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GRINDING FIXTURE OPERATING INSTRUCTIONS

12

29)

( 15

14

27

35.

Scale RodPlate 19. DrawbarTaper 23. 1 . Swivel Lever 16. 20.StopperSupport Device Workiece 13. 24. KnurledGripDevice Micro Swivel Cross Micrometer Index P Pin Plate Switch Slide 31 14. 34. 30. 33. 21 17. Axial Base26. Piece NutPlate Device 29. 25. . Stop' Bolts Plate at 18. 27. Cross 28. Knob Lever Work Finger Tension 15. Stopper for Scale Quick Adjustment Adapter . 32. Mounting Clamping for Clamping Spindle Support Electromagnet S/-lpport 22. Work'Spindle

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X2

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HawemaGmbH 078647 Trossingen


Datum~ Bearb. 1-"!.3.03. r.)
Gepr. Norm

Manstab

Jt Name /It/A

Betriebsmittelliste

Blatt
BI

Zust.

An derung

Datum IName

SChalterbezeichnungen des UFS ---------------------------------155

in der folgenden Bedienungsanleitung Schalter wie folgt abgekurzt:

werden die

Indexierung

K 2

Steuerrolle

K 5

Autornatik

Manuell

KS/K2

"OFF"

An den Ausgangsbuchsen "Indexierung" und "Steuerrolle kann wahlweise der Handtaster oder der FuBtaster angeschlossen werden.'

/1
.J

L.

.5

"T

.:;

-I

B
F1

510-"\
13

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131j.

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111

A1

V2

K1
V4
A2"

IS1 fv7--- ---

1<311" A2

':' I
E

. iPE L1 ..r:"1

L
Indexierun,

Inde-x Pin

Hand70s1er Hand Swihh

HikroschaUer
Micro

1t
Swi/ch

.E .

n~eruna

Do:1um ....

I Name
2

UFS 155 Stromlaufplan

Hawema GmbH Dolum: 21.01.55 78647 Trossingen . I3earb: I .Jh./? beDy.

Blatt:
Folge:

'7

ELECTRICAL

CONTROL

BOX

On/Off

Power

suplly

0/1

220/110

AC

24

DC

Red/active

Power Green/active

Rheostat
M

M2

Green/active
1

Receptacles for Foot and Hand Switches

Control Automatic/Manual Index pin

Roller

''-../"

Time

Lag

Relay

Foot

SII'Jitch

Hand

Switch

INDEX
Introduction Mounting to Tool & Cutter Grinder Electrical Installation Mounting the support fInger adaptor Adjusting the support fmger Changing the index plate Clamping the tools Length adjustment Cross adjustment Radial quick adjustment Radial micro adjustment Switching of the index pin (20) Indexing without spiral mechanism Indexing with spiral mechanism Clearance angle grinding on the O.D. with the fmger Rake angel grinding on the O.D. with spiral mechanism Clearance angel grinding on O.D with spiral mechanism Rake angle grinding on the end of the tool Clearance angle grinding on the end of the tool Axial relief grinding without cam device Grinding with controlled slippage Helix angle chart Cam device (Step drills) Mounting the taper -tool attachment Electronic device Maintenance and service Adjusting the control roller - Sketch Adjusting the control roller Adjusting the micro switch (21)

Paragraph

Page

1
1.0 1.1

2 3 3
4

2.0- 2.2 3.0- 3.4


4.1 4.2 4.3 4.4

5 5
5

6 6
6

5.0- 5.2 6.0- 6.5 7.0- 7.5 8.0- 8.14 9.0- 9.14 10.0-10.14 11.0-11.8 12.0-12.7 13.0-13.9 14.0-14.6 15.0 16.0-16.6 17.0-17.5 18.0 19.0-19.4 20.0 20.0-20.22 21.0-21.6

6 6 7

8
9
10 10

11 11
12
13
15

16 17 18
19

19

Introduction This manual is written for the operator of the Universal Spiral Grinding Device UFS 155. The manufacturer is not responsible for damages that may occur due to non compliance with this manual. The manufacturer is continuously improving the UFS 155. It is therefore possible that this manual may not be totally complete. Please contact the manufacturer if further assistance is necessary. All technical specifications are subject to change without notice.

