Operating Instructions Thread Rolling Heads F 001, F 01, K 01-1

Transcription

1 Head in fixed application (for F and K types): The front part of the head is turned by using the handle (25) with the ball (23) (if used on automatics, closing is accomplished by using closing roller over a cam) until the coupling rests between the spring housing (2) and shank (1). Head in rotating application (only for K 01-1): The front part of the head is slowed down in its revolving motion by using an additional yoke with brake shoes, the front part is then turned against the shank until the coupling rests between the spring housing (2) and the shank (1). Machining of the component: Starting diameter to be thread rolled must be the equivalent to the effective diameter. eviations are possible, depending upon type of component material being used. The starting diameter arrived at now should never be increased. The components have to be chamfered under = against the axis and must be concentric. An undercut at the thread run-out is not required. If an undercut is called for, the same should be chamfered according to sketch below. The diameter must be below the root diameter of the thread. Also important is the accurate alignment of the head to the component. Possible errors to be made: 1. Starting diameter selected too large or head setting too small, that means overload pressure is generated, which in most cases may be seen at the thread end by building up a bead at the thread crests over approx. the width of the rolls. 2. Chamfering (also at the undercut) is not in line with the rolling instructions. 3. Setting for length selected incorrect or component length variating (rolls are running against a shoulder).. Jamming of the rolls or evidence of wear on the eccentric spindles caused be heavy dirt accumulated in the coolant. 5. Unclean thread start and possible damage to the Rolls caused by incorrect teed approach at the start of rolling.. amage on the Rolls or rolling of two-start threads caused by incorrect assembly of the Rolls. 7. Premature opening of the rolling head caused by the wear of the wedges for coupling in part 1 an. Operating Instructions Thread Rolling Heads F 001, F 01, K 01-1 Undercut Tolerance for the starting diameter: Once the accurate starting diameter, determined by a test rolling operation, has been found, then this should be considered as the maximum dimension, if the thread has been rolled just up to its crest and the effective diameter is approx. at the maximum dimension within the permissible thread tolerance. Among others the tolerance of the starting diameter is depending to what extent the thread has been rolled to. As a guide for standard threads with tolerance class g the following may be used: starting diameter tolerance half effective diameter tolerance. Rolling Speed: According to component profile and spindle speeds available, the following rolling speeds are recommended: for V-type threads approx m/min (5 200 ft/min) for Acme-type threads approx m/min ( ft/min). The rolling speed is arrived at by figuring the same as tor the cutting speed. Rolling operation: The feed rate of approach should be equivalent to the pitch of thread to be rolled. After engagement over 3 thread pitches, the head itself takes over the feed movement. The support respectively the adaptor sleeve should be set-up tor easy movement in either direction at any rate. Coolants and lubricants: Recommended coolants and lubricants are those, which are also used for cutting operations, i. e. solutions with diluted ratio of 1:10 up to 1:20 perhaps with high pressure additives and thin cutting oils. LMT FETTE Werkzeugtechnik GmbH & Co. KG Grabauer St Schwarzenbek Germany Phone Fax Rolling Head-Hotline Hotline teamrollen@lmt-tools.com Printed in Germany, No G ( M/H)

