INSTRUCTIONS FOR USE LA, MAMMUT & STR KNURLING TOOLS
Contents
CONTENTS 1. General .............................................................. 2 1.1 Introduction................................................ 2 1.2 Tool Construction....................................... 3 2. LA-Tool .............................................................. 5 2.1 Technical Data........................................... 5 2.2 Overview: Main Components..................... 6 2.3 Tool Adjustment LA/KF .............................. 7 2.4 Tool Adjustment LA/FL............................. 11 3. Mammut-Tool .................................................. 15 3.1 Technical Data......................................... 15 3.2 Overview: Main Components................... 16 3.3 Tool Adjustment M/KF.............................. 17 3.4 Tool Adjustment M/FL .............................. 21
5. Wear Parts .......................................................32 6. Knurling of Stepped Workpieces ..................32 7. Knurl Cutters with Bevel ................................34 8. Troubleshooting..............................................35 9. Dimensions and Pitches Available................37 10. Reference Values for Feeds and Cutting Speeds ...........................................................39
4. STR-Tool.......................................................... 25 4.1 Technical Data......................................... 25 4.2 Overview: Main Components................... 27 4.3 Tool Adjustment STR ............................... 28
1
General Introduction
1. General 1.1 Introduction Please read through the Instructions for Use carefully before using the QUICK knurl cutting tools! The instructions have been written for operators with qualified training in the field of machining and cutting. Compliance with the Instructions for Use increases reliability in use,
Symbols in these instructions ATTENTION: This Symbol warns that operating procedures carried out without paying attention to the measures specified may lead to damage to the tool and/or the machine tool.
increases the service life of the tools,
NOTE:
and prevents downtimes.
This Symbol refers to further information and provides additional information for using the Quick knurling tools.
We reserve the right to make alterations to the technical details of the tools by comparison with the information and illustrations contained in these Instructions for Use.
Text markups: This symbol identifies lists This symbol identifies an action sequence
Swarovski Optik KG
2
General Tool Construction
1.2 Tool Construction QUICK knurl cutting tools are easy to operate and flexible in use due to their design, and may be employed on all lathes from conventional to CNCcontrolled automatic lathes, as a left-hand or righthand tool depending on the type of tool.
The tools have a cutting action, are free-cutting and it is not possible to make them adopt a specific speed ratio to the diameter of the workpiece by means of sustained forcing. As a result the number of teeth of the knurl produced may differ. The difference is approx. +/- 1-3 teeth depending on the pitch.
Type of knurl
DIN 82
Tool
Knurl cutters
Straight knurl
RAA
LA/FL, M/FL STR
30°L / 30°R
Spiral knurl
RBL / RBR
LA/FL, M/FL
As required
Cross knurl
similar to RKE
LA/KF, M/KF STR
15°L + 15°R
RGE
LA/KF, M/KF STR
2 x 90°
Diamond knurl
3
General Tool Construction
Tool definition LA-model range
Perfect results may be achieved with:
LA knurl cutting tools are available in both righthand and left-hand versions. Use only tools marked R (right-hand version) in holders for right-hand cutting tools and tools marked L (left-hand version) in holders for left-hand cutting tools.
Correct adjustment
left
right
left
right
Tool definition Mammut-model range Knurl cutting tools of the Mammut range are only available in a right-hand version.
4
Closely following the instructions regarding the start of the knurling process Appropriate feed and cutting speed Selection of the correct tool size. QUICK knurl cutter tools with large dimensioned knurl cutters, e.g. Ø 42 mm instead of Ø 32, have a longer service life NOTE: It is imperative to ensure an abundant supply of coolant or cutting oil directly onto the knurl cutters to ensure perfect cooling and lubrication of the knurl cutters.
LA-Tool Technical Data
2. LA-Tool 2.1 Technical Data 8/10/12
20 28
Cross and diamond Ø 1.5-12 mm 8x8, 10x10 or 12x12 mm / L or R Ø 8.9 mm 1 x 15°L and 1 x 15°R 2 x 90° see page 37 0.15 kg
83 105
Straight and spiral Ø 1.5-12 mm 8x8, 10x10 or 12x12 mm / L or R Ø 8.9 mm 1 x 30°L / 30°R
8/10/12
20
20
LA/FL Types of knurl Working range Shank dimension Knurl cutters Straight Spiral Pitches Weight
22
20
LA/KF Types of knurl Working range Shank dimension Knurl cutters Cross Diamond Pitches Weight
as required
see page 37 0.13 kg
88 108
(figure — right-hand tool)
5
LA-Tool Overview: Main Components
2.2 Overview: Main Components Pos. Designation 1
Tool head
1.1
Cutter holder
2
Screw
3
Washer
4
Knurl cutter
5
Bushing
6
Scale ring (diameter adjustment)
7
Index point
8
Clamping screw
9
Shank
10
Adjusting screw — tool correction
LA/KF 2
3
5 1.1
4
1
A
A 10
9
6
7
8
LA/FL 2
3
4
5
1.1
1
A
A 9
10
1 1.1
(figure — right-hand tool)
6
LA-Tool Tool Adjustment LA/KF
2.3 Tool Adjustment LA/KF Preliminary work:
Step 2: Install knurl cutters
Clamp workpiece and turn Maximum out-of-roundness 0.03 mm
Clean the contact surface of bushing 5 and cutter holder 1.1.