Periodical

cleaning

The only cleaning required are the surfaces of the grinding device. Simply wipe off with brush or rag, use oil if necessary. Warning: Do not use compressed air to clean. Beware of dangerous chemical solution not suitable to apply to metal and high precision instruments.

Mounting

the spiral grinding

device on a tool & cutter grinder

The fIxture can be mounted on any conventional tool and cutter grinder. The grinding wheel spindle must be adjustable for height. The grinding machine table must be adjustable in length and must be secured with positive stops on each end. The table should also be secured from tilting sideways. The most suitable machines are the ones fItted with a cross roller table. Usable machines: Cincinnati - KO.Lee - Hybco - Seneca Falls - Saacke UW I-II - Schuette - Deckel - Jungner - Walter - and many others. The fIxture is mounted on the machine table using conventional bolts (2). Keys are used to align the fIxture with the machine. Using the swivel base plate (1) the fIxture can be swiveled 360 degrees, whereby the degrees can be read directly ofTthe scale (3) on the mounting plate (4). The swivel plate is locked into position with the nut (5) using a 22 rom wrench. The machine table must be locked axially to prevent tilting.

Electrical 1. 2.

Installation

The e1ectrical box is supplied by either 220V AC or 110V AC respectively - The fixture is hooked up to the 24V DC cable. The power on/off switch is located on top of the box indicated by a red light.. If the green light If the green light With the rotating numbers = more M 1 is on - the spiral magnet is activated. M 2 is on - the index magnet is activated. switch of the rheostat the pressure of the control roller is adjusted. Higher pressure for bigger tools, lower number = less pressure for smaller tools.

4.

With the toggle switches on the side K5JK2 the microswitch (21) on the fIxture is activated. With the K5JK2 on "ON"the control roller (M1) and the index pin (M2) is switched in sequence with the micro switch (21). The timing of the index pin can be regulated with a time relay between 0.5 - 10 seconds. The relay is found in the electrical box. Also in this position the foot and hand switch do not operate. If K5JK2 is switched to "OFF' the control roller (M1) and the index pin (M2) can only be operated with the hand or foot switch. The receptacles 1\2 and K5 are for the hand or foot switch respectively. The function of the hand- or foot switch can be reversed with the toggle switch 1\2 and K5. The hand- or foot switch can be plugged into either receptacle.

5.

1.0

Mounting

the support

finger

(31)

The support fInger is mounted onto the Universal spiral grinding device using an allen wrench. The adaptor must rest upon the precise ground round stop. This assures exact repeatability when mounting and demounting. ~. ~~.- . ~

Without fmger support

With fmger support

In the fmger support (31) insert the spindle (14). With the groove in the spindle (14) and the tension lever (16) the fmger (11) is always center with the tool. If the spindle (14) is taken off, the support casting should be covered with the enclosed plastic covers to prevent any damages to the ball bearings. The support fmger device can be mounted on either side of the unit.

Ll

Aqjustingthe finger (11)


A rod which is approximately 1/2" in diameter that has been ground halfway to the center, is chucked into the spindle taper and lined up horizontally to the machine table. Thereafter the fmger is adjusted to the center of the ground gauge. Set the axial stopper of the fmger assembly. In order to check repeatability, swing the fmger 180 degrees and index the gauge by 180 degrees .. -------.......

--------.

Pas. 1

Pas. 2

2.0
2.1

Changing the index plate


For a fast and errorless indexing we recommend to use index plates with the same index configuration as ~~?l. l.~," 1.1., ~- -

Without index plate

With index plate and clamping piece

2.2

To change the index plate loosen the index plate clamping piece (26) with a spanner wrench and screw it off the workpiece spindle (15). The index plate then can be exchanged by hand pulling it off the spindle (15).

3.0
3.1 3.2

Clamping the tool


Work piece spindle adaptor: ISO/NST 40 or Morse Taper 5. Cutters with arbor holes are mounted on suitable shell mill holders and are tightened by hand using the knurled grip (7) on the drawbar (6). End mills with straight shanks are chucked in ISO/NST 40 or MT 5 collet or in regular end mill holders and tightened using the knurled grip (7) on the drawbar (6). End mills with tapered shanks NST 40 or MT 5 are directly mounted in the work piece spindle taper (8) and are tightened using the drawbar (6). End mills with Morse tapers 4-3-2-1 have to be mounted on suitable mill sleeves. (DIN 6363-6463) MT-l/ MT-2/ MT-3/ MT-4/ MT-5/ NST 40 Several bolts are available for the drawbar (6): M6 - MI0 - M12 - M20 - 5/8-11 inch, as well as specially threaded bolts. The drawbar (6) is adjustable in length with the knob (32) to fit various holding devices.