2 IMPORTANT: In the case of re-ordering of Spare Parts, please state Rolling Head Type and Serial-No. Please note marking on the Front Plate! S = Special angle (example F 001 S) L = esign for Left Hand Threads (example F 001 L) SL = Special angle for Left Hand Threads (example F 001 SL) X... = Special design (example F 001 X101) In case of re-ordering of Rolls, please state the Roll-Code-No., which is marked on the letter side of the Roll in addition to the dimension (e. g. for rolling head F 001 e. g. 001/...)! Spare Parts No. Pcs. escription 1 1 Clutch or shank 2 1 Spring housing 3 1 Centre plate 1 Front plate 5 3 Eccentric spindles 3 Front Plate screw 7 1 Clutch plate 8 3 Ball lever 9 1) 1 Handle 10 1 Coil spring 11 3 Hardened slides 12 1 Circlip 13 3 Studs 1 3 Carbide bushing 15 3 Hexagon nut 1 1 Washer 17 1) 1 Hexagon nut 18 3 Thread roll 19 3 Shear pins 20 1 Stop screw body 21 1 Stop screw 22 1 Hexagon nut 23 1) 1 Ball 2 2 Set screw 25 1) 3 Washer 1) only for fixed application Rolling Heads F 001, F 01 (only for fixed application) Rolling Heads K 01-1 (for fixed and rotating application) Assembly of Thread RolIs: Remove front plate (), apply very thin coat of grease or a thin layer of MOLYKOTE to eccentric spindles (5), as well as to the inclined surfaces on front- () and centre plate (3). lnsert rolls (18) in the order or A-B-C in clockwise direction (for left hand heads in counter-clockwise direction). Insert carbide bushing (1). Fit front plate () to this assembly and tighten screws. Adjustment of Head to thread diameter: The head is closed, i. e. the teeth of the coupling of parts 1 an are in complete engagement. Parts 1 an are spring loaded. First loosen three nuts (15) and insert between the rolls a screw plug gauge, or threaded sample, or if neither are available a plain plug with root diameter of the thread. The front part of the head (roller cage) is turned with the range of the three slotted holes of the spring housing (2) until the rolls (18) become fully engaged with the screw plug gauge, sample or plain plug. The three nuts (15) are then retightened. Should the effective diameter of the thread rolled not be correct, i. e. the effective diameter is too large, the three nuts (15) must be loosened and the front part of the head turned one half a calibration in the direction of the minus sign. A rolled thread should not be over rolled, or re-rolled a second time. If the length of the three slotted holes (2) is insufficient for the necessary adjustment and the zero mark 0 on the roller cage is at the ultimate minus setting, proceed as follows: Head to be adjusted to a smaller diameter: Remove the three nuts (15) and ring type washer (1). The roller cage is then drawn off and turned round 120 approx, in the direction of the minus sign. It is then re-assembled. The secondary zero marking now appears on the plus side (+) of the scale. Ring type washer (1) and nuts (15) are put on again, the head finally adjusted to correct size as per previous paragraph and nuts are tightened. It is now possible to adjust the head to a smaller diameter. Head to be adjusted to a larger diameter: Same procedure as before, but turning direction is just reversed. Adjustment of Head to thread length: Adjustment to thread length is always done when the head is in an open position, i. e. the head is opened in axial direction by disengaging the dog coupling (1 an). This brings the front position of the head forward corresponding to the height of the dog coupling. a) Operation with Inside Stop: Stop screw (21) is adjusted to required thread length and locked by hexagon nut (22). If the component touches the stop screw (21), the dog coupling (1 an) is disengaged and the head opens automatically. The unclamped length of the component is not of decisive importance here. Operation with Outside Stop: Opening operation with Outside Stop: The thread length, where chucking length is controlled, is set by a stop on the machine, which limits the forward travel of the sleeve, or the threading spindle or the turret slide. When the stop is reached, the dog coupling is disengaged and the head opens automatically. Important: As opposed to opening by means of inside stop it is in this case absolutely necessary to maintain uniform component length extending beyond the clamped portion, in case rolling is done against a shoulder or similar. Closing of Head: When the head is closed, the rolls (18) are brought back into the rolling position.