Step 1: Cutter selection
Coat bushing 5 and the face ends as well as the hole of knurl cutter 4 with a little Molykote G paste
Cross knurl: 1x 15° left-hand spiral toothed knurl cutter on cutter holder „L“ 1x 15° right-hand spiral toothed knurl cutter on cutter holder „R“
With knurl cutter 4 and washer 3 pushed on, insert bushing 5 into the cutter holder Screw in screw 2 and only tighten enough to allow knurl cutter 4 to rotate free of play 2
Diamond knurl:
3
4
5
1.1
2x 90° toothed knurl cutters L
LA/KF R R
7
LA-Tool Tool Adjustment LA/KF
Step 4: Clamp tool in tool holder
Step 3: Set diameter Measure off workpiece diameter Unscrew clamping screw 8
Step 5: Pre-adjust turning centre
Turn scale ring 6 until the required diameter aligns with index point 7
The tool must be centered when used on conventional lathes.
Clamp clamping screw 8 6
7
8
NOTE: This adjustment does not apply when used on CNC machines as the tools are already centered.
8
LA-Tool Tool Adjustment LA/KF
Step 6: Re-align turning centre Carefully bring into contact with the workpiece Both cutters must be in contact simultaneously. Precision adjustment is carried out using adjusting screw 10 When adjusting by way of screw 10a, first loosen screw 10b and vice versa Tighten the opposing screw again hand-tight when adjustment is complete 10a
Sequence: Unscrew clamping screw 8 Adjust scale ring 6 slightly towards the next smaller diameter until the correct cutter setting is reached Tighten clamping screw 8 6
8
10b
Step 7: Adjust cutter The ideal position of the knurling cutters is when they lie parallel on the workpiece and still cut very slightly, i.e. the cutting edge of the cutters can be pressed in somewhat deeper (approx. 1-2°). In the case of materials which are hard to machine, the knurling cutters may be inclined up to max. 3-4°.
9
LA-Tool Tool Adjustment LA/KF
Step 8: Start of knurl The start of the knurl should be in a width no greater than 1,0 mm. With this width now move the tool to the full depth without interruption. The feed on infeeding should be approx. 0.05-0.1 mm. The knurling depth corresponds to the pitch of the knurling cutter being used, e.g. 1.0 mm pitch requires 1.0 mm infeed with reference to the diameter. The depth is measured from the knurling cutter's point of contact with the workpiece. After an idle time of 2-3 seconds, the workpiece is knurled by using the longitudinal feed. The surface deformation of the workpiece cannot be determined exactly as this is different from material to material. The knurling depth, however, should be sufficient to ensure that the knurl is only just sharp. max 1,0 mm
ATTENTION: Under no circumstances knurl with longitudinal feed into the face edge of the workpiece. Starting the knurl within the workpiece can be done only in certain circumstances. NOTE: Note that the protective bevel at the beginning of the workpiece may not be applied until knurling is complete. The coarser the pitch, the smaller the feed. Feed and cutting speed have no effect on the knurl pitch.
Step 9: Knurling NOTE: If the knurl is not accurate or is onesided, then the knurling process may be repeated after correcting the tool.
10
LA-Tool Tool Adjustment LA/FL
2.4 Tool Adjustment LA/FL Preliminary:
Step 2: Install knurl cutters
Clamp workpiece and turn Maximum out-of-roundness 0.03 mm
Clean the contact surface of bushing 5 and cutter holder 1.1.
Step 1: Cutter selection
Coat bushing 5 and the face ends as well as the hole of knurl cutter 4 with a little Molykote G paste
Straight knurl – right-hand tool: 1x 30° right-hand spiral toothed knurl cutter Straight knurl - left-hand tool: 1x 30° left-hand spiral toothed knurl cutter NOTE: Right-hand tool requires the workpiece to rotate in a clockwise direction. Left-hand tool requires the workpiece to rotate in an anti-clockwise direction.