3.3

3.4

4.0
4.1

Infeed
The axial infeed is performed with the workpiece spindle (15) and is set with the stop (17) and the micrometer (29).

Stop with micrometer 4.2 The cross feed movement is controlled with the micrometer screw (18) which is held in position with a loaded spring. The total cross movement is 10mm or .394".

Micrometer for the cross feed

4.3 4.4

The radial quick adjustment is done by opening the lever (25). The degrees can be read directly off the scale (23). The radial micro adjustment is done by turning the knurled screws (22). The degrees can be read directly off the scale (23).

Radial Quick adjustment


IMPORTANT:

Radial micro adjustment

If the radial infeed is adjusted while the index pin (20) is not engaged, it is necessary to re-index prior to grinding in order to reposition the workpiece spindle (15) correctly. the Control Roller and the Indexpin (20)

5.0 Switching 6.1 5.2

During the setup of the tool the control roller (M1) and the index pin (0) are electromagnetically activated with the foot- or the hand switch respectively. The toggle switch K5/K2 is switched to the OFF" position. When grinding begins, the toggle switch K5/K2 is switched to ON". The control roller (M1) and the indexpin (M2) is then controlled automatically with the micro switch (21). The switching is done in sequence. Indexing without using the spiral device

6.0 6.1 6.2 6.3 6.4 6.5 7.0 7.1 7.2 7.3 7.4

Switch K.5/K2 to "OFF". Lift control roller. Pull the workpiece spindle (15) toward the back and turn to the desired index position. Lock (M2/1) index position with the index pin (20) (operated with either hand- or foot switch). To facilitate indexing, set and secure the work spindle stopper (17) while locked into the index hole. Execute grinding with the machine table. (Adjust stoppers on the machine table) Indexing using the spiral device

7.5

Switch K.5IK2 to "ON". The workpiece spindle (15) is pulled to the back activating the micro limit switch (21) which lifts the control roller off the workpiece spindle (15) electromagnetically. Now turn the workpiece spindle to the desired index position. Pull the workpiece spindle again back to activate the micro switch (21). At this time the index pin (20) is lowered into the index holes and the control roller is pressing onto the workpiece spindle (15) again. After the preset time of 0.5 - 10 seconds is passed the index pin (20) is lifted automatically and the grinding can begin. If the micro switch (21) is disabled by switching K.5IK2 to "OFF" the indexing must be done manually in the following sequence; Lift control roller M I/O - turn workpiece spindle to next index position lock index pin (20) M 2/1 - lower control roller M 1/1 - lift index pin (20) M 2/0.

8.0
8.1 8.2 8.3 8.4 8.5

Grinding the 0.0. of the tool using the support finger


Main power switch "OFF". Adjust the desired relief angle by using the scale (34) and secure with the tension lever (35). Place the support fmger (11) approximately .020" behind the cutting edge and secure with the tension lever (12). Set the support fmger (11) 90 degree to the tool and secure with tension lever (13). Push the support fmger rod (14) far enough toward the front (add some space needed to index) so that the work spindle (15) can be pulled over the entire cutting length. Lock position of the support fmger rod (14) with tension lever (16) and stopper (27). Adjust the work piece spindle stopper (17) so that the cutter tooth remains on the finger (11) by approximately .040" - .080" when the work piece spindle (15) is extended. Move the center of the fmger (11) to the grinding wheel's point of application. Secure machine table against shifting. ----

8.6

8.7

8.8 8.9 8.10

Loosen the micrometer (18) at the cross roller support (19) and adjust the stroke length to approximately .120" (3 rom). Set the rotation of the grinding wheel Oeftor right respectively) against the fmger (11) so that the grinding wheel pressure forces the cutter against the finger. Press the fIxture away from the grinding wheel using the cross slide (19) and maintain this position. Feed the work spindle (15) forward until stopped by stopper (17) and set the cutter tooth onto the support fmger (11). Release the cross slide (19) against the micrometer stop (18) and pull the cutter tooth axially over the support fmger (11) to the back. Repeat operation for every cutter tooth. The grinding feed is adjusted with the micrometer (18). The grinding operation for the second relief angle is identical to the fIrst clearance angle.

