BA_QUICK_A_EN_V20

INSTRUCTIONS FOR USE A1 & A2 KNURLING TOOLS

Contents

CONTENTS 1. General .............................................................. 2 1.1 Introduction................................................ 2 1.2 Tool Construction....................................... 3 2. A1-Tools ............................................................ 5 2.1 Technical Data........................................... 5 2.2 Overview: Main Components..................... 6 2.3 Tool Adjustment A1/KF .............................. 7 2.4 Optical Measurement A1/KF.................... 12 2.5 Tool Adjustment A1/FL............................. 13 2.6 Optical Measurement A1/FL .................... 17 2.7 Adapter for long-turning lathes ................ 18 3. A2-Tools .......................................................... 19 3.1 Technical Data......................................... 19 3.2 Overview: Main Components................... 20 3.3 Tool Adjustment A2/KF ............................ 21 3.4 Optical Measurement A2/KF.................... 26 3.5 Tool Adjustment A2/FL............................. 27 3.6 Optical Measurement A2/FL .................... 31

4. Coolant Unit A1/A2..........................................32 4.1 General ....................................................32 4.2 Technical Data .........................................32 4.3 Overview: Main Components ...................33 4.4 Assembly/Starting up ...............................34 4.5 Clean the Coolant Unit .............................35 4.6 Subsequent Machining of Shank A2 ........36 5. Wear Parts .......................................................37 6. Knurling of Stepped Workpieces ..................37 7. Knurl Cutters with Bevel ................................38 8. Troubleshooting..............................................39 9. Dimensions and Pitches Available................40 10. Reference Values for Feeds and Cutting Speeds..............................................41

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 A-series tools are flexible in use and may be employed on all lathes from the conventional to CNC-controlled dual-spindle lathes, optionally as a left-hand or right-hand tool, in front or behind the turning centre.

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

A/FL

30°L /30° R

Spiral knurl

RBL / RBR

A/FL

As required

Cross knurl

similar to RKE

A/KF

15°L + 15° R

RGE

A/KF

2 x 90°

Diamond knurl

3

General Tool Construction

Tool definition

Perfect results may be achieved with:

Definition of the tool as left- or right-handed is determined by the position of the knurl cutters when the tool is viewed from the front in the clamped position. left right left right

 Correct adjustment  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 21.5 mm instead of Ø 14.5, have a longer service life

Clamping Clamping of the holder on the shaft is effected by means of an eccentric chuck. The surface clamping generated as a result reduces the vibrations arising due to machining and increases the service life of the knurl cutters.

Shafts and bodies may be individually assembled easily and without much effort by the customer himself.

4

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.

A1-Tools Technical Data

2. A1-Tools 2.1 Technical Data

A1/FL Types of knurl Working range Shaft dimension Knurl cutters Straight Spiral

Straight and spiral Ø 3-50 mm 10x16, 12x16 or 16x16 mm Ø 14.5 mm 1 x 30°L / 30°R As required

Pitches Weight

see page 40 0.3 kg

10/12/16

16

36

Cross and diamond Ø 3-50 mm 10x16, 12x16 or 16x16 mm Ø 14.5 mm 1 x 15°L and 1 x 15°R 2 x 90° see page 40 0.3 kg

36

35

80 115

16

10/12/16

32

26

34

A1/KF Types of knurl Working range Shaft dimension Knurl cutters Cross Diamond Pitches Weight

80 106

5

A1-Tools Overview: Main Components

2.2 Overview: Main Components Pos. Designation 1

Tool head

2 3

Countersunk screw Washer

4

Knurl cutter

5

Bushing

6

Index disc (diameter adjustment)

7

Index point

8

Clamping segment

9

Shaft

10

Eccentric bolt

11

Spindle screw

12

Hexagonal socket head screws - tool correction (A1/FL)

13

Adjustment gauge - A1/KF

14

Adjustment gauge - A1/FL

A1/KF 7 2

3

4

1

10

11 9 13

8

2

3

4

5

A1/FL

1 10

11 14

9 12

6

6

5

A1-Tools Tool Adjustment A1/KF

2.3 Tool Adjustment A1/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 countersunk screw 2 and only tighten enough to allow knurl cutter 4 to rotate free of play

Diamond knurl:  2x 90° toothed knurl cutters

2

3

4

5

1.1

7

A1-Tools Tool Adjustment A1/KF

Step 3: Pre-adjust turning centre For centring of the tool, the mark M on the shaft must be aligned with the mark on the head.  The mark in the middle of the head should be selected for use in conventional machines.  The outer marks should be selected for use in CNC machines depending on the shaft dimensions.

