type: KSN 1 / IKZZ / MMS KSN 3 / IKZZ / MMS KSN 4 / IKZZ / MMS Date of edition: 01.02.2008 Stage of alteration: 2 Please keep this for future use
Contents: 1 Application range, safety instructions and technical data... 3 1.1 Application range, determined use... 3 1.2 Specifications... 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 Re-putting into operation... 7 2.4 Application and use of the quick-change adapters... 8 2.5 Insert tool... 9 2.5.1 Quick-change adapters types EM... 9 2.5.2 Quick-change adapters type EM-E-Lock...10 2.6 Insert quick-change adapter...11 2.7 Remove quick-change adapter...12 2.8 Remove tool...13 3 Maintenance... 14 3.1 Maintenance schedule...14 3.2 External cleaning...14 4 Storage when not in use... 14 Edition: 01.02.2008 1
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. Protected Protected Protected Sectional view: Quick-change tap holder KSN/IKZZ/MMS 2 Edition: 01.02.2008
1 Application range, safety instructions and technical data 1.1 Application range, determined use The quick-change tap holders are mainly determined for the use on CNC machining centers, CNC turning machines and other machine tools working with minimum quantity lubrication (MQL). The quick-change tap holders are marked by a green 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 resp. to ASME B 5.11 Hollow taper shank acc. to DIN 69893-HSK-A For the cutting range of each type, please refer to Table 1, page 6. The locking of the tool is executed via the quick-change adapters type EM. The quick-change adapters must be chosen depending on size and type of the tool used, for more information please refer to chapter 2.4, page 8. The quick-change tap holders are equipped with a length compensation on tension and a front release, for more information please refer to chapter 1.2, page 4. The quick-change tap holders are specially made for minimum quantity lubrication, for more information please refer to chapter 1.2, page 4. The non-determined use exempts the manufacturer from any liability! Edition: 01.02.2008 3
1.2 Specifications Further features of the quick-change tap holders are: Small, compact overhang Length compensation on tension: 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 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 quickchange tap holder and avoids expensive damages. Minimum quantity lubrication (MQL): Especially used for minimum quantity lubrication: Target-oriented, easy-flow guidance of the coolant-lubricant through the centre of the quick-change tap holder. Environmentally sound lubrication. The high cutting values for wet machining may be kept. Reduction of the machine hour rate by omission of purchase and maintenance of expensive filter devices and disposal of the emulsions 4 Edition: 01.02.2008
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 feeds. Please observe such data. - Please observe the maximum tool dimensions. - Furthermore, the instructions of the tool manufacturers are valid! Edition: 01.02.2008 5
1.4 Dimensions and technical data Grip sleeve T ZA ØD 1 ØD green ring Picture 1: Dimensions of the quick-change tap holders KSN/IKZZ/MMS Table 1: Technical data of the quick-change tap holder KSN/IKZZ/MMS Type Cutting range Adapter size D D 1 T 1 ZA 2 KSN 1/IKZZ/MMS KSN 3/IKZZ/MMS KSN 4/IKZZ/MMS M6 M14 1/4 9/16 M6 M24 1/4 1 M14 M36 9/16 1 3/8 [mm] [mm] [mm] [mm] EM01 36 19 8 2,1 EM03 53 31 15 2,8 EM04 78 48 23,5 4,1 Quick-change tap holders with shank acc. to DIN69893-HSK-A have an integrated coolant-lubricant tube which must not be disassembled, otherwise the function of the MQL transfer is no longer guaranteed! When ordering, please remember to clarify the transfer of the MQL system (1 or 2 channels). Design with shank type DIN69893-HSK-C for 1-/2-channel MQL systems upon request. Further outer dimensions depend on the required shank. The dimensions may be taken from the EMUGE main catalogue or refer to our local representative. 1 Length compensation on tension 2 Front release 6 Edition: 01.02.2008
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! 2.2 First putting into operation The quick-change tap holders are inserted into the machine manually or, if provided, by the tool exchanger. The tool change must not be executed while the machine spindle rotates! - Only use tool shanks and tightening bolts suitable for the specific machine. - Make sure the tool is correctly clamped. Risk of accident by spinning of the tool! - Please see also the indications in the operating instruction of your machine tool! 2.3 Re-putting into operation If the quick-change tap holder is reput into operation, as described in chapter 4, page 14, please carry out the following 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 on tension: Hold the quick-change tap holder and pull the grip sleeve forward, let go of 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: 01.02.2008 7
