Push the body unit [10] into the guide ring [30].
Ensure that the marking is in the correct position.
Twist the body unit [10] so that the threaded holes come into
view underneath the clamping segments [11]. Screw in the
cheese-head screws [13] and tighten. Fix the closing segments
[32] using countersunk screws [34]. To do this, first you have to
turn the body unit back to the correct position. Screw in closing
bolts [35].
5. Check the function of the twisting mechanism, any absence of
easy-running indicates twisted segments. This can be eliminated by means of a light blow on the body unit when the guide
ring is in place.
20
6. Place the body unit with the guide ring on the flange [67].
Take care that the guide element [63] is correctly positioned
in relation to the groove.
Insert opening screws [71] with pressure springs [73] and
tighten.
7. Check the closing and opening function.
8. Mount the roll holder and cam ring [300] and check overall
function.
21
10.0 Troubleshooting
10.1 Defects in the rolled thread
Attribute
Cause and remedy
The effective diameter is too large/ small
Cause: Tool has not been adjusted correctly to the thread diameter.
Remedy: Chap. 6.3 »Adjustment of the thread diameter«, page 11.
The effective diameter is not uniform.
Cause: The pre-machining diameter has not been uniformly maintained.
Remedy: Chap. 7.2 »Preparation of the workpiece«, page 14.
The major diameter is too large/ small
Cause: The pre-machining diameter is too large/ small
Remedy: Chap. 7.2, page 14.
The major diameter is tapered
Cause: The threaded bolt has a bore, or centre hole. If the walls are
too thin the thread will be compressed more intensively.
Remedy: Make the bore after the thread rolling operation.
The first few threads have sheared off,
the beginning of the thread is »unclean« (1)
Cause: In case of an excessively large starting chamfer the starting
pressure force is too great. Due to this, increased wear on profile
rolls [204].
Remedy: Chap. 7.2, page 14.
The beginning of the thread is »unclean« (2)
Cause: Starting pressure is incorrect (Feed force). At excessively
slow starting pressure the thread profiles of the rolls [204] do not
engage into the prescribed thread pitch, but only press into the
starting chamfer, so that the material is hardened to an unacceptable degree. If starting pressure is too fast an excessively strong
force is exerted on the roll profiles: In both cases there is danger
of profiles breaking on the rolls.
Remedy: Check and correct starting pressure.
Thread flanks are flaking off or have a
rough or patchy surface;
threads are destroyed when rolled
Cause:
The material is not suitable for rolling, because it is too brittle
(might has experienced unacceptable hardening due to a foregoing cold forming)
High proportions of sulphur or lead which favour (short machining in the case of free cutting steel)
Swarf and abrasives in the coolant: roll breakage if large swarfs
Residues of lubricants on the surface of cold-drawn materials
A surface which has been too coarsely pre-machined
Remedy:
Use suitable material
Use a filter in the coolant line
Clean workpieces before rolling
Cleanly pre-machining
22
Attribute
Cause and remedy
Thread pitch is not uniform
Cause:
Rough-running feed carriage
Feed is not adjusted to the pitch
Non-homogeneous material
Remedy:
Check feed carriage for easy running when subjected to a load
Adjust the feed to the pitch
Check homogeneity of the material
The thread is incomplete and only partially
rolled.
Cause: Contamination or incorrectly adjusted tool
Remedy:
Check whether the rolling head is correctly engaged when it closes and clean if necessary
Verify whether the set screws [301] (do not tighten!) and the
cheese head screws [305] in the cam ring are perfectly tight, and
correct adjustments if necessary
The thread pitch tends unifomly to plus or
minus
Cause:
Pitch angle is too large/ small
Pitch errors due to material (mainly with tubes)
Remedy:
Replace the roll holders [201] with the next smaller or the next larger pitch angle
Larger pitch corrections are only possible by using special rolls
with a specially corrected pitch
The pitch can also be influenced by closing or opening
The thread has been overrolled
(roll breakage due to a heavily overrolled
thread)
Cause:
The pre-machining diameter is too large
Thread diameter is too small
Remedy: see Chap. 6.3, page 11 and Chap. 7.2, page 14.
The desired number of threads is not being
rolled: e.g. instead of a single thread, a
double thread is obtained
Cause:
The 1-2-3 sequence of the roll holders [201] together with the
profile rolls [204] has not been complied with when assembling
them in the rolling head.
In case of correct sequence, starting pressure is too fast
Remedy:
Take care of correct sequence of holders [201] and rolls [204]
Use correct starting pressure (especially for fine threads!)