3 Machining of the component: Starting diameter to be thread rolled must be the equivalent to the effective diameter. eviations are possible, depending upon type of component material being used. The starting diameter arrived at now should never be increased. The components have to be chamfered under = against the axis and must be concentric. An undercut at the thread run-out is not required. If an undercut is called for, the same should be chamfered according to sketch below. The diameter must be below the root diameter of the thread. Also important is the accurate alignment of the head to the component. Undercut Position for Assembly Looking at the gears Working Position Operating Instructions Thread Rolling Heads F1C1, F12C1, F1223C1, F2C2, F23C2, F23300C2, F3C2, F3C2 Tolerance for the starting diameter: Once the accurate starting diameter, determined by a test rolling operation, has been found, then this should be considered as the maximum dimension, if the thread has been rolled just up to its crest and the effective diameter is approx. at the maximum dimension within the permissible thread tolerance. Among others the tolerance of the starting diameter is depending to what extent the thread has been rolled to. As a guide for standard threads with tolerance class g the following may be used: starting diameter tolerance half effective diameter tolerance. Rolling Speed: According to component profile and spindle speeds available, the following rolling speeds are recommended: for V-type threads approx m/min (5 200 ft/min) for Acme-type threads approx m/min ( ft/min). The rolling speed is arrived at by figuring the same as tor the cutting speed. Rolling operation: The feed rate of approach should be equivalent to the pitch of thread to be rolled. After engagement over 3 thread pitches, the head itself takes over the feed movement. The support respectively the adaptor sleeve should be set-up tor easy movement in either direction at any rate. Coolants and lubricants: Recommended coolants and lubricants are those, which are also used for cutting operations, i. e. solutions with diluted ratio of 1:10 up to 1:20 perhaps with high pressure additives and thin cutting oils. Possible errors to be made: 1. Effective starting diameter selected too large or head setting was too small, that means an overload is generated, which shows up in most cases as a bead on the thread crest over a length of the roll width at the thread end. 2. Chamfering (also at the undercut) is not in line with the rolling instructions. 3. Length adjustment was selected incorrect, or component length are deviating from each other (Rolls run against a shoulder).. Jamming of Rolls or signs of wear on the Eccentric Spindles caused by heavy dirt of the coolant. 5. Unclean thread start and possible damage to the Rolls caused by incorrect teed approach at the start of rolling.. amage on the Rolls or rolling of two-start threads caused by incorrect assembly of the Rolls. 7. Premature opening of the Rolling Head caused by the wear of the Wedges for Coupling No. 1 or Coupling No. 2. Tooth is at right angle to the flat for types F 1, F 12, F 23, F 3, F 3, F 1223, F Gap is at right angle to the flat tor type F 2 Assembly Instruction for Spare Parts If parts 3, or are re-ordered as spare parts, they should be assembled as shown on the sketch above; finishing work to be done if necessary. When assembling parts 5 and 8 in part 3, make sure that there is some play (clearance) between the parts. Part 5 must be able to rotate easily together with part 8. LMT FETTE Werkzeugtechnik GmbH & Co. KG Grabauer St Schwarzenbek Germany Phone Fax Rolling Head-Hotline Hotline teamrollen@lmt-tools.com 3 The flats in the bores of the planet gears must be in the same position relative to the centre gear. Insert hone from this side Position of the flats for right-hand threads. For left-hand threads the flats are on the opposite side. With the assembly in the correct working position, shank and spring housing are mounted with closed coupling. Plug gauge 0.02 mm (.00787") larger than journal portion on eccentric spindle Printed in Germany, No. F1C1-F3C2 E ( M/H)