Pos. 0 a b c -a -b -c

Application conventional CNC CNC CNC CNC CNC CNC

Shaft 10/12/16 10 12 16 10 12 16

Adjustment:  Unscrew eccentric bolt 10

c b a 0 -a -b -c

 Adjust tool head 1 accordingly by way of spindle screw 11  Clamp eccentric bolt lightly M

1 10

10

11 11

8

A1-Tools Tool Adjustment A1/KF

Step 5: Clamp tool in tool holder

Step 4: Set diameter  Measure off workpiece diameter  Unscrew clamping segment 8 by two turns

Step 6: Re-align turning centre

 Turn index disc 6 until the required diameter aligns with index point 7

 Carefully bring into contact with the workpiece

 Only clamp clamping segment 8 lightly for subsequent adjustment of cutter 7

6

 Both cutters must be in contact simultaneously.

Precision adjustment is carried out using spindle screw 11  Tighten eccentric bolt 10 hand-tight when alignment is finished 10

10

11 11

8

9

A1-Tools Tool Adjustment A1/KF

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°.

6

8

Step 8: Start of knurl

Sequence:  Adjust index disc 6 slightly towards the next smaller diameter until the correct cutter setting is reached  Tighten clamping segment 8

10

The start of the knurl should be in a width no greater than 1.5 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.

A1-Tools Tool Adjustment A1/KF

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.

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 1,5 mm

Step 9: Knurling NOTE: If the knurl is not accurate or is onesided, then the knurling process may be repeated after correcting the tool.

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.

11

A1-Tools Optical Measurement A1/KF

2.4 Optical Measurement A1/KF The tool may be optically measured on the presetting device using adjustment gauge 13 supplied.  Dismantle knurl cutter 4 and bushing 5  Unscrew eccentric bolt 10 and pre-set the turning centre by means of spindle screw 11

8 13

z=0

x=0

 Clamp eccentric bolt 10 lightly 4

5 10

11

 Push adjustment gauge 13 onto closed clamping segment 8  Precision adjust the turning centre under the pre-setting device, clamp eccentric bolt 10 hand-tight and determine the X and Z values

12

The measured Z value is the start of the knurl not the collision measurement. The measured X value is adopted without a correction value for a workpiece diameter of 5 mm.

The radius values shown in the table must be added to the X values depending on the workpiece diameter. With this measurement the knurl cutters are positioned approximately 0.2-0.3 mm above the diameter to be knurled. Precise adjustment of the tool must be carried out on the machine. Ø 5 6 8

X+ 0 0.3 0.6

Ø 10 13 17

X+ 0.9 1.2 1.5

Ø 23 31 50

X+ 1.8 2.1 2.5

A1-Tools Tool Adjustment A1/FL

2.5 Tool Adjustment A1/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 Straight knurl - right-hand tool:

 Coat bushing 5 and the face ends as well as the hole of knurl cutter 4 with a little Molykote G paste

 1x 30° right-hand spiral toothed knurl cutter Straight knurl - left-hand tool:

 With knurl cutter 4 and washer 3 pushed on, insert bushing 5 into the cutter holder

 1x 30° left-hand spiral toothed knurl cutter

 Screw in countersunk screw 2 and only tighten enough to allow knurl cutter 4 to rotate free of play

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.

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.

13

A1-Tools Tool Adjustment A1/FL

Step 3: Adjust turning centre For centring of the tool, the mark M on the shaft must be aligned with the mark on the head.  The mark in the middle of the head should be selected for use in conventional machines.  The outer marks should be selected for use in CNC machines depending on the shaft dimensions.

c b a 0 -a -b -c

Pos. 0 a b c -a -b -c

Application conventional CNC CNC CNC CNC CNC CNC

Shaft 10/12/16 10 12 16 10 12 16

Adjustment:  Unscrew eccentric bolt 10  Adjust tool head 1accordingly by way of spindle screw 11  Clamp eccentric bolt again hand-tight M

1 11 10

10

11

NOTE: Precision adjustment of the turning centre can only be carried out on the optical pre-setting device.