With knurl cutter 4 and washer 3 pushed on, insert bushing 5 into the cutter holder Screw in screw 2 and only tighten enough to allow knurl cutter 4 to rotate free of play 2
3
4
5
1.1
Spiral knurl: Knurl cutters are to be mounted with 15°, 30° or 90° spirals depending on the pitch of the spiral desired on the workpiece. It is advisable due to the large number of possible variations to consult your dealer or the manufacturer.
11
LA-Tool Tool Adjustment LA/FL
Step 3: Clamp tool in tool holder Step 4: Adjust turning centre The tool must be centered when used on conventional lathes.
NOTE: This adjustment does not apply when used on CNC machines as the tools are already centered.
12
Step 5: Adjust cutter The ideal position of the knurling cutters is when they lie parallel on the workpiece and still cut very slightly, i.e. the cutting edge of the cutters can be pressed in somewhat deeper (approx. 1-2°). In the case of materials which are hard to machine, the knurling cutters may be inclined up to max. 3-4°.
Sequence: Correction is achieved by turning the tool slightly in the tool holder
LA-Tool Tool Adjustment LA/FL
Step 6: Start of knurl The start of the knurl should be in a width no greater than 1,0 mm. With this width now move the tool to the full depth without interruption. The feed on infeeding should be approx. 0.05-0.1 mm. The knurling depth corresponds to the pitch of the knurling cutter being used, e.g. 1.0 mm pitch requires 1.0 mm infeed with reference to the diameter. The depth is measured from the knurling cutter's point of contact with the workpiece. After an idle time of 2-3 seconds, the workpiece is knurled by using the longitudinal feed. The surface deformation of the workpiece cannot be determined exactly as this is different from material to material. The knurling depth, however, should be sufficient to ensure that the knurl is only just sharp.
ATTENTION: Under no circumstances knurl with longitudinal feed into the face edge of the workpiece. Starting the knurl within the workpiece can be done only in certain circumstances. NOTE: Note that the protective bevel at the beginning of the workpiece may not be applied until knurling is complete. The coarser the pitch, the smaller the feed. Feed and cutting speed have no effect on the knurl pitch.
max 1,0 mm
13
LA-Tool Tool Adjustment LA/FL
Step 7: Knurling If the track generated does not run paraxially, this may be put right by correcting the two adjusting screws 10. ď‚„ When adjusting by way of screw 10a, first loosen screw 10b and vice versa ď‚„ Tighten the opposing screw again hand-tight when adjustment is complete
10a
10b
Note: If the knurl is not accurate or is onesided, then the knurling process may be repeated after correcting the tool.
14
Mammut-Tool Technical Data
3. Mammut-Tool 3.1 Technical Data
as required
see page 37 1.6 kg
40 (60)
79 (117)
45 (68) 27 104 55
120
35
Straight and spiral Ø 20-3000 mm 35x27 mm Ø 42 mm 1 x 30°R
280 (445)
110 (165)
Cross and diamond Ø 20-1000 mm (30-3000 mm) 45x40 mm (90x60 mm) Ø 32 mm (42 mm) 1 x 15°L and 1 x 15°R 2 x 90° see page 37 6 kg (18 kg)
57
M/FL Types of knurl Working range Shank dimension Knurl cutters Straight Spiral Pitches Weight
160 (275)
(Dimensions in brackets MII/KF)
71
MI-MII/KF Types of knurl Working range Shank dimension Knurl cutters Cross Diamond Pitches Weight
150 195
15
Mammut-Tool Overview: Main Components
3.2 Overview: Main Components Pos. Designation Screw Washer
4
Knurl cutter
5
Bushing
6
Scale ring (diameter adjustment)
7
Index point
8
Clamping screws
9
Shank
10
Adjusting screw — tool correction
11
Locking screw / Clamping screw (M/FL)
12
Hexagonal nut
2
3
4
5
1
9
11 10 11 7
8
A
A
8
M/FL 2
3
4
5
1
9
10
A
12
16
6
80
2 3
M/KF
20 0
Tool head
120
1
11
A
10
1
Mammut-Tool Tool Adjustment M/KF
3.3 Tool Adjustment M/KF Preliminary work:
Step 2: Install knurl cutters
Clamp workpiece and turn Maximum out-of-roundness: 0.05 mm
Clean the contact surface of bushing 5 and cutter holder 1.1.