4 IMPORTANT: In the case of re-ordering of Spare Parts, please state Rolling Head Type and Serial-No. Please note marking on the Front Plate! S = Special angle (example F3S C2) L = esign for Left Hand Threads (example F3L C2) SL = Special angle for Left Hand Threads (example F3SL C2) X... = Special design (example F3 C2 X 101) Ke = Rolling Head for rolling of Serrations (example F3 Ke X 102) In case of re-ordering of Rolls, please state the Roll-Code-No., which is marked on the letter side of the Roll in addition to the dimension (e. g. for rolling head F3C2 e. g. 3/...)! 7 10 Changeable shanks Straight shank Straight shank VI shank HSK shank Others with flat e. g. tapered shanks (upon request) (upon request) 15 2 Spare Parts Rolling Heads F1C1, F12C1, F1223C1, F2C2, F23C2, F23300C2, F3C2, F3C2 (only for fixed application) Assembly of Thread RolIs: Remove front plate (), apply a very thin coat of grease or a thin layer of MOLYKOTE to the eccentric spindles (5), as well as to the inclined surfaces on front- () and centre plate (3). If washer, part 25, is fitted in the rolling head, it should also be greased. Insert rolls (18) in the order or A-B-C in clockwise direction. (For left hand heads in counter-clockwise direction.) Insert needle roller bearings (13) or carbide bushings. Fit front plate () to this assembly and tighten screws. Adjustment of Head to thread diameter: The head is closed, i. e. the teeth of the coupling of parts 1 an are in complete engagement. Parts 1 an are spring loaded. First loosen three nuts (15) and insert between the rolls a screw plug gauge, or threaded sample, or if neither are available a plain plug with root diameter of the thread. The front part of the head (roller cage) is turned within the range of the three slotted holes (2) until the rolls (18) become fully engaged with the screw plug gauge, sample or plain plug. The three nuts (15) are then re-tightened. Should the effective diameter of the thread rolled not be correct, i. e. the effective diameter is too large, the three nuts (15) must be loosened and the front part of the head turned one half a calibration in the direction of the minus sign. A rolled thread should not be over rolled, or re-rolled a second time. If the length of the three slotted holes (2) is insufficient for the necessary adjustment and the zero mark 0 on the roller cage is at the ultimate minus setting, proceed as follows: No. Pcs. escription 1 1 Clutch or shank 2 1 Spring housing 3 1 Centre plate 1 Front plate 5 3 Eccentric spindles 3 Spacing studs 7 1 Centre gear 8 3 Gear 9 2) 1 Stud (Handle) 10 1 Coil spring 11 1 Circlip 12 1 Circlip 13 1 set Needle roller bearings or carbide bush 1 3 Counter-Sunk-Screws 15 3 Hexagon nut 1 1 Washer (ring type) 17 2) 1 Hexagon nut 18 3 Thread roll 20 1 Stop screw body 21 1 Stop screw 22 1 Stop screw lock nut 23 2) 1 Ball 2 1 Washer 25 1) 3 Washer 1) F12 C1, F23 C2, F23300 C2 and F3 C2 2) F1223 C1 and F23300 C2 Head to be adjusted to a smaller diameter: Remove the three nuts (15) and ring type washer (1). The roller cage is then drawn off and turned round 120 approx, in the direction of the minus sign. It is then re-assembled. The secondary zero marking now appears on the plus side (+) of the scale. Ring type washer (1) and nuts (15) are put on again, the head finally adjusted to correct size as per previous paragraph and nuts are tightened. It is now possible to adjust the head to a smaller diameter. Head to be adjusted to a larger diameter: Same procedure as before, but turning direction is just reversed. Adjustment of Head to thread length: Adjustment to thread length is always done when the head is in an open position, i. e. the head is opened in axial direction by disengaging the dog coupling (1 an). This brings the front position of the head forward corresponding to the height of the dog coupling. Operation with Inside Stop: Stop screw (21) is adjusted to required thread length and locked by hexagon nut (22). If the component touches the stop screw (21), the dog coupling (1 an) is disengaged and the head opens automatically. The unclamped length of the component is not of decisive importance here. Operation with Outside Stop: The thread length, where chucking length is controlled, is set by a stop on the machine, which limits the forward travel of the sleeve, or the threading spindle or the turret slide. When the stop is reached, the dog coupling is disengaged and the head opens automatically. Closing of Head: When the head is closed, the rolls (18) are brought back into the rolling position. The front part oft he head is turned by using the handle (9) with ball (23), (if used on Automatics, closing is accomplished by using closing roller over a cam) until the coupling rests between the spring housing (2) and shank (1).