23
Attribute
Cause and remedy
Drunkenness in the threads
(poor thread quality)
Cause: Roll holders [201] with an incorrect roll holder angle leads
to an increased load on the profile rolls [204].
(The holder angle has an influence on the thread pitch, which will
lead to drunkenness and sinking quality.
In case of fine threads the holder angle effects the number of
threads)
Remedy: Use correct roll holders [201] with correct holder angle
(see roll holder table, page 32)
Lengthwise brush marks on the rolled
thread
Cause: The rolling head does not open sufficiently, thus when pulled out, markings on the major diameter of the thread by the profile
rolls [204].
Causes might be a heavily contaminated rolling head or a plastic
deformation of the pressure springs [36], which are responsible for
opening the rolling head.
Remedy: Clean the rolling head. Check the pressure springs [36]
and replace them if necessary.
Long threads: The thread has been rolled
one-sided or the thread bolt is bent
Cause:
Concentricity precision between the rolling head and the workpiece is insufficient. In case of marked deviation: danger of breakage for the profile rolls [204]!
The starting chamfer has not been selected correctly, too much
material is suppressed axially
The material has internal stress
Rolling speed too slow
Remedy:
Correct the concentricity between rolling head and the workpiece
Correct the selection of the starting chamfer
Before thread rolling, stress relief annealing of the material
Increase the rolling speed (at least 30 m/min)
The thread is incompletely rolled or partially overrolled, the threaded rod becomes
bent
Cause:
Blanks with marked diameter deviations or bent blanks
Using rolled material or forged steel with decarburized outer
layers
Thread pitch is incorrectly adjusted
Incorrect pre-machining diameter
In case of extreme overrolling danger of breakage of the rolls!
Remedy:
Correctly adjust the thread diameter (Chap. 6.3, page 11)
Exactly adhere to the pre-machining diameter (Chap. 7.2, pg 14)
Use suitable blanks
24
Attribute
Cause and remedy
Elongation of the thread (profiles possibly Cause: Feed during thread rolling is not in compliance with the
pitch:
breaking on the rolls)
} Pitch errors: A forward feed applied during rolling which does not
comply precisely with the thread pitch arising in the rolling tools
during the rolling process, influences the pitch.
Remedy:
Select the correct feed force (Chap. 8.3, page 16)
Switch off the forward feed after rolling the first two or three
threads in order to pull the workpiece through the rolling tools
with as little resistance as possible.
In special cases an extraction extension can provide a remedy.
10.2 Faults in the equipment
Destruction of the needles [203], jamming Cause: Bearing needles [203] in the roll bearing do not have the
prescribed quantity or are not flawless (Needles with brown
of the profile roll [204] and roll breakage
tarnishing on the tip are not utilizable).
Remedy: When inserting profile rolls [204] always use a full set of
flawless bearing needles [203] with a complete quantity of needles.
The roll bolts [202] are very heavily worn
Cause: The surface on the pressure face of the roll bolt [202] is
being destroyed little by little by pitting due to being rolled over by
the bearing needles [203] (not to be mistaken for bare pressure
points).
Remedy: Where this pitting, initially occurring in various places,
forms a continuously destroyed surface on the pressure face, replace the roll bolt [202].
CAUTION: Danger of needle/ roll breakage!
Roll breakage
Cause: Overrolled threads
Remedy:
Adhere to the adjustment of the thread diameter (Chap.6.3)
Exactly adhere to the pre-machining diameter (Chap. 7.2)
NOTE: Thread profile rolling tools are not straightening rolls!
Service life of thread rolls [204] are too
short
Cause:
Rolling speed is too slow
Thread rolls are inappropriate for application
Remedy:
Rolling speed must be at least 30m/min
Use suitable thread rolls [204]
25
Cause and remedy
Attribute
Cam ring [300] cannot be twisted towards Cause: Adjusting screws [301] are tightened too heavily.
Remedy: Check and correct adjustments.
the guide ring [30]
Profile rolls [204] are breaking off.
Cause:
The thread has been rolled over too heavily about the major
diameter, i.e. it has been rolled with excessive pressure
Upon initial rolling the rolls [204] were forced in too hard (starting
pressure is too fast/ bevel angle is too large)
The workpiece was not driven into the rolls centrically enough
The rolls are jammed due to contamination of the coolant by
swarf
Swarf between the workpiece and the profile rolls
Remedy:
Check starting pressure and correct if necessary
Check concentricity between the rolling head and the workpiece
Clean coolant and remove swarf from the rolling head and the
workpiece
10.3 Failures during operation
The profile rolls [204] or the roll holders
[201] run up against the collar on the
workpiece. Roll breakage occurs.