Step 1: Cutter selection
Coat bushing 5 and the face ends as well as the hole of knurl cutter 4 with a little Molykote G paste
Cross knurl: 1x 15° left-hand spiral toothed knurl cutter on the cutter holder closest to scale ring 6 1x 15° right-hand spiral toothed knurl cutter on the opposing cutter holder Diamond knurl: 2x 90° toothed knurl cutters
With knurl cutter 4 and washer 3 pushed on, insert bushing 5 into the cutter holder Screw in screw 2 and only tighten enough to allow knurl cutter 4 to rotate free of play 2
3
4
5
1.1
6
17
Mammut-Tool Tool Adjustment M/KF
Step 3: Set diameter
Step 4: Clamp tool in tool holder
Measure off workpiece diameter Unscrew clamping screw 8
Step 5: Pre-adjust turning centre
Turn scale ring 6 until the required diameter aligns with index point 7
Clamp tool in carriage so that holder shank is perpendicular to rotary axis
Clamp clamping screw 8
Align centering device C at tip height on the swivel axis
6 7 80
0
8
18
0 20
120
8
80
120
20
C
Mammut-Tool Tool Adjustment M/KF
Step 6: Re-align turning centre Carefully bring into contact with the workpiece Both cutters must be in contact simultaneously. Unscrew locking screws 11 and carry out realignment using adjustment screw 10 Once the adjustment has been made, tighten locking screws 11 and screw down hand-tight
11
0 20
120
10
80
11
the knurling cutters may be inclined up to max. 3-4°.
Sequence: Unscrew clamping screw 8 Adjust scale ring 6 slightly towards the next smaller diameter until the correct cutter setting is reached Tighten clamping screw 8
The ideal position of the knurling cutters is when they lie parallel on the workpiece and still cut very slightly, i.e. the cutting edge of the cutters can be pressed in somewhat deeper (approx. 1-2°). In the case of materials which are hard to machine,
0 20
120
Step 7: Adjust cutter
80
6
8 8
19
Mammut-Tool Tool Adjustment M/KF
Step 8: Start of knurl The start of the knurl should be in a width no greater than 3.0 mm. With this width now move the tool to the full depth without interruption. The feed on infeeding should be approx. 0.05-0.1 mm. The knurling depth corresponds to the pitch of the knurling cutter being used, e.g. 1.0 mm pitch requires 1.0 mm infeed with reference to the diameter. The depth is measured from the knurling cutter's point of contact with the workpiece. After an idle time of 2-3 seconds, the workpiece is knurled by using the longitudinal feed. The surface deformation of the workpiece cannot be determined exactly as this is different from material to material. The knurling depth, however, should be sufficient to ensure that the knurl is only just sharp. max 3,0 mm
ATTENTION: Under no circumstances knurl with longitudinal feed into the face edge of the workpiece. Starting the knurl within the workpiece can be done only in certain circumstances. NOTE: Note that the protective bevel at the beginning of the workpiece may not be applied until knurling is complete. The coarser the pitch, the smaller the feed. Feed and cutting speed have no effect on the knurl pitch.
Step 9: Knurling NOTE: If the knurl is not accurate or is onesided, then the knurling process may be repeated after correcting the tool.
20
Mammut-Tool Tool Adjustment M/FL
3.4 Tool Adjustment M/FL Preliminary work:
Step 2: Install knurl cutters
Clamp workpiece and turn Maximum out-of-roundness 0.03 mm
Clean the contact surface of bushing 5 and cutter holder 1.1.
Step 1: Cutter selection
Coat bushing 5 and the face ends as well as the hole of knurl cutter 4 with a little Molykote G paste
Straight knurl – right-hand tool: 1x 30° right-hand spiral toothed knurl cutter NOTE: Right-hand tool requires the workpiece to rotate in a clockwise direction.
With knurl cutter 4 and washer 3 pushed on, insert bushing 5 into the cutter holder Screw in screw 2 and only tighten enough to allow knurl cutter 4 to rotate free of play 2
3
4
5
1.1
Spiral knurl: Knurl cutters are to be mounted with 15°, 30° or 90° spirals depending on the pitch of the spiral desired on the workpiece. It is advisable due to the large number of possible variations to consult your dealer or the manufacturer.
21
Mammut-Tool Tool Adjustment M/FL
Step 3: Clamp tool in tool holder Step 4: Adjust turning centre Clamp tool in carriage so that holder shank is perpendicular to rotary axis Align centering device C at tip height on the swivel axis
Step 5: Adjust cutter The ideal position of the knurling cutters is when they lie parallel on the workpiece and still cut very slightly, i.e. the cutting edge of the cutters can be pressed in somewhat deeper (approx. 1-2°). In the case of materials which are hard to machine, the knurling cutters may be inclined up to max. 3-4°.