5 of the rolls (1 K = approx. 2.3 x pitch, 2 K = approx. 3.3 x pitch). The diameter, must be below the root diameter of the thread. Also important is the accurate alignment of the head to the component. Tolerance for the starting diameter: Once the accurate starting diameter, determined by a test rolling operation, has been found, then this should be considered as the maximum dimension, if the thread has been rolled just up to its crest and the effective diameter is approx. at the maximum dimension within the permissible thread tolerance. Among others the tolerance of the starting diameter is depending to what extent the thread has been rolled to. As a guide for standard threads with tolerance class g the following may be used: starting diameter tolerance half effective diameter tolerance. Rolling Speed: According to component profile and spindle speeds available, the following rolling speeds are recommended: for V-type threads approx m/min (5 200 ft/min) for Acme-type threads approx m/min ( ft/min). The rolling speed is arrived at by figuring the same as tor the cutting speed. Rolling operation: The rate of feed approach should correspond to the pitch of thread to be rolled. After three to four pitches of thread have been rolled, the Rolling Head takes over the feed movement. The support respectively the adapter sleeve should be set up for easy movement in either direction at any rate. Undercut Fig. 1 Example of Assembly for Rolling Heads in FU -design Separate Parts to be assembled into groups (fig. 1). Apply ample grease to Ball Bearings to avoid drop out when putting into the Gear Ring (fig. 2). The gears on the Gear Sector then point to the centre. The gears are to be brought into engagement (fig. 3), attention is to be paid to uniformness and perhaps marking 0 is to be noted. Gearings to be brought into approx. centre position. Assembly group (fig. 3) to be put on Lower Assembly Group (fig. ). The 0 marking has to be in the area of the Guide Scale. Care should be taken to ensure that there is no gap within the ball track, because otherwise the Ball Bearings could drop out. Fig. 2 Fig. Operating Instructions Thread Rolling Heads FU 32, FU 3-1, FU 3-1 Coolants and lubricants: Recommended coolants and lubricants are those, which are also used for cutting operations, these are solutions with diluted ratio of 1:10 up to 1:20 perhaps with high pressure additives and thin cutting oils. Possible errors to be made: 1. Starting diameter selected too large or head setting was too small, that means an overload pressure is generated, which in most cases may be seen at the thread end by building up a bead at the thread crests over approx. the width of the rolls. 2. Chamfering (also at the undercut) is not in accordance with the rolling instructions. 3. Setting for length selected Incorrect or component length variating (rolls are running against a shoulder).. Jamming of the rolls or evidence of wear on the eccentric spindles caused be heavy dirt accumulated in the coolant. 5. Unclean thread start and perhaps damage of the rolls caused by incorrect feed approach.. amage on the Rolls or rolling of two-start threads caused by incorrect assembly of the Rolls. 7. Premature opening gof the Rolling Head caused by wear on the Wedges for the Coupling (9) or the og Coupling (2). Wedges for the Coupling (9) can be used several times more by tuming them around. Fig. 3 LMT FETTE Werkzeugtechnik GmbH & Co. KG Grabauer St Schwarzenbek Germany Phone Fax Rolling Head-Hotline Hotline teamrollen@lmt-tools.com Printed in Germany, No G ( M/H)

6 IMPORTANT: In the case of re-ordering of Spare Parts, please state Rolling Head Type and Serial-No. Please note marking on the Front Plate! S = Special angle (example FU 3-1 S) L = esign for Left Hand Threads (example FU 3-1 L) SL = Special angle for Left Hand Threads (example FU 3-1 SL) X... = Special design (example FU 3-1 X101) Ke = Rolling Head for rolling of Serrations (example FU 3-1 Ke) In case of re-ordering of Rolls, please state the Roll-Code-No., which is marked on the letter side of the Roll in addition to the dimension (e. g. for rolling head FU 3-1 e. g. 3/...)! Spare Parts No. Pcs. escription 1 1 Flange 2 1 og coupling 3 1 Operating ring 1 Spring housing 5 1 Gear ring 3 Gear sectors 7 1 Centre plate 8 1 Front plate 9 1 Sleeve 10 3 Pin 11 1 Coil spring 12 1 Brake ring 13 Spring pads 1 3 Eccentric spindles 15 3 Spacing studs 1 1 Ball bearing cage 18 3 Thread rolls Ball bearings 21 1 set 3) Needle roller bearnings or carbide bushing 22 3 Keys 23 Coil spring 2 3 Allen screws 25 3 Allen screws 2 Allen screws 27 Studs 28 3 Allen screws 29 Hexagon nuts 30 Washer 31 3 Spring washer 33 3 Pins 3 3 Locking pins 35 1 Stop screw body 3 1 Stop screw 37 1 Hexagon nut 38 2) 1 Ball for handle 39 2) 1 Hexagon nut 0 2) 1 Handle 1 3 Fitting keys 2 2 Fitting keys 3 2 Locking pin Schnorr-circlip 5 3 Grub screw 3 Grub screw 7 1) Thrust bearings 8 1) 3 Axial washer 9 3 Coupling wedge 50 8 Allen screws 51 1) 3 Centering plate 52 1) 3 Centering plate 1) only for Typ FU 3-1 2) only for fixed application 3) for FU 32 only carbide bushes Rolling Heads FU 32, FU 3-1, FU 3-1 (for fixed and rotating application) Assembly of Thread RolIs: Remove Front