14

A1-Tools Tool Adjustment A1/FL

Step 4: Clamp tool in tool holder

Step 6: Start of knurl

Step 5: Adjust cutter

The start of the knurl should be in a width no greater than 1.5 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 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°.

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 1,5 mm

Sequence:  Correction is achieved by turning the tool slightly in the tool holder

15

A1-Tools Tool Adjustment A1/FL

Step 7: Knurling 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.

If the track generated does not run paraxially, this may be put right by correcting the two hexagonal socket head screws 12. ď‚„ When adjusting by way of screw 12a, first loosen screw 12b and vice versa ď‚„ Tighten the opposing screw again hand-tight when adjustment is complete

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.

12b 12a

NOTE: If the knurl is not accurate or is one-sided, then the knurling process may be repeated after correcting the tool.

16

A1-Tools Optical Measurement A1/FL

2.6 Optical Measurement A1/FL The tool may be optically measured on the presetting device using adjustment gauge 14 supplied.  Dismantle knurl cutter 4 and bushing 5  Unscrew eccentric bolt 10 and adjust the turning centre by means of the spindle screw 11  Clamp eccentric bolt 10 lightly again 4

 Mount adjustment gauge 14 on tool holder 1.1  Precision adjust the turning centre under the pre-setting device, clamp eccentric bolt 10 hand-tight and determine the X and Z values 2

14 1.1

5

z=0

x=0

10

11

The measured Z value is the start of the knurl not the collision measurement. If the measured X value is programmed, the knurl cutter is positioned approximately 0.2-0.3 mm above the diameter to be knurled and precise adjustment of the tool must be carried out on the machine.

17

A1-Tools Adapter for long-turning lathes

2.7 Adapter for long-turning lathes Dimensions – adapter for long-turning lathes A1/KF

14

A1 adapter for long turning lathes 15 may be mounted on appropriate A1 shaft 9 simply by means of the two screws 16.

Retention in the machine is by means of the adapter. As a result the tool is aligned completely flush with the knurl cutters.

9

80

15

10/12/16

11,6

A1/FL

16 80

18

10/12/16

A2-Tools Technical Data

3. A2-Tools 3.1 Technical Data

20/25 25

50 63

Cross and diamond Ø 5-250 mm 20x25 or 25x25 mm Ø 21.5 mm 1 x 15°L and 1 x 15°R 2 x 90° see page 40 1.2 kg

111 159

25

Straight and spiral Ø 5-250 mm 20x25 or 25x25 mm Ø 21.5 mm 1 x 30°L / 30°R As required see page 40 1.0 kg

20/25

38

50

A2/FL Types of knurl Working range Shaft dimension Knurl cutters Straight Spiral Pitches Weight

48

56

A2/KF Types of knurl Working range Shaft dimension Knurl cutters Cross Diamond Pitches Weight

111 149

19

A2-Tools Overview: Main Components

3.2 Overview: Main Components A2/KF

Pos. Designation

7

1

Tool head

2 3

Countersunk screw Washer

4

Knurl cutters

11

5

Bushing

10

6

Index disc (diameter adjustment)

7

Index point

8

Clamping segment

9

Shaft

10

Eccentric bolt

11

Spindle screw

12

Hexagonal socket head screws - tool correction (A2/FL)

13

Adjustment gauge - A2/KF

14

Adjustment gauge - A2/FL

2

3

4

10

5

9

13

2

8

3

4

5

A2/FL

1 11 10

10 9 12 14

20

6

1

A2-Tools Tool Adjustment A2/KF

3.3 Tool Adjustment A2/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 countersunk screw 2 and only tighten enough to allow knurl cutter 4 to rotate free of play

Diamond knurl:  2x 90° toothed knurl cutters

2

3

4

5

1.1

21

A2-Tools Tool Adjustment A2/KF

Step 3: Pre-adjust turning centre For centring of the tool, the mark M on the shaft must be aligned with the mark on the head.  The mark in the middle of the head should be selected for use in conventional machines.  The outer marks should be selected for use in CNC machines depending on the shaft dimensions.