2.4 Application and use of the quick-change adapters The adaptation of the tool is executed via quick-change adapters. The following adapters are available when using minimum quantity lubrication: Type EM.. Type EM..-E-Lock Rigid design, without overload clutch. Main application range: Production of through hole threads. Rigid design, without overload clutch, locking of the tool is secured by form-fitting. The tool must be provided with a groove at one square face. Main application range: Clamping of hard metal and HSS tools. The function of the minimum quantity lubrication is only guaranteed with the use of the quick-change adapters types: EM, EM-E-Lock in connection with an IKZ resp. IKZN tool. The tool adaptation is executed via a quick-change ball clamping system. The torque arising during the thread producing operation is transferred via the square integrated in the quick-change adapter. All quick-change adapters are suitable for producing left- and right-hand threads. The adapter sizes for the appropriate quick-change tap holder may be taken from Table 1, page 6. The clamping diameter is defined by the tool used. Owing to the quick-change principle, a separate adapter is required for each diameter. 8 Edition: 01.02.2008
2.5 Insert tool 2.5.1 Quick-change adapters types EM Choose the appropriate quick-change adapter for the tool used! Quick-change adapter Guiding bush Tool 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 type: EM. Edition: 01.02.2008 9
2.5.2 Quick-change adapters type EM-E-Lock Choose the appropriate quick-change adapter for the required tool! The tool must be provided with a groove in the square face! Quick-change adapter Tool 1. Press guiding bush back and hold it. Guiding bush 2. Push tool into the guiding bush. Groove in the tool Position of holding pin and groove in the tool must match! Holding pin Tool 3. Let go of the guiding bush. The tool may only be changed if the quick-change adapter is not fixed in the quick-change tap holder. If quick-change adapter and tool are fixed in the quick-change tap holder, the holding pin in the adapter stops the tool being taken out. The instruction is valid for all quick-change adapters type: EM-E-Lock. 10 Edition: 01.02.2008
2.6 Insert quick-change adapter The change of the adapter must not be executed while the machine spindle rotates! Fixing of the shank 1. Fix shank Tool ie, by adaptation of the quick-change tap holder in the machine spindle Shank Grip sleeve Quick-change adapter 2. Insert quick-change adapter Watch position of driver and groove! 3. Strongly pull at the grip sleeve of the quick-change tap holder and hold it The pressure point must be overcome! 4. Press quick-change adapter back 5. Let go of grip sleeve The grip sleeve returns to its initial position Edition: 01.02.2008 11
2.7 Remove quick-change adapter Operating instruction for the quick-change tap holders The change of the adapter must not be executed while the machine spindle rotates! Fixing of the shank Quick-change adapter Tool 1. Strongly pull at the grip sleeve of the quick-change tap holder and hold it Shank Grip sleeve The pressure point must be overcome! 2. Remove quick-change adapter 3. Let go of grip sleeve 12 Edition: 01.02.2008
2.8 Remove tool Quick-change adapter Guiding bush Tool 1. Press guiding bush back and hold it 2. Pull out tool 3. Let go of guiding bush The instruction is valid for all quick-change adapters type: EM and EM-E-Lock EM-E-Lock: The tool may only be detached, if the adapter is not fixed in the quickchange tap holder. Edition: 01.02.2008 13
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 quick-change tap holder is taken out of service, please go through the following steps: 1. Clean the quick-change tap 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 and machining residues must be removed. 14 Edition: 01.02.2008
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ZB10020.GB 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 info@emuge-franken.com www.emuge-franken.com