USER AND BUYERS GUIDE Quick Change for CNC Lathes
Contents Quick Change 3 Key benefits 6 Increase machine utilization – Green Light Machining 6 Improved safety and ease of use for operator 9 Coromant Capto® Quick Change features 10 Increased metal cutting efficiency with Coromant Capto® 18 Working with Quick change - planning to production 22 Machine options 24 Clamping unit styles and options 29 Driven tool holders 32 Accessories to be considered for Quick Change 34 2
Quick Change Making all lathes more efficient Using quick change will reduce the measuring, set up and tool change time allowing extra metal cutting time for all these machines. Through coolant delivery ensures that the full capabilities of the machine are harnessed with optimized cutting units to deliver the coolant with maximum impact and reduce setting.
Quick Change Making all lathes more efficient Turning Centers – fast tool indexing but typically have a lower utilization than machining centers due to the tool change and setup time. Quick change holders ensure the green light on the machine is on for longer! Machine options such as sub spindle, Y-axis and half turret indexing allow for extra tool positions to be added to each turret position. This increases the number of tool positions for sister tooling or reduced tool changing.
Heavy duty & flat bed lathes – extremely high stability but slow tool indexing and changing with no ATC. Shank tool holders are very heavy often needing a crane. Quick change is widely used with VDI DIN 69881 (dovetail) holders on flat bed lathes or dedicated clamping unit blocks on heavy duty lathes. With the limited number of tool positions quick change has a dramatic effect on machine efficiency.
Key benefits Quick change versus shank and conventional ER driven units 5-10 mins Increase machine utilization – Green Light Machining 1. Reduced batch change over time using tooling kits Quicker tool changing - External turning (5 to 10 mins) this increases when using shank tools with high pressure coolant. - Internal turning (5 to 15 mins) with boring bars it takes longer time than a shank tool with center height and internal coolant setting.
2. Increased number of tool positions with double tool holders When the machine has one or more of the following options: - Y axis - Half turret - Sub spindle Turning centers with driven tool holders often have limited space - using double clamping units allows either sister tooling or increased variety of tools thereby reducing tool change requirement for a wider range of components. 30 secs 3.
4. Eliminate coolant pipe setting Varies from application to application but when operators are setting the coolant pipe direction it normally takes 2 to 3 attempts to get it right – red light on! Poor chip control often then knocks the pipe and so setting is quite a regular occurrence. 5. Quicker production start up By eliminating either ‘first test component’ or ‘measuring cuts’ the production rate is increased and scrap reduced. The best analogy is the pit stop in motor racing.
Improved safety and ease of use for operator Easy to use - Change the insert outside the machine reducing accidents, errors and searching for dropped parts - Eliminate coolant setting with fixed nozzle position - Remove safety issues with changing ER driven tool holders where 2 wrenches are sometimes called ‘knuckle busters’ - Offset dimensions in tool code – consistent for each size - Only one version of coupling reducing errors (ISO 26623) - Technical and user support - CAD drawings (DXF) and 3D models (.
Coromant Capto® Quick Change features Coromant Capto was introduced in 1990 and since then there have been no modifications to the coupling design. In 2008 it became an ISO standard and Coromant Capto could also be described as the standard for quick change on turning centers now. The cutting tool program has expanded over the years as well as one new size added in 2010 – C10 for really heavy duty applications.
Repeatability The high precision of the coupling and its self centering design ensures a repeatable accuracy less than ±2 microns in the x, y and z axes for one and the same cutting unit in the same female receiver. This allows pre-setting outside the machine for high batch production or tool kits for batch change over. Both eliminate measuring cuts allowing faster start up and reduced scrap rates.
Increased stability Stability is measured in terms of bending stiffness and torque transmission. The key features providing the superior stability are: Face and taper contact - resisting bending moments and providing positional accuracy. Polygon coupling - the large contact area transmits torque without any loose parts such as pins or keys. The torque load is spread symmetrically without peaks irrespective of direction with the polygon shape self centering for accurate tip seat center height.