Pos. 0 a b -a -b

Application conventional CNC CNC CNC CNC

Shaft 20/25 20 25 20 25

Adjustment:  Unscrew eccentric bolt 10  Adjust tool head 1 accordingly by way of spindle screw 11  Clamp eccentric bolt lightly

b a 0 -a -b

M

1 10 11

11

10 10

22

A2-Tools Tool Adjustment A2/KF

Step 4: Set diameter

Step 5: Clamp tool in tool holder

 Measure off workpiece diameter  Unscrew clamping segment 8 by two turns

Step 6: Re-align turning centre

 Turn index disc 6 until the required diameter aligns with index point 7

 Carefully bring into contact with the workpiece

 Only clamp clamping segment 8 lightly for subsequent adjustment of cutter 7

6

 Both cutters must be in contact simultaneously.

Precision adjustment is carried out using spindle screw 11  Tighten eccentric bolts 10 hand-tight when alignment is finished 10

11 8

11

10 10

23

A2-Tools Tool Adjustment A2/KF

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°.

6

8

Step 8: Start of knurl

Sequence:  Adjust index disc 6 slightly towards the next smaller diameter until the correct cutter setting is reached  Tighten clamping segment 8

24

The start of the knurl should be in a width no greater than 1.5 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.

A2-Tools Tool Adjustment A2/KF

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 1,5 mm

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.

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.

25

A2-Tools Optical Measurement A2/KF

3.4 Optical Measurement A2/KF The tool may be optically measured on the presetting device using adjustment gauge 13 supplied.

8

 Dismantle knurl cutter 4 and bushing 5

z=0

 Unscrew eccentric bolt 10 and pre-set the turning centre by means of spindle screw 11

x=0

13

 Clamp eccentric bolt 10 lightly 10 11

4

5

10

11 10

 Push adjustment gauge 13 onto closed clamping segment 8  Precision adjust the turning centre under the pre-setting device, clamp eccentric bolt 10 hand-tight and determine the X and Z values

26

The measured Z value is the start of the knurl not the collision measurement. The measured X value is adopted without a correction value for a workpiece diameter of 8 mm The radius values shown in the table must be added to the X values depending on the workpiece diameter. With this measurement the knurl cutters are positioned approximately 0.2 — 0.3 mm above the diameter to be knurled. Precise adjustment of the tool must be carried out on the machine. Ø 8 11 14 16 19

X+ 0 0.3 0.6 0.9 1.2

Ø 27 35 45 55 65

X+ 1.9 2.2 2.5 2.8 3.0

Ø 80 120 150 200 250

X+ 3.2 3.5 3.6 3.7 3.8

A2-Tools Tool Adjustment A2/FL

3.5 Tool Adjustment A2/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 Straight knurl - right-hand tool:

 Coat bushing 5 and the face ends as well as the hole of knurl cutter 4 with a little Molykote G paste

 1x 30° right-hand spiral toothed knurl cutter Straight knurl - left-hand tool:

 With knurl cutter 4 and washer 3 pushed on, insert bushing 5 into the cutter holder

 1x 30° left-hand spiral toothed knurl cutter

 Screw in countersunk screw 2 and only tighten enough to allow knurl cutter 4 to rotate free of play

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.

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.

27

A2-Tools Tool Adjustment A2/FL

Step 3: Adjust turning centre For centring of the tool, the mark M on the shaft must be aligned with the mark on the head.  The mark in the middle of the head should be selected for use in conventional machines.  The outer marks should be selected for use in CNC machines depending on the shaft dimensions.

b a 0 -a -b

M

Pos. 0 a b -a -b

Application conventional CNC CNC CNC CNC

Shaft 20/25 20 25 20 25

Adjustment:  Unscrew eccentric bolt 10  Adjust tool head 1 accordingly by way of spindle screw 11  Clamp eccentric bolt again hand-tight 1

11

10 10

11

10

NOTE: Precision adjustment of the turning centre can only be carried out on the optical pre-setting device.

28

A2-Tools Tool Adjustment A2/FL

Step 4: Clamp tool in tool holder

Step 6: Start of knurl

Step 5: Adjust cutter

The start of the knurl should be in a width no greater than 1.5 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 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°.