8.11 8.12 8.13 8.14

9.0 9.1 9.2 9.3

Grinding

the rake angle with the spiral device

(Fluting)

Lower control roller Kl/1; pull out index pin K2/0. Approximate setup of the spiral according to the chart (see page 12) using the scale adjustment plate (9). Precise setup of the spiral is achieved by using a dial indicator set up in the flute face. One hand is constantly stroking the workpiece spindle (15) back and forth while the other hand is turning the scale adjustment plate (9) simultaneously until a spiral run out of not more than 0.02 rom or 0.00078" is obtained over the entire cutting length .

9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 9.12 9.13 9.14

Prevent the scale adjustment plate (9) from turning by using the clamping device (10). The rake angle is ground using the hollow side of a tapered dish grinding wheeL The desired helix angle is set with the grinding wheel head - but if not possible can be set with the turn plate (1) or a combination of the two. Add approximately 1 degree to prevent double cutting. Clamp grinding machine table at the proper position. Switch K5/K2 to "OFF". With the spindle (15) free and the tool chucked, rotate the workpiece spindle (15) and adjust the height and the cross feed of the machine. Positioned the tool so that the grinding wheel touches on the cutter tooth equally from edge to bottom. At this position lower the control roller M 1/1. Pull the workpiece spindle (15) all the way back to the stop. With the quick adjustment (24) opened, insert the index pin (20) into the index plate and clamp the quick adjustment with the tension lever (25). In this position (Index pin still inserted) the scale of the index clamping device (26) is adjusted to the zero mark. Switch K5/K2 to "ON". Now begin grinding. Not to alter the rake angle on the tool, the infeed is performed radially by turning the knurled screws on the micrometer device (22). The grinding wheel wear is corrected with the machine saddle.

Calculation

of the setup angle on the UPS 155 Diameter x II = ---------------- + approx. 1 degree Lead (mmfinches) Diameter x II

tg

lead tg

10.0 Grinding
10.1 10.2 10.3

0.0. clearance

angles with the spiral device

10.4

Lower control roller M 1/1; pull out index pin M 2/0. K5/K2 "OFF" Approximate set up of the spiral according to the chart (see page 12) using the scale adjustment plate (9). Precise setup of the spiral is achieved by using a dial indicator set up in the flute face. One hand is constantly stroking the workpiece spindle (15) back and forth while the other hand is turning the scale adjustment plate (9) simultaneously until a spiral run out of not more than 0.02 mID or 0.00078" is obtained over the entire cutting length . Prevent the scale adjustment plate (9) from turning by using the clamping device (10).

10.5 10.6 10.7 10.8 10.9 10.l0 10.11 10.12 10.13 10.14

The relief angle is ground using a cylindrical or a tapered cup grinding wheeL The fIXture is turned approximately 1 degree toward the grinding wheel using the rotating base plate (1) to avoid double cutting on longer tools. Lift control roller M 1/0. Time the tool to the point of application on the grinding wheel using a height gauge (or the support fmger) and rotating the workpiece spindle. At this position lower the control roller M 1/1 and pull back the workpiece spindle (15) all the way back to the stop. Loosen the quick adjustment (24) with the lever (25). Insert the index pin (20) into the index plate. Move scale on the index plate clamping device (26) to the zero mark. Lift control roller M 1/0. In this position (Index pin (20) still inserted) choose the desired clearance angle with the scale (23) and clamp with tension lever (25). Activate micro switch (21) with toggle switch K51K2 set on "ON". Now grinding begins. The grinding feed is accomplished with the grinding machine saddle or with the micrometer (18) of the cross support. For the secondary clearance angle the quick adjustment device (24) is opened with the lever (25) and the angle is set with the scale (23). Lock the new position with lever (25). Now you must index again to reposition the cutting tool. -\

..