Plate (8), apply Molykote or similar lubricating agents to the Roll Bearing surfaces if possible. For type FU 3-1: insert axial washers (8) together with Centering Plates (51) and Trust Bearings (7) on the side of the Centre Plate (7). Assemble Rolls in the sequence as marke-2-3 or A-B-C in clockwise direction (for left hand threads in counter-clockwise direction). Insert Needle Roller Bearings or Carbide Bushings (21). Put on Front Plate (8) and tighten screws. For type FU 3-1: Fit Centering Plates (52) with Thrust Bearings (7). Setting of the Rolling Head to thread diameter: The Rolling Head has to be set to thread diameter when it is in closed position, that means this is done by turning the Gear Ring by means of Ball Handle (38) and the og Coupling (2) gets into locking position and there will be a wide gap between Flange (1) and og Coupling (2). The Hexagon Nuts (29) have to be loosened. By using a Setting Gauge, a Thread Sample or a Plain Plug having the root diameter of the thread to be rolled, the Gear Ring (5) is turned by means of Ball Handle (38) in such a way until the outside diameter of the Rolls touch in Setting Gauge. After that the Hexagon Nuts (29) are tightened up in some cases it may be necessary when setting that a slight correction has to be made on the guide scale towards minus. The accurate setting should be determined by test rolling! If the effective diameter reached is too big or too small then the head setting has to be corrected towards minus or plus. A rolled thread should never be overrolled a second time. Setting of the Rolling Head to thread length: The thread length is set basically when the Rolling Head is in opened position, to do this it is necessary that the Operating Ring (3) is pushed towards Flange (1). Between Flange (1) and og Coupling (2) there is now only a very small gap to be noted. a) Opening by means of Internal End Stop: Stop Screw (3) is to be set to the required thread length and is locked by Hexagon Nut (37). In doing this the length of the component extending beyond the clamped portion is of no importance in this case. b) Opening by means of External End Stop over Operating Ring: The thread length is set by an End Stop for use with an additional yoke, keeping the length of component extending beyond the clamped portion uniform. When the yoke touches the End Stop, the Rolling Head opens automatically. Important: As opposed to opening by means of Internal End Stop it is in this case absolutely necessary to maintain uniform component length extending beyond the clamped portion, in case rolling is done against a shoulder or similar. Closing of Head: In case of fixed application the Rolling Head is closed by means of Ball Handle (38) and turning of the Gear Ring (5). In case of revolving application closing of the Rolling Head is accomplished by quick brake action in split second time, this is done by pushing the operating ring by means of the additional yoke against the Brake Ring (12). Machining of the component: Starting diameter to be thread rolled must be equivalent to the effective diameter. eviations are possible, depending upon type of component material being used. The starting diameter arrived at now should never be increased. The components have to be chamfered under) against the axis and must be concentric. An undercut at the thread run-out is not required. If an undercut is called for, the same should be chamfered according to sketch below. The width of the undercut depends upon the lead

7 Undercut Tolerance for the starting diameter: Once the accurate starting diameter, determined by a test rolling operation, has been found, then this should be considered as the maximum dimension, if the thread has been rolled just up to its crest and the effective diameter is approx. at the maximum dimension within the permissible thread tolerance. Among others the tolerance of the starting diameter is depending to what extent the thread has been rolled to. As a guide for standard threads with tolerance class g the following may be used: starting diameter tolerance half effective diameter tolerance. Rolling Speed: According to component profile and spindle speeds available, the following rolling speeds are recommended: for V-type threads approx m/min (5 200 ft/min) for Acme-type threads approx m/min ( ft/min). The rolling speed is arrived at by figuring the same as tor the cutting speed. Rolling operation: The feed rate of approach should be equivalent to the pitch of thread to be rolled. After engagement over 3 thread pitches, the head itself takes over the feed movement. The support respectively the adaptor sleeve should be set-up tor easy movement in either direction at any rate. Coolants and lubricants: Recommended coolants and lubricants are those, which are also used for cutting operations, i. e. solutions with diluted ratio of 1:10 up to 1:20 perhaps with high pressure additives and thin cutting oils. Fig. 1 Example of Assembly for Rolling Heads in FU -design Separate Parts to be assembled into groups (fig. 1). Apply ample grease to Ball Bearings to avoid drop out when putting into the Gear Ring (fig. 2). The gears on the Gear Sector then point to the centre. The gears are to be brought into engagement (fig. 3), attention is to be paid to uniformness and perhaps marking 0 is to be noted. Gearings to be brought into approx. centre position. Assembly group (fig. 3) to be put on Lower Assembly Group (fig. ). The 0 marking has to be in the area of the Guide Scale. Care should be taken to ensure that there is no gap within the ball track, because otherwise the Ball Bearings could drop out. Fig. 2 Fig. Operating Instructions Thread Rolling Heads FU -1, FU 5-1 Possible errors to be made: 1. Starting diameter selected too large or head setting was too small, that means an overload is generated, which in most cases may be seen at the thread end by building up a bead at the thread crests over approx. the width of the rolls. 2. Chamfering (also at the undercut) is not in line with the rolling instructions. 3. Setting for length selected Incorrect or component length variating (rolls are running against a shoulder).. Jamming of the rolls or evidence of wear on the eccentric spindles caused be heavy dirt accumulated in the coolant. 5. Unclean thread start and perhaps damage of the rolls caused by incorrect feed approach.. amage on the Rolls or rolling of two-start threads caused by incorrect assembly of the Rolls. 7. Premature opening of the Rolling Head caused by wear on the Wedges for the Coupling (9) or the og Coupling (2). Wedges for the Coupling (9) can be used several times more by tuming them around. Fig. 3 LMT FETTE Werkzeugtechnik GmbH & Co. KG Grabauer St Schwarzenbek Germany Phone Fax Rolling Head-Hotline Hotline teamrollen@lmt-tools.com Printed in Germany, No G ( M/H)

8 IMPORTANT: In the case of re-ordering of Spare Parts, please state Rolling Head Type and Serial-No. Please note marking on the Front Plate! S = Special angle (example FU -1 S) L = esign for Left Hand Threads (example FU -1 L) SL = Special angle for Left Hand Threads (example FU -1 SL) X... = Special design (example FU -1 X101) Ke = Rolling Head for rolling of Serrations (example FU -1 Ke X 102) In case of re-ordering of Rolls, please state the Roll-Code-No., which is marked on the letter side of the Roll in addition to the dimension (e. g. for rolling head FU -1 e. g. 3/...)! Spare Parts No. Pcs. escription 1 1 Flange 2 1 og coupling 3 1 Operating ring 1 Spring housing 5 1 Gear ring 3 Gear sectors 7 1 Centre plate 8 1 Front plate 9 1 Sleeve 10 3 Pins 11 1 Coil spring 12 1 Brake ring 13 Spring pads 1 3 Eccentric spindles 15 3 Spacing studs 1 1 Ball bearing cage 17 1) Axial washer 18 3 Thread rolls Ball bearings 21 1 set Needle roller bearnings 22 3 Keys 23 Coil spring 2 3 Allen screws 25 3 Allen screws 2 Allen screws 27 Studs 28 8 Allen screws 29 Hexagon nuts 30 Washer 31 3 Spring washer 33 3 Pins 3 3 Locking pins 35 1 Stop screw body 3 1 Stop screw 37 1 Hexagon nut 38 2) 1 Ball for handle 39 2) 1 Hexagon nut 0 2) 1 Handle 1 3 Fitting keys 2 2 Fitting keys 3 2 Locking Pin Schnorr-circlip 5 3 Grub screw 3 Grub screw 7 1) Thrust bearings 8 3 Cover plate 9 3 Coupling wedge 50 8 Allen screws 1) only for Typ FU 5-1 2) only for fixed application Rolling Heads FU -1, FU 5-1 (for fixed and rotating application) Assembly of Thread RolIs: Remove Front Plate (8), apply Molykote or similar lubricating agents to the Roll Bearing surfaces if possible. For type FU 5-1: Assemble Thrust Bearings (7) together with the axial Washers (17) and fix them on both sides of the Rolls. Assemble Rolls in the sequence as marke-2-3 or A-B-C in clockwise direction (for left hand threads in counter-clockwise direction). Insert Needle Roller Bearings (21), put on Front Plate (8) and tighten screws. Setting of the Rolling Head to thread diameter: The Rolling Head has to be set to thread diameter when it is in closed position, that means this is done by turning the Gear Ring by means of Ball Handle (38) and the og Coupling (2) gets into locking position and there will be a wide gap between Flange (1) and og Coupling (2). The Hexagon Nuts (29) have to be loosened. By using a Setting Gauge, a Thread Sample or a Plain Plug having the root diameter of the thread to be rolled, the Gear Ring (5) is turned by means of Ball Handle (38) in such a way until the outside diameter of the Rolls touch in Setting Gauge. After that