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 1,5 mm

Sequence:  Correction is achieved by turning the tool slightly in the tool holder

29

A2-Tools Tool Adjustment A2/FL

Step 7: Knurling 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.

If the track generated does not run paraxially, this may be put right by correcting the two hexagonal socket head screws 12. ď‚„ When adjusting by way of screw 12a, first loosen screw 12b and vice versa ď‚„ Tighten the opposing screw again hand-tight when adjustment is complete

12a

12b

NOTE: If the knurl is not accurate or is onesided, then the knurling process may be repeated after correcting the tool.

30

A2-Tools Optical Measurement A2/FL

3.6 Optical Measurement A2/FL The tool may be optically measured on the presetting device using adjustment gauge 14 supplied.  Dismantle knurl cutter 4 and bushing 5  Unscrew eccentric bolt 10 and adjust the turning centre by means of the spindle screw 11  Clamp eccentric bolt lightly 10 again 4

 Mount adjustment gauge 14 on tool holder 1.1  Precision adjust the turning centre under the pre-setting device, clamp eccentric bolt 10 hand-tight and determine the X and Z values 2

14

1.1

5

z=0

x=0

10

11 10

The measured Z value is the start of the knurl not the collision measurement. If the measured X value is programmed, the knurl cutter is positioned approximately 0.2-0.3 mm above the diameter to be knurled and precise adjustment of the tool must be carried out on the machine.

31

Coolant Unit A1/A2 General

4. Coolant Unit A1/A2 4.1 General

4.2 Technical Data

This innovative cooling system enables targeted cooling and lubrication of the cutters or workpieces and thus increases the service life of the tools. Easy assembly and cleaning are further distinguishing features of the system.

There are two versions available for A series knurling tools:  Coolant unit with three adjustable ball nozzles for A/KF tools  Coolant unit with a flat nozzle for A/FL tools

Coolant pressure: max. 8 bar

A2

32

32

17

11

A1

49

28

7

KF

32

FL

22

A1/A2

Coolant Unit A1/A2 Overview: Main Components

4.3 Overview: Main Components Pos. Description 1

Housing

2 3

Jet nozzle KF - 3 adjustable nozzles Jet nozzle FL - flat nozzle

4

Gasket

5

Push-in connection

6

Blanking plug

7

Coolant hose

8

Cyl. head screw

KF

6

5

1

8

5

7

6

5

1

8

5

7

4 2

FL 4 3

33

Coolant Unit A1/A2 Assembly/Starting up

4.4 Assembly/Starting up NOTE: The illustration for the following work steps show the tool A1/KF with coolant unit KF. The same manner of proceeding also applies for the other tools of the A series.

Step 1: Assembly  Position coolant unit 1 with alignment pin on shank 10.  Screw in cyl. head screw 8 and tighten handtight.

Step 2: Connect coolant supply  Clamp tool in tool holder  Press top push-in connector 5 in slightly and feed in hose 7 until limit stop is reached.  Route hose 7 with corresponding bending radius to connection on tool holder, cut to length as necessary and connect.  Press push-in connector 5 in slightly at second coolant connection of coolant unit and insert blanking plug 6 until limit stop is reached.

7

10

5

1 5

8

34

6

Coolant Unit A1/A2 Clean the Coolant Unit

4.5 Clean the Coolant Unit Step 3: Activate cooling system

 Loosen coolant hose on tool holder

 Activate the cooling system before commencing knurling

 Unscrew and remove cyl. head screw and detach coolant unit

ATTENTION: The coolant unit is designed for a max. pressure of 8 bar.

 Press push-in connectors 5 slightly and detach coolant hose 7 as well as blanking plug 6 1

7

Step 4: Precision adjustment of ball nozzles on coolant unit KF

5

 To ensure the best possible cooling for A/KF tools, direct the two outer nozzles onto the knurl cutters and the middle nozzle onto the workpiece

5

8

6

35

Coolant Unit A1/A2 Subsequent Machining of Shank A2

4.6 Subsequent Machining of Shank A2  Unlatch mounting of nozzle insert 2 via the lateral slotted openings and pull out of housing 1 with gasket 4 2

4

1

2

No receiving holes were provided in models A2/KF and A2/FL prior to introduction of the coolant unit.