Cause: The limit stop for opening the head when it rolls up against
a collar has not been correctly employed or adjusted
Remedy: Check the adjustment of the limit stop and correct if necessary
During rolling the workpiece is pressed Cause: Too small force to clamp the workpiece
Remedy: Correctly clamp the workpiece
back into the clamping device.
The workpiece slips during rolling.
The desired thread length is not achieved.
Upon reaching the thread length the work- Cause:
Workpiece is not clamped correctly
piece is pulled out of the clamping device
Rolling head does not open (Danger of roll breakage!)
when the forward feed is stopped
Remedy:
Correctly clamp the workpiece
Check opening function of the rolling head, clean head if necessary and exchange pressure springs [36].
The rolling head opens ahead of time or Cause: Locking plates [69] and [37] are worn out (roundings on the
edges)
does not open.
Remedy: Check the locking plates [69] and [37] and replace them if
necessary.
26
11.0 Technical Data
Rolling Head
opening stroke
Closing ring
27
Cylindrical shank DIN 69880
NC-shank
Shanks
RS 27/56
30 x 80
32 x 80
40 x 80
50 x 120
NC 30 x 55
NC 40 x 63
NC 50 x 78
D8
D9
80
30
32
40
50
30
40
50
D10
D11
D13
23.5
M251x 1.5
27.5
M28 x 1.5
R½”
16.2
25
32
–
–
42
NC-shanks with connection dimensions according to DIN 69 880.
28
L7
L8
1.8
8
17.8
24
L9
80
80
80
120
55
63
78
L10
–
13.5
L11
72
72
72
105
64.5
64.5
79.5
L12
–
16
–
12.0 Component Parts/ Accessories
Part no. 737175
Part
no.
10
11
13
15
16
30
32
34
35
36
37
38
63
64
67
69
70
71
73
75
78
Qty.
Designation
Product no.
1
2
4
3
3
1
2
4
2
2
2
2
1
1
1
2
2
3
3
3
1
Body unit
Clamping segment
Cheese-head screw M5x16
Pressure spring
Thrust bushing
Guide ring
Closing segment
Countersunk screw M5x16
Closing bolt M10x1x9
Pressure spring
Locking plate
Guide element
Flange
Locking plate
Countersunk screw M5x16
Opening screw
Pressure spring
Holding disc
Location bolt
734633
734635
02015055
03310709
710826
780454
734636
02015055
734645
03310128
734643
02018103
734641
02015110
734634
734643
02018104
734642
03310201
734644
737267
Screw driver 4
Screw driver 5
Screw driver 6
02677004
02677005
02677006
Accessories
1
504
1
505
1
506
Additional parts for RS 27/56
Bolt
1
50
Supporting bolt
1
51
Circlip
1
53
Closing bolt
1
400
Ball knob
1
401
734640
03443331
02084003
737177
02270008
Additional parts cam ring
Cam ring
1
300
Adjusting screw
2
301
Clamping piece
2
303
Cheese-head screw M5 x 50
2
305
Cheese-head screw M5 x 70
3
501
737325
734639
734638
02015064
02015068
29
12.0 Component Parts/ Accessories
Shanks and internal stops RS 27/56
Designation
Ø D9
Shank 600
30 x 80
32 x 80
40 x 80
50 x 120
NC 30 x 55
NC 40 x 63
NC 50 x 78
30
32
40
50
30
40
50
Product no.
Shank
730767
730768
730769
731427
730777
730780
730783
Product no.
Internal stop
731465
731465
731466
731466
–
–
–
Complete with fixing screws, part no. 601
Internal stop
731465
Internal stop
731466
30
Part
no.
701
702
703
704
706
707
708
723
727
Qty.
Designation
Product no
1
1
1
1
1
1
3
1
1
Threaded bush
Stop spindle
Hex. nut M12
Steel ball Ø 6
Stop Ø 6
Stop Ø 15
Snap ring
Back-up ring
Back-up ring
756724
726761
0206203
02460118
731482
731483
02087003
731493
732506
701
702
703
704
706
707
708
727
1
1
2
1
1
1
3
1
Threaded bush
Stop spindle
Hex. nut M 12
Steel ball Ø 6
Stop
Stop
Snap ring
Back-up ring
726764
726761
0206203
02460118
731482
731483
02087003
732506
31
32
13.0 Annex
Roll Holder Table RA 27/56 for thread rolling heads type RS 27/56
Roll holder
Designation
Part no.