11.0 Grinding
ILl

the rake angle on the end of the tool

11.2 11.3 11.4 11.5

lLfi
11.7 11.8

Lift off the control roller M 1/0; insert index pin M 2/1. Adjust the spindle stop (17). Switch K5/K2 to "OFF" Set axial stop (17). The Fixture is rotated to the desired rake angle using the scale on the base plate (1). The cutting edge is lined up level with the machine table and ground with the hollow side of a tapered dish grinding wheel. The grinding movement is performed with the machine table. The grinding depth is adjusted using the machine table stopper of the grinding machine. The feed of the grinding wheel is executed by using the machine saddle.

12.0 Grinding 12.1 12.2 12.~ 12.4 12.5 12.6 12.7

the relief

angle on the end of the tool

Lift the control roller M 1/0; insert the index pin M 2/1; set up the spindle stopper (17). Line up the cutting edge of the cutter parallel to the grinding machine table with the quick adjustment (24). Rotate the fIXture to 89 degrees on the scale (3) of the base plate (1) and tighten. Cutters are ground using a cylindrical or tapered cup grinding wheel. Tilt the grinding wheel to the desired relief angle and adjust the height to the correct grinding position using the height adjustment on the machine. Primary relief angle is 6 - 8 degrees, Secondary relief angle is approximately 15 degrees. The grinding feed is executed with the grinding machine table. The infeed of the grinding wheel is performed with the machine saddle.

13.0 Grinding axial relief angle on single or multi tools, without additional cam (countersink, tap, sheet metal drill, step drill) 13.1 13.2 13.3 13.4 1a.5 13.6 13.7 13.8 13.9

fluted tapered

Lower the control roller MIll; Insert the index pin (20) M 2/1. Switch K5/K2 "OFF". Grind with the periphery of a dressed grinding wheel. Position the grinding wheel to the tool center (Center height 175 mm I 6.89") Set correct taper angle with rotating base plate (1) Set the scale adjustment plate (9) to 89 degrees 30 min. and clamp with the tension lever (10). Index is positioned between the teeth. Position the machine table to the stop. Pull the index pin (20) M 2/0 and relief the fIrst cutting edge. If adjustment is necessary after the fIrst grind, move the scale adjustment plate (9) accordingly. The infeed of the grinding wheel is executed by using the machine saddle. Pull the machine table back. Index and repeat this operation until all flutes are done.

3 flutes countersink 90 deg. Setting of the scale adjustment plate (9) approx. 89 deg. 30 min.

Tap Setting of the scale adjustment plate (9) approx. 87 deg.

1~.0 Grinding 14.1 14..2 14.3 14.4 14.5 14.6

with controlled

slippage

on roughing

end mills

Set up grinding wheel into the rake angle. The radial infeed during grinding is executed by generating a slippage between the control roller and the work spindle. The amount of slippage is adjustable with the rheostat at the electrical box. For larger diameter tools apply more pressure to the workpiece spindle and apply less for smaller tools. On a right spiral for example, the workpiece spindle (15) is turned to the right and back pressure is applied slightly. This procedure is generating a radial infeed. Start grinding from the index position. The strokes are counted e.g. 5 or 10 per tooth. In this manner every tooth is ground equally, starting from its index position. After all teeth have been ground according to that procedure, index the workpiece spindle (15). The acquired gap between tooth and grinding wheel is compensated radially with the micro adjustment (22). The cutter is now ground without slippage into the exact index.