C
Sequence: Correction is achieved by turning the tool slightly in the tool holder
22
Mammut-Tool Tool Adjustment M/FL
Step 6: Start of knurl The start of the knurl should be in a width no greater than 3.0 mm. With this width now move the tool to the full depth without interruption. The feed on infeeding should be approx. 0.05-0.1 mm. The knurling depth corresponds to the pitch of the knurling cutter being used, e.g. 1.0 mm pitch requires 1.0 mm infeed with reference to the diameter. The depth is measured from the knurling cutter's point of contact with the workpiece. After an idle time of 2-3 seconds, the workpiece is knurled by using the longitudinal feed. The surface deformation of the workpiece cannot be determined exactly as this is different from material to material. The knurling depth, however, should be sufficient to ensure that the knurl is only just sharp.
ATTENTION: Under no circumstances knurl with longitudinal feed into the face edge of the workpiece. Starting the knurl within the workpiece can be done only in certain circumstances. NOTE: Note that the protective bevel at the beginning of the workpiece may not be applied until knurling is complete. The coarser the pitch, the smaller the feed. Feed and cutting speed have no effect on the knurl pitch.
max 3,0 mm
23
Mammut-Tool Tool Adjustment M/FL
Step 7: Knurling If the track generated does not run paraxially, this may be put right by correcting the two adjusting screws 10. Unscrew hexagonal nut 12 Unscrew clamping screw 11 and subsequently tighten lightly again to achieve a tolerance-free adjustment When adjusting by way of screw 10a, first loosen screw 10b and vice versa Tighten the opposing screw again hand-tight when adjustment is complete Tighten clamping screw 11 and hexagonal nut 12 12 10a 11 10b
24
NOTE: If the knurl is not accurate or is onesided, then the knurling process may be repeated after correcting the tool.
STR-Tool Technical Data
4. STR-Tool 4.1 Technical Data A
(Dimensions in brackets STR/B)
E D
Cross, diamond and straight Ø 2.8 (core Ø)-25 mm (Ø 5-55 mm) see page 26 Ø 14.5 mm (21.5 mm) 2 x 15°R and 1 x 15°L 3 x 90° 2 x 30°L and 1 x 30°R see page 37 0.5 kg (2.0 kg) 20 mm (35 mm)
B
STR/A-STR/B Types of knurl Working range Shank diameter Knurl cutters Cross Diamond Straight Pitches Weight Bore of knurling head (A) Bore length (B) Knurling head Ø (C) Length of knurling head (D) Length of cutter holder (E)
25.5 mm (37 mm) 54 mm (95 mm) 37 mm (52 mm) 15 mm (30 mm)
C
25
STR-Tool Technical Data
Clamping length (G) 50 mm 50 mm 50 mm 50 mm 50 mm 50 mm 69 mm
Bore Ø (H) 9 mm 10 mm 15 mm 9 mm 9 mm 15 mm 8,5 mm
Shanks STR/B Clamping Ø (F) 20 mm 25 mm 30 mm 1“ 1 ¼“ 1 ½“ MK3
Clamping length (G) 70 mm 70 mm 70 mm 70 mm 70 mm 70 mm 86 mm
Bore Ø (H) 10 mm 15 mm 18 mm 15 mm 18 mm 25 mm 10 mm
26
G
Shanks STR/A Clamping Ø (F) 15 mm 20 mm 25 mm ¾“ ⅝“ 1“ MK2
H
F
STR-Tool Overview: Main Components
4.2 Overview: Main Components Pos. Designation 1
Tool head
2 3
Countersunk screw Washer
4
Knurl cutter
5
Bushing
6
Cutter holder „0“
7
Cutter holder „1“
8
Clamping segment
9
Clamping screw
10
Set spindle
11
Set spindle for opposite spindle
12
Shank
13
Cheese-head screw — to mount shank
6
2
3
4
1
11
8
10
12
5
13
7
9
6
27
STR-Tool Tool Adjustment STR
4.3 Tool Adjustment STR Preliminary work:
Step 1: Install shank
Clamp workpiece and turn Maximum out-of-roundness 0.03 mm
Attach shank 12 to tool head 1 using three hexagonal socket head screws 13
Turn a shoulder or, with smaller pitches up to 0.6 mm, a 30° bevel
13
1
ø-0,5xT
30°
12
1,5xT
1,5xT
T = pitch NOTE: This chamfering means that the knurl cutters only have to remove a small amount of material at the beginning and can therefore centre themselves better. The shoulder is particularly important for flat knurls.
28
13
STR-Tool Tool Adjustment STR
Step 2: Cutter selection
Step 3: Install knurl cutters
Straight knurl:
Clean the contact surface of bushing 5 and cutter holder 1.1.