1,5 1,0 Deflection [mm/m] Bending Stability 0,5 Bending moment [Nm] 0 0 1000 2000 C6- 45kN HSK-A 63- 22kN 10 Deflection [mm/m] Torque Stability 12 5,0 Torsional moment [Nm] 0 0 500 1000 C8- 46kN HSK-A 63- 22kN Comparison of bending and torque stability between HSK-A 63 and Coromant Capto C6 carried out by the well-reputed RWTH Aachen University in Germany. The results show that C6 compared to HSK 63 has 2.
Clamping unit assortment C3 through to C10 are all used for Quick Change on CNC lathes. The size is depending upon the machine size and cutting parameters. The following clamping units are available for the different machine and turret styles.
VDI-DIN 69880 Shank CBI (Bolt on) CDI Dovetail VDI-DIN 69881 VTL - machine specific 15
Coromant Capto clamping units for Bolt on Interfaces (CBI) Machine adapted clamping units (MACU) are available as standard products for the following machine tool builder’s own turret interface designs : • Doosan (BT¹) • Mazak (MZ) • Mori-Seiki (MS) • Nakamura-Tome (NA) • Okuma (OK) ¹) The BT interface is a common interface used by other machine tool builders.
Non standard clamping units – clamping unit sets Clamping unit sets are used to make clamping units to specific requirements. These are used commonly for tool blocks for vertical lathes, double units or retrofitting quick change onto existing turrets. The clamping set sleeves are available in different forms depending upon the application. Contact your local representative.
Increased metal cutting efficiency with Coromant Capto® CoroTurn HP for high pressure coolant The majority of new machines have 35 to 80 bars as a standard option.
Boring bars and Silent Tools Boring bars are most problematic with longer set up times (center height/length setting and coolant connection) and vibration with longer overhangs. The quick change function on a boring bar saves a lot more production time compared to a normal external turning tool. When starting to implement quick change it is not uncommon to start with just internal. Long boring bars create extra issues with vibration and also collision risks when other tools are being used.
Coromant Capto Short Each machine has a maximum turret swing diameter. All external tool projections need to be within this diameter to allow the turret to rotate without collision. Turning cutting units have a common length and offset dimension for each Coromant Capto size. The clamping units for each machine turret interface are designed so that the standard cutting units fit within the turret swing diameter.
For external tools which exceed these LF dimensions the turret swing diameter can often be a limitation.
Working with Quick change – planning to production Adoption of quick change is a decision to optimize the machine utilization ensuring that production output is as high as it can be. Combining quick change with best metal cutting efficiency ensures that a machine reaches maximum productivity output. For successful implementation it is important to consider the best way to work inside and outside the machine. Pre-measuring and tool kits Quick change can be compared to a pit stop in a Formula one race.
Pre-measuring Using a fixture block with dial indicator close to the machine or a tool pre-setting measuring machine, the precision of the Coromant Capto coupling ensures excellent repeatability when changing the same tool unit. When the pre-measured unit is returned to the clamping unit in the turret, the edge deviation is compensated for through the machine control offset. A master gauge should be used to define the same ‘zero’ position for clamping units and measuring fixtures.
Machine options There is a wide range of machine options which will affect which clamping units are best. The type of components being produced obviously determines the requirements. Careful consideration of both the machine and options will ensure that the process can be made most optimal. Turret interface options The two traditional types of turret – Shank and VDI were developed when turning centers only carried out turning and center line drilling operations.
CBI - Bolt on interface CDI The bolt on interfaces are unique to each machine tool builder. The machine adapted clamping units (MACU) suit the specific machine model. CDI (Coromant Capto Disc Interface) was developed as a turret interface which can be standardized on regardless of the machine type. It is mainly European machine builders who supply CDI as a replacement to VDI. Sub spindle To be able to complete a part often machining from both sides is required.
Driven tool Driven tools allow milling and drilling operations. Without a Y axis just 2 axis operations can be carried out – i.e. keyway slots or holes on the center line. To be able to mill pockets or drill off center line then a Y axis option is needed. For drilling operations it is best to use DTHs with internal coolant supply and high pressure coolant to provide the best chip evacuation and process security.
High pressure coolant (HPC) Most machines now offer a HPC capability around 70 bars. The benefits are great for both turning and drilling operations and offer quick payback due to increased machine utilization and increased metal cutting efficiency. Chip ‘bird nests’ around tools and ‘bailing’ in the conveyor account for a high percentage of all machine stoppages. The system requirements to consider are:• Filter – 20 microns.