11

- .. --30 ---- ------- ....--------------------------------------------3.429.0 1.890 48.0 295.4 31.81156 29.094 53 0.650 6.870 5.008 4160 42251.4 4465 71 84 22.1 72 54.1 174.5 51.0 2.252 69 70 194.0 88.4258.25 mm/R 2246 3.287 3.150 26.772 22 11.157 11.630 12.138 12.677 3.717 0.000 0.108 0.217 0.325 0.433 4.173 0.541 4.331 3.866 6.634 4362 55141.4 89261.4 88272.1 584 57409 87 85 86 73 11.0 13.75 168.5 110.0 283.4 102.0 308.3 24.803 89 21.575 37 23.071 70 20.236 17.953 15.315 16.988 2.130 0.870 2.008 4.492 1.201 0.980 4.831 1.315 1.429 1.772 1.657 1.543 7.114 1.091 5.189 6.185 5.768 6.406 5.972 45241.9 4763 4673.3 54136.6 52131.8 49106.0 51118.4 503 48891 30.5 81 27.7 80 33.4 36.3 42.1 45.0 39.2 79 24.9 82 78 77 75 74 180.7 16.5 157.1 146.5 162.7 151.7 44.0162.752997 50.3545 4.4 Inch/R 39.055992 Inch/R Chart for 35.079Deg. 14.567 2.626 2.374 2.500 0.760 4.661 7.638 7.917 7.370 4061 39114.1 53122.7 37Deg. 38739 60.3 57.2 208.5 201.1 83 187.2 66.7 67 63.5 68 19.3 1279 1118 36548 216.2 66 70.66998.2 4498 2.886 3.016 9.169 8.831 35630 34 224.3 76.6 64 232.9 1795 10.291 9.898 9.524 31680 32586 33514 87.1 90.7 83.5 80.0 13.268 4.016 56127.2 59808 13.898 16.102 5.378 5.567 76 431.5 483.5 8.209 58.8580.5 mm/R lead of tool (in.) 2.752 8.512 69.9 1495 10.713 3.571 15.019.035 8999 inches 1.9685" x 3.1416 setting up helix Conversion d of tool (mm) ---0 metric x 3.1416 cessary: spindle Deg. Inch/Ran scale based on the work spindle diameter of 50 mm) For lead work = Setting of tg calculation see on page 8. (calculation (9)
..

angle on the scale

(9)

12

16.0 Axial 16.1

relieving

attachment

for step drills

(optional)

Mounting and operatingthe ~ttpYing device To mOWltthe device insert 3 index pins into the index holes spaced 120 degrees apart.

16.2

Slide the device from the back, over the workpiece spindle (15) Wltil the index pins are flush with the plane of the spindle guide. Clamp the device with the allen screw M6. By repositioning the pins the index can be changed to 1-2-3-4-6indexes.

Indexing Device

16.3

Mounting and operating the adjustablecaIn The earn is mOWlted onto the work spindle and clamped with the M6 allen screw.

I
Adjustable Carn

To adjust the earn there are two allen screws M6 where as one is at the circumference of the earn and marked with O. This screw is turned all the way in against the stop, whereas the allen screw on the opposite side should be loosened. At this position there is no pitch noticeable. Now 13

the screw at the zero mark is turned away from the stop and the opposite screw turned in against its stop. One revolution with the screw marked 0 equals a lead of .157" (4 rom) per revolution on the cam, whereas the cam is producing a 180 deg. right-hand and a 180 deg. left-hand helix. The highest point on the cam is marked with a pointer. To grind a right-hand spiral the pointer is positioned to the right of the index pin on the indexing device. To grind a left-hand spiral the pointer is positioned to the left of the index pin. With the adjustable caw no linear helix can be produced. 16..(
MOlmtiol!.

grinding and operating the clamping device for individual cams

The raw cam is inserted into the clamping device and locked with the M6 allen screw.

Clamping device with cam

Grinding the cam

16.5

To grind the cam demount the index device (26) off the workpiece spindle (15), mount the clamping device instead and lock with the allen screw M6. Now dial in your desired lead angle with the scale (9). To determine the helix angle easier, set up a dial indicator to the face of the cam. By advancing the workpiece spindle (15) one revolution the lead is indicated on the dial. The flat side of the earn must be ground rectangularly and will produce a linear helix angle in opposition to the adjustable cam.

Individual earn with index

Grinding step drills

14

16.6

To grind a tool the cam is mounted at the end of the workpiece spindle (15) and clamped with the allen screw M6. The earn is followed over the index pins on the indexing device. A separate cam must be ground to produce either a left or a right-hand spiral. the tapered tool attachment

17.0 Mounting 17.1

Swing the universal grinding device perpendicular to the grinding machine table and unscrew the support (33).

17.2

Replace with the support for the taper attachment and swing fIXture back on the machine table. With the new support plate, a slot is provided to position the adaptor for the sin bar. Tighten screw. The bearing is mounted onto the workpiece spindle (15) and by turning the eccentric, locked into position. Slightly tighten safety screw in the eccentric without (Iamag;ng the workpiece spindle.