2x 30°L knurl cutter on cutter holder„0“
Coat bushing 5 and the face ends as well as the hole of knurl cutter 4 with a little Molykote G paste
1x 30°R knurl cutter on cutter holder„1“ Cross knurl: 2x 15°R knurl cutter on cutter holder„0“ 1x 15°L knurl cutter on cutter holder„1“ Diamond knurl:
With knurl cutter 4 and washer 3 pushed on, insert bushing 5 into the cutter holder Screw in countersunk screw 2 and only tighten enough to allow knurl cutter 4 to rotate free of play
2x 90° knurl cutter on cutter holder„0“ 1x 90° knurl cutter on cutter holder„1“
1.1 2
3
4
5
0
0
1
Step 4: Clamp tool in tool holder
29
STR-Tool Tool Adjustment STR
Step 5: Set diameter Version with infeed Unscrew six clamping screws 9 on the clamping jaws Open cutter holder 6 by means of positioning spindles 10 and cutter holder 7 via central positioning spindle 11 enough for the tool to be positioned above the workpiece Position the tool above the workpiece and lightly tighten clamping screws 9 Adjust positioning spindles 10/11 individually until the knurl cutters just touch the workpiece lightly 4
6
10
7
30
9
11
6
10
Retract the knurl cutting tool for subsequent infeed The infeed depth is adjusted in the direction of the arrow using the indexing on positioning spindles 10/11 The number of index pitches to be adjusted is calculated as follows: Cutter pitch (T)/2 x 7, results in an adjustment by 3.5 index pitches for a cutter pitch of 1 mm for example Adjust the cutter holders individually by the value calculated and then screw down clamping screws 9 hand-tight 10
9
11
10
STR-Tool Tool Adjustment STR
Version - Adjustment to core diameter Turn workpiece to knurl core diameter DK Unscrew six clamping screws 9 on the clamping jaws Open cutter holder 6 by means of positioning spindles 10 and cutter holder 7 via central positioning spindle 11 enough for the tool to be positioned above the workpiece Position tool above shoulder and lightly tighten clamping screws 9 6
10
9
11
10
Retract knurl milling tool Screw down clamping screws 9 hand-tight
Step 6: Start of knurl Feed in quickly to the shoulder and only very little into the full material using a feed rate of 0.10.15 mm/rev After an idle time of 2-3 seconds, the workpiece is knurled by using the longitudinal feed
DK
4
Adjust positioning spindles 10/11 individually until the knurl cutters just touch the workpiece lightly on core diameter DK
After completing the knurl, retract the tool in rapid traverse
7
6
The coarser the pitch, the smaller the feed. Feed and cutting speed have no effect on the knurl pitch.
31
Wear Parts Tool Adjustment STR
5. Wear Parts
6. Knurling of Stepped Workpieces
The fixing elements for the knurl cutters of the QUICK knurl cutting tools are wear parts and must be replaced frequently.
It must be noted that with all QUICK knurl cutting tools it is not possible to knurl right up to a shoulder due to the inclined position of the knurl cutters. Please refer to the table for dimensions.