Automatic Tool Change Turning centers have developed in many ways with Y-axis, multiple revolvers, sub spindle etc. However changing of tool holders and worn inserts is traditionally a manual intervention. For larger vertical turning centers automatic tool change option with Coromant Capto is now available with a disc magazine which adds advantages for long boring bars and unmanned production.
Clamping unit styles and options The machine options selected or available will dictate which clamping units are possible to use for each machine. For bolt on turrets the wide range of styles of machine adapted clamping units (MACU) allow to really tailor and optimize the turret to the type of components being machined within the machine option capabilities.
External – OD turning Cx-TRE-xxxxA Single external Cx-TRE-xxxxA-DT Double for sub spindle Cx-TRE-xxxxA-YT Y axis Cx-TRE-xxxxA-TT Half Turret APB-TNE-xxxxA-25 Parting blade adaptor Cx-TRI-xxxxA-SS Sub spindle Cx-TRI-xxxxA-DT Double for sub spindle Cx-TRI-xxxxA-YT Y axis Cx-TRI-xxxxA-TT Half Turret Cx-DTI-xxxxA-E/I Internal Cx-DTI-xxxxA-DTE/I Double internal Internal – ID turning/drilling Cx-TRI-xxxxA Single internal Driven Cx-DTE-xxxxA-E/I External E = External coolant I = Internal coolant 3
Selecting Correct Clamping Unit Configuration Single version also left hand Single version also right hand R Right-hand cutting unit L Left-hand cutting unit TR Right hand clamping unit TL Left hand clamping unit Clockwise spindle rotation (M04) Anti-clockwise spindle rotation (M03) clockwise Left hand for r counter Right hand fo kwise) i cloc clockwise (ant 31
Driven tool holders Operation instructions Coolant requirements – Coolant filter max 50 μm (0.002 in). – DTH with internal coolant supply must not be operated without coolant – Coolant must be turned on and present before tool rotation. Running dry will damage the internal seals. Seal damage is not cov ered under warranty. – For machining cast iron, only external coolant design should be used. – All DTH's with IC (internal coolant supply) are speci fied for a max coolant pressure of 80 bars up to their max.
Service interval The life expectancy of a DTH is application dependent. Periodically, perishable parts such as bearings and seals will need to be replaced. Operating under normal conditions with 2 shifts we recommend to send the DTH for service after 1 year. When operating under 3 shifts or heavy conditions or high RPM a more frequent inspection is recommended. For DTH with internal coolant supply, the service interval is every 6 month. Maintenance work is recommended to be done by Sandvik Coromant.
Accessories to be considered for Quick Change Torque Wrench Always to be used for clamping and unclamping the cutting units in the machine and the pre-measurement fixture. This is recommended to prevent any damage to the cam shaft but also to ensure a consistent clamping force which is important to get the most consistent repeatability. The correct clamping torque is marked on each clamping unit.
Master Gauge • Cx-MAS-01 • Cx-MAS-11 To qualify the datum position on all clamping units and pre-measuring units For clamping unit alignment – important for drilling Cx-MAS-01 Cx-MAS-11 Pre-measuring fixture For pre-measuring close to the machine a fixture block with dial indicator can be used. When the pre-measured unit is returned to the clamping unit in the turret, the edge deviation is compensated through the machine control offset.
C3-PMU-01M C4-PMU-01M C5-PMU-01M C6-PMU-01 C8-PMU-01 C-HP01 (holds C3 to C8 blocks) The holding plate (C-HP01) is screwed to a bench to allow a consistent clamping of the cutting unit in the measuring fixture (Cx-PMU-01) – Ensure the torque wrench is used.
Tool storage Working with tool kits and sister tooling provides savings in batch and tool change over time. It is important to have the replacement tools or kits close at hand. The tool storage wagon is used mainly for tool kits for batch production and for transport when using a central pre-setting facility. The wagon kit (CCW-KIT) is delivered with 4 tool cradles. The bench stand is for sister tooling or when pre-setting is done at the machine using the pre-measuring fixture.
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