17.3

17.4

Open the micrometer (18) of the cross roller support far enough so that the bearing is touching the sine bar during the entire cutting length. In order to achieve a precision taper it is recommended to check the sine bar and the spindle (15) with a dial indicator. If necessary line up the new support plate.

17.5

15

19.0 Service

and Maintenance

In order for the Universal Spiral Grinding System to work properly, please follow the instructions below: 19.1 19.2 19.3 When the Device is mounted on and removed from the base machine, the cross roller slides must be locked by setting the micrometer (18) to the zero position. The workpiece spindle (15) must be secured from any movement with the spindle stopper (17). A unlocked spindle may cause damage to the micro limit switch (21). Neither the tension ring (26) for the index plate nor the drawbar should be loosened while the index pin is inserted. The index pin can be damaged if too much side pressure is executed. This could result in indexing errors. For absolute smooth operation of the workpiece spindle, a few drops of light spindle oil should be applied daily to the two lip seals.

19.4

16

1 7

20.0 Diagram

for control

roller and scale adjustment

20

20.0 Adjustment of the control roller


20.1 20.2 20.3 20.4 20.5 20.6 20.7 20.8
2().9

(See Diagram on page 18)

20.10 20.11 20.12 20.13

Lock the scale plate (6) with the tension lever (4). Loosen the hexagonal socket screw (1). Loosen the tension lever (4) and the screw (3). Place the tension lever (4) and tension piece (5) aside. Remove scale plate (6) and washer (2). Loosen all four hexagonal socket screws (7) and remove the head plate (8). Loosen the locking screw (10) in the counter nut (9) and unscrew with spanner wrench. Loosen the locking screw (12) in the lower counter nut (13). With the spanner wrench, turn the counter nut (13) slightly to the right on the control roll shaft (19) - the pressure between the control roll and the workpiece spindle should be increasing. Important: If the counter nut (13) is turned too far to the right, the pressure will start to decrease. In that case turn counter nut (13) to the left. Now begin turning to the right again to find the highest pressure setting. To test the pressure, the slots (11) of the control roller shaft must be parallel to the workpiece spindle then turn the spindle by hand. If the pressure is satisfactory, begin assembly. Tighten the locking screw (12) in the counter nut (13) so that counter nut (13) cannot move. Turn the top counter nut (9) by hand onto the lower counter nut (13). Then back off the counter nut (9) one half turn. In this position tighten the counter nut (9) with the locking screw
(10).

20.14 2~).15

29.16
20.17

20.19

2p.20 20.21 2p.22

Screw the head plate (8) on using the four socket screws (7). Mount the scale plate (6) using the washer (2) and tighten lightly with the screw (1). Mount the tension piece (5) with tension lever (4) and secure with the screw (3). Resetting the scale plate (6): Tighten the stopper (15) on the workpiece spindle with the tension lever (14) at the permanent stop (20). Turn the scale ring (6) until the stopper (15) can be turned radially on the permanent stop (20) without seeing a light gap. Loosen the socket screw (1) and turn the scale ring to the 90 degree position. Maintain the scale ring (6) position with the tension piece (5) and tightly lock the socket screw
(1).

The fme adjustment of the scale plate (6) is done by adjusting the vernier (17). Loosen the two screws (18) and adjust the vernier (17). Make sure the vernier is not touching the scale ring (6).

21.0 Adjusting the micro switch (21)


2.1.1 21.2

2L3
2L4 21.5

2L6

If the micro switch is not adjusted right, indexing mistake can happen. It is corrected as follow; Insert index pin (20) into the index plate and switch K2 so that index pin (20) stays inserted. Open counter nut at the micro switch (21) with 5.5 mm wrench. Set a dial indicator with magnetic base on top of the mounting screw of the helix adjustment scale (9). Turn the adjustment screw at the micro switch (21) to the right until the electromagnet is switching the control roller. The dial indicator has moved up approximately .001" (0.25 mm). No the control roller has released the workpiece spindle (15). The index pin (20) stays in the index plate. The adjustment screw at the micro switch (21) is now turned to the left until the electromagnet is switching the control roller - Dial indicator moved downward. Add another half turn to the left to assure proper switching, then counter lock with nut. Now it is assured that the control roller is switching before indexing and thus eliminating index errors.

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