1a
1b
1c
2a
2a
2b
3
3
3
a
b
Pos. 1a 1b 1c 2a 2b 3
32
Designation
Typ
Slot screw Cheese-head screw Countersunk screw Washer Washer Bushing
LA M/KF, M/FL STR LA, M/KF, M/FL STR
Knurling of Stepped Workpieces
Distance b corresponds to the Ø of the knurl cutters Ø 8.9
Ø 14.5
Ø 21.5
Ø 32
Ø 42
b 1.0 2.5 3.0
b 1.3 1.8 2.2
b 2 2.6 3.0
b 1.5 2.5 3.1
b 1.8 3.0 4.3
4
2.6
3.8
3.8
5.7
5
2.8
4.5
4.5
6.7
6
3.1
4.7
5.1
7.5
7
5
6.2
8.1
8
5.3
7.6
8.6
9
5.3
a 1 2 3
9.4
9.1
10
9.8
9.5
11
10.4
9.8
12
10.6
10.1
13
10.8
12.2
14
11.1
13.1
15
13.6
16
14.1
18
14.6
33
Knurl Cutters with Bevel
7. Knurl Cutters with Bevel A knurl cutter's teeth may break off when knurling "hard" materials.
Arrangement for KF- tools
It is possible to increase the knurl cutter's service life by cutting a 45° bevel. This is only applicable for the KF and STR models. The drawing beside shows which knurl cutter may have bevel. Ø 32 mm and Ø 42 mm cutters are already produced with bevel. 0,5 x t 45°
34
t
Arrangement for STR- tools
Troubleshooting
8. Troubleshooting KF-Tools
FL-Tools
Knurl trailing spirally
Knurl trailing spirally
Correct position of head using precision adjustment screws Look at start of knurl Look at knurling depth Tool tilted sideways -> check position Clearance of tool too positive or too negative
Look at start of knurl Look at knurling depth Tool tilted sideways -> check position Clearance of tool too positive or too negative
Overlapping of the knurl (double knurl) Incorrect adjustment of diameter Approach to knurl depth too slow as a result of which too little guidance of knurl cutters in track Look at start of knurl
Teeth of knurl cutters knocked off
Overlapping of the knurl (double knurl) Approach to knurl depth too slow as a result of which too little guidance of knurl cutters in track Look at start of knurl
Bevel knurl cutters with hard materials Knurl cutter has been overloaded too much feed, cutting depth too great Incorrect adjustment of diameter Fixing screws of knurl cutters loose Look at adjustment of cutters
Teeth of knurl cutters knocked off
Unevenly deep knurl track
Seizing of knurl cutters on bushing
Re-align position of head using spindle
Seizing of knurl cutters on bushing (see FL)
Knurl cutter has been overloaded feed too great, cutting depth too great Fixing screws of knurl cutters loose Look at direction of rotation Look at adjustment of cutters Reduce cutting speed Use Molykote paste Coolant jet directly onto the knurl cutter
35
Troubleshooting
STR-Tools Knurl does not come up to the requirements
Seizing of knurl cutters on bushing
Are the knurl cutters on the right holder? Tool head and workpiece axis are not aligned All three knurl cutters do not have the same cutting depth
Reduce cutting speed Use Molykote paste Coolant jet directly onto the knurl cutter
Knurl trailing spirally Look at start of knurl (turn a centering stepp) Look at knurling depth Tool tilted sideways -> check position
Overlapping of the knurl (double knurl) Approach to knurl depth too slow as a result of which too little guidance of knurl cutters in track Look at start of knurl Incorrect adjustment of diameter
Teeth of knurl cutters knocked off Bevel knurl cutters with hard materials Knurl cutter has been overloaded too much feed, cutting depth too great Fixing screws of knurl cutters loose Incorrect adjustment of diameter
36
Dimensions and Pitches Available
9. Dimensions and Pitches Available Technical Description Material: Powder metallurgy tool steel
Ø
Heat treatment: Hardened to HRC 62-64 Models: Ground or ground + coated with Q-Dur
Tooth pitch angle
21.5 90° toothed 15°L/15°R toothed
Dimensions and pitches
30°L/30°R toothed 90°
t
Pitches (t) 0.4/0.5/0.6/0.8/1.0/ 1.2/1.5/1.6/2.0 0.4/0.5/0.6/0.8/1.0/ 1.2/1.5/1.6/2.0 0.4/0.5/0.6/0.8/1.0/ 1.2/1.5/1.6/2.0