max. shoulder Ø
RA 27/56-1-3.0
737330
CD + 16,4
RA 27/56-1-2.0
737332
CD + 16,4
RA 27/56-2-3.0
737334
CD + 16,4
RA 27/56-2-2.0
737336
CD + 16,4
RA 27/56-3-2.8-22
737338
CD + 16,4
RA 27/56-3-2.0
737340
CD + 16,4
RA 27/56-4-1.5
737342
CD + 16,4
RA 27/56-5-1.2
737346
CD + 16,4
RA 27/56-6-1.0
737350
CD + 16,4
RA 27/56-7-1.0
737352
CD + 16,4
RA 27/56-8-0.8*
737354
CD + 16,4
Rolls
D/dxB
R27=35/17x17
R27/22=35/17x22
Rolls
Designation
Rolling range
Core-Ø in mm
from ... to
Max. outer-Ø
Types of threads
WhitworthMetric
pipe threads
Threads
DIN ISO 228
DIN 13
6.6 ... 12.6
16.0
M8-14
M12x1.5
Whitworthpipe threads
3/8...7/16-14...16
½-13
9/16-12
5/8-11
12.6 ... 18.6
22.0
R27
702393
R27/22
724113
24.6 ... 30.6
34.0
R27
702393
30.6 ... 36.6
40.0
36.6 ... 42.6
46.0
42.6 ... 48.6
52.0
48.6 ... 54.6
58.0
Qty, needles
DxL
54-2.5 x 16.8
54-2.5 x 21.8
Part no.
03462065
03462067
Roll bolts
DxL
12x33
12x35
UN
UNS
7/16-20
3/8-20
½-16
5/8-12
9/16-24
9/16-16...20
3/8...7/1618...27
½-12...18
9/16...5/8-14
½-24...27
9/16-27
¾-12
7/8-9
G 3/8"
G ½"
R 3/8"
R ½"
NPT
1/8-27
¼-18
3/8-18
7/8-18
¾-16
5/8...11/16-24
¾-20
5/8-16...20
11/16-12...20
13/16-12...16
5/8-14...27
¾-14...27
7/8-14
15/16-20
1-20
¾-20
7/8-20
1-20
1.1/16...1.1/4-18
1.1/8-12...18
7/8...15/16-12...16
1-16
1.1/6-12
1.1/16...1¼-16...20
1.3/16-12...20
1.5/16-12
1.5/6...1.3/8-16...20
1.7/16-12...20
1.1/2-16...20
1.5/8...1¾-10...20
1.13/16-12
7/8-18...27
1-14...27
1.13/16...1.15/1616...20
2-12...16
2-20
2.1/8-12...20
2.1/4-12
1.7/8-14...18
2-14...18
¾-14
1-8
M24-27
M21-26x1
M21-26x1.5
M22-27x2
M27-32x1
M27-32x1.5
M28-33x2
M33-38x1
M34-39x1.5
M35-40x2
M39-44x1
M40-45x1.5
M41-45x2
M45-50x1
M46-50x1.5
M46-52x2
M51-56x1
M52-56x1.5
M53-56x2
3/8-24
½-20
9/16-18
R 1/8"
R ¼"
M16-22
M15-20x1
M16-20x1.5
M18-21x2
18.6 ... 24.6
28.0
G 1/8"
G ¼"
UNEF
DIN 2999
ISO 7/1-82
R27
737344
M9-14x1
M12-16x1.5
American standard threads
UNF
UNC
G 5/8"
G ¾”
R ¾”
G 7/8"
G 1"
1¼ -12
G 1.1/8"
1.3/8-12
1½ -12...18
G 1¼"
G 1.3/8"
G 1½"
G 1.5/8"
G1¾”
Part no.
Carbide bushes
Part no.
702392
724113
17/12 x 16.8
–
03463103
–
1.5/16-18
1.3/8-18
1.7/16-18
1.5/8-18
1.11/16-18
1.1/8-14...24
1¼ -14...24
1.3/8-14...24
1½ -14...24
1.5/8-10...24
1¾ -14...18
2.1/16-16
2.3/16-16
2.1/4-14
* max. thread length including run-out in case of threads larger than
52 = 31 mm length
Efficient external threading thread rolling, thread cutting, skin turning and
turning with WAGNER®- tool systems!
Tool Systems by WAGNER® are at your disposal for many different external
operations. Multi-Cutter Turning Heads are used for end machining before
the thread cutting or thread rolling.
®
Special WAGNER tools offer other machining possibilities like beading,
knurling, crimping, diminishing of tubes, etc.
RS 2756 11/2007
01462 491919
sales@floydautomatic.co.uk
www.floydautomatic.co.uk

Thread Rolling Head Stationary RS27-56 EN

Transcription

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