The shanks have to be machined subsequently to retrofit the coolant unit.  1x threaded hole M4  1x slot with fit for alignment pin 0 33 +0,1

6

4,5

12,5 +0,05 -0,05

 Clean all parts in soap solution and rinse with clear water to remove microchips.  Re-insert nozzle insert 2 with gasket 4 into housing 1 and fix with snap closure

36

1 +- 0,1 0,1

M4

4 H11

 Assemble remaining parts and re-attach coolant unit to shank

Wear Parts

5. Wear Parts

6. Knurling of Stepped Workpieces

The fixing elements for the knurl cutters of the QUICK A-series 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.

1

2

3

a

b

Distance b corresponds to the Ø of the knurl cutters Pos. 1 2 3

Designation Countersunk screw Washer Bushing

Ø 14.5

Ø 21.5

a 1 2 3

b 1.3 1.8 2.2

b 2 2.6 3

a 5 6 7

4

2.6

3.8

8

Ø 14.5

Ø 21.5

b 2.8 3.1

b 4.5 4.7 5 5.3

37

Knurl Cutters with Bevel

7. Knurl Cutters with Bevel A knurl cutter's teeth may break off when knurling "hard" materials.

It is possible to increase the knurl cutter's service life by cutting a 45째 bevel. This is only applicable for the KF models.

Only one knurl cutter 4 with bevel may be used depending on the direction in which the workpiece rotates.

4

0,5 x t 45째

Arrangement for cutters with bevel

t

4

38

Troubleshooting

8. Troubleshooting A/KF Tools

A/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 A/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

39

Dimensions and Pitches Available

9. Dimensions and Pitches Available Technical Description

Order numbers and designation

Material: Powder metallurgy tool steel Heat treatment: Hardened to HRC 62-64 Models: Ground or ground + coated with Q-Dur

Dimensions and pitches

Ident. no.

ØA

ØB

C

271

14.5

5

3

272

21.5

8

5

90° 90°

Ø

15°

Tooth pitch angle

14.5 90° toothed 15°L/15°R toothed 30°L/30°R toothed 21.5 90° toothed 15°L/15°R toothed 30°L/30°R toothed

40

30°

t

Pitches (t) 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 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

Pos. Description 1 2 3 4 5 6 7 8

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 Ø 3-12 Material Cutter Ø V s m/min mm/rev Steel up to 600 N/mm² 14.5 45 0.07-0.09 21.5 60 0.07-0.14 Steel up to 900 N/mm² 14.5 35 0.06-0.08 21.5 50 0.06-0.12 Stainless steels 14.5 30 0.06-0.08 21.5 40 0.06-0.12 Ms58 Ms60

14.5 21.5 14.5 21.5

70 100 60 90

0.08-0.12 0.08-0.20 0.06-0.10 0.07-0.15

Workpiece Ø 12-40 V s m/min mm/rev 40 0.07-0.09 60 0.07-0.15 30 45 28 35

0.06-0.08 0.06-0.12 0.06-0.08 0.06-0.12

60 100 60 90

0.08-0.12 0.08-0.20 0.06-0.10 0.07-0.15

Workpiece Ø 40-250 V s m/min mm/rev 55

0.07-0.15

40

0.06-0.12

32

0.06-0.12

90

0.08-0.20

80

0.07-0.15

41

Reference Values for Feeds and Cutting Speeds

Workpiece Ø 3-12 Material Cutter Ø V s m/min mm/rev Bronze 14.5 45 0.07-0.09 21.5 60 0.07-0.14 Aluminium Grey cast iron Cast steel

Workpiece Ø 12-40 V s m/min mm/rev 40 0.07-0.09 60 0.07-0.14

14.5 21.5 14.5 21.5

80 120 30 40

0.08-0.18 0.10-0.25 0.06-0.08 0.06-0.12

70 110 28 35

0.08-0.18 0.10-0.25 0.06-0.08 0.06-0.12

14.5 21.5

35 50

0.06-0.08 0.06-0.12

30 45

0.06-0.12 0.06-0.12

NOTE: Generally speaking the values applicable to aluminium are also valid for plastics. Test runs are imperative.

42

Workpiece Ø 40-250 V s m/min mm/rev 55

0.07-0.14

100

0.10-0.25

32

0.06-0.12

40

0.06-0.12

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-669-21-EN