90° toothed
1.0/1.5/2.0/2.5/3.0
15°L/15°R toothed
1.0/1.5/2.0/2.5/3.0
90° toothed
1.0/1.5/2.0/2.5/3.0/4.0
Pitches (t)
15°L/15°R toothed
1.0/1.5/2.0/2.5/3.0/4.0
90° toothed
0.3/0.4/0.5/0.6/0.8/1.0
30°R toothed
1.0/1.5/2.0/2.5/3.0/4.0
15°L/15°R toothed
0.3/0.4/0.5/0.6/0.8/1.0
30°L/30°R toothed
0.3/0.4/0.5/0.6/0.8/1.0
14.5 90° toothed 15°L/15°R toothed 30°L/30°R toothed
0.4/0.5/0.6/0.8/1.0/1.2 0.4/0.5/0.6/0.8/1.0/1.2 0.4/0.5/0.6/0.8/1.0/1.2
90°
30°
15°
32
42 Ø 8.9
Tooth pitch angle
37
Dimensions and Pitches Available
Order numbers and designation Ident. no. 270 271
ØA 8.9 14.5
ØB 4 5
C 2.5 3.0
272
21.5
8
5.0
273
32
14
8.0
274
42
18
12.0 Pos. Description 1 2 3 4 5 6 7 8
38
Production date MM/YY Tooth pitch angle Tooth pitch direction R (right) L (left) Tooth pitch Material Tooth tip angle Production process G (ground) / M (milled) Coated with QDUR / TiCN / TIN
Reference Values for Feeds and Cutting Speeds
10. Reference Values for Feeds and Cutting Speeds Workpiece Material
Cutter Ø
Ø 1.5-12 V s m/min mm/rev
Workpiece Ø 12-40 V m/min
s mm/rev
Workpiece Ø 40-250 V s m/min mm/rev
Workpiece Ø over 250 V s m/min mm/rev
Steel up to
8.9
35
0.05-0.08
600 N/mm²
14.5
45
0.07-0.09
40
0.07-0.09
21.5
60
0.07-0.14
60
0.07-0.15
55
0.07-0.15
90
0.10-0.20
85
0.10-0.20
80
0.10-0.20
100
0.10-0.30
95
0.10-0.20
60
0.08-0.16
32 42
Steel up to
8.9
25
0.04-0.07
900 N/mm²
14.5
35
0.06-0.08
30
0.06-0.08
21.5
50
0.06-0.12
45
0.06-0.12
40
0.06-0.12
70
0.08-0.16
65
0.08-0.16
80
0.09-0.25
32 42
Stainless steels
8.9
22
0.04-0.06
14.5
30
0.06-0.08
28
0.06-0.08
21.5
40
0.06-0.12
35
0.06-0.12
32
0.06-0.12
45
0.08-0.16
42
0.08-0.16
40
0.08-0.16
55
0.09-0.25
50
0.09-0.25
32 42
39
Reference Values for Feeds and Cutting Speeds
Workpiece Material
Cutter Ø
Ms58
8.9
Ø 1.5-12 V s m/min mm/rev
Workpiece Ø 12-40 V m/min
s mm/rev
Workpiece Ø over 250 V s m/min mm/rev
0.06-0.10
14.5
70
0.08-0.12
60
0.08-0.12
21.5
100
0.08-0.20
100
0.08-0.20
90
0.08-0.20
140
0.10-0.30
130
0.10-0.30
115
0.10-0.30
160
0.10-0.30
140
0.10-0.30
42 8.9
50
0.05-0.09
14.5
60
0.06-0.10
60
0.06-0.10
21.5
90
0.07-0.15
90
0.07-0.15
80
0.07-0.15
125
0.10-0.20
120
0.10-0.20
105
0.10-0.20
140
0.10-0.30
120
0.10-0.30
32 42
40
Ø 40-250 V s m/min mm/rev
60
32 Ms60
Workpiece
Reference Values for Feeds and Cutting Speeds
Workpiece Material Bronze
Cutter Ø 8.9
Ø 1.5-12 V s m/min mm/rev
Workpiece Ø 12-40 V s m/min mm/rev
Workpiece Ø over 250 V s m/min mm/rev
0.05-0.08
14.5
45
0.07-0.09
40
0.07-0.09
21.5
60
0.07-0.14
60
0.07-0.14
55
0.07-0.14
90
0.10-0.20
85
0.10-0.20
80
0.10-0.20
100
0.10-0.30
95
0.10-0.30
42 8.9
70
0.06-0.13
14.5
80
0.08-0.18
70
0.08-0.18
21.5
120
0.10-0.25
110
0.10-0.25
100
0.10-0.25
150
0.10-0.35
135
0.10-0.35
125
0.10-0.35
160
0.10-0.50
150
0.10-0.50
32 42
Grey cast iron
Ø 40-250 V s m/min mm/rev
35
32 Aluminium
Workpiece
8.9
22
0.04-0.06
14.5
30
0.06-0.08
28
0.06-0.08
21.5
40
0.06-0.12
35
0.06-0.12
32
0.06-0.12
45
0.08-0.16
42
0.08-0.16
40
0.08-0.16
55
0.09-0.25
50
0.09-0.25
32 42
41
Reference Values for Feeds and Cutting Speeds
Workpiece Material Cast steel
Cutter Ø 8.9
Ø 1.5-12 V s m/min mm/rev
Workpiece Ø 12-40 V s m/min mm/rev
Ø 40-250 V s m/min mm/rev
Workpiece Ø over 250 V s m/min mm/rev
25
0.04-0.06
14.5
35
0.06-0.08
30
0.06-0.12
21.5
50
0.06-0.12
45
0.06-0.12
40
0.06-0.12
90
0.08-0.16
65
0.08-0.16
60
0.08-0.16
80
0.09-0.25
75
0.09-0.25
32 42
NOTE: Generally speaking the values applicable to aluminium are also valid for plastics. Test runs are imperative.
42
Workpiece
Notes
Notes
EN 04/2011 We reserve the right to make changes regarding design and delivery. We accept no liability for printing errors.
SWAROVSKI OPTIK VERTRIEBS GmbH, 6067 Absam, Austria Tel. +43/5223/511- 0, Fax +43/5223/511-6550 info@quick-tools.at, www.quick-tools.at BA-669-31-EN