the Hexagon Nuts (29) are tightened up in some cases it may be necessary when setting that a slight correction has to be made on the guide scale towards minus. The accurate setting should be determined by test rolling! If the effective diameter reached is too big or too small then the head setting has to be corrected towards minus or plus. A rolled thread should never be overrolled a second time. Setting of the Rolling Head to thread length: The thread length is set basically when the Rolling Head is in opened position, to do this it is necessary that the Operating Ring (3) is pushed towards Flange (1). Between Flange (1) and og Coupling (2) there is now only a very small gap to be noted. a) Opening by means of Internal End Stop: Stop Screw (3) is to be set to the required thread length and is locked by Hexagon Nut (37). In doing this the length of the component extending beyond the clamped portion is of no importance in this case. b) Opening by means of External End Stop over Operating Ring: The thread length is set by an End Stop for use with an additional yoke, keeping the length of component extending beyond the clamped portion uniform. When the yoke touches the End Stop, the Rolling Head opens automatically. Important: As opposed to opening by means of Internal End Stop it is in this case absolutely necessary to maintain uniform component length extending beyond the clamped portion, in case rolling is done against a shoulder or similar. Closing of the Rolling Head: In case of fixed application the Rolling Head is closed by means of Ball Handle (38) and turning of the Gear Ring (5). In case of revolving application closing of the Rolling Head is accomplished by quick brake action in split second time, this is done by pushing the operating ring by means of the additional yoke against the Brake Ring (12). Machining of the component: Starting diameter to be thread rolled must be equivalent to the effective diameter. eviations are possible, depending upon type of component material being used. The starting diameter arrived at now should never be increased. The components have to be chamfered under) = against the axis and must be concentric. An undercut at the thread run-out is not required. If an undercut is called for, the same should be chamfered according to sketch below. The width of the undercut depends upon the lead of the rolls (1 K = approx. 2.3 x pitch, 2 K = approx. 3.3 x pitch). The diameter d, must be below the root diameter of the thread. Also important is the accurate alignment of the head to the component.

9 of the rolls (1 K = approx. 2.3 x pitch, 2 K = approx. 3.3 x pitch). The diameter d, must be below the root diameter of the thread. Also important is the accurate alignment of the head to the component. Tolerance for the starting diameter: Once the accurate starting diameter, determined by a test rolling operation, has been found, then this should be considered as the maximum dimension, if the thread has been rolled just up to its crest and the effective diameter is approx. at the maximum dimension within the permissible thread tolerance. Among others the tolerance of the starting diameter is depending to what extent the thread has been rolled to. As a guide for standard threads with tolerance class g the following may be used: starting diameter tolerance half effective diameter tolerance. Rolling Speed: According to component profile and spindle speeds available, the following rolling speeds are recommended: for V-type threads approx m/min (5 200 ft/min) for Acme-type threads approx m/min ( ft/min). The rolling speed is arrived at by figuring the same as tor the cutting speed. Rolling operation: The feed rate of approach should be equivalent to the pitch of thread to be rolled. After engagement over 3 thread pitches, the head itself takes over the feed movement. The support respectively the adaptor sleeve should be set-up tor easy movement in either direction at any rate. Undercut Fig. 1 Example of Assembly for Rolling Heads in FU -design Separate Parts to be assembled into groups (fig. 1). Apply ample grease to Ball Bearings to avoid drop out when putting into the Gear Ring (fig. 2). The gears on the Gear Sector then point to the centre. The gears are to be brought into engagement (fig. 3), attention is to be paid to uniformness and perhaps marking 0 is to be noted. Gearings to be brought into approx. centre position. Assembly group (fig. 3) to be put on Lower Assembly Group (fig. ). The 0 marking has to be in the area of the Guide Scale. Care should be taken to ensure that there is no gap within the ball track, because otherwise the Ball Bearings could drop out. Fig. 2 Fig. Operating Instructions Thread Rolling Heads FU 5-1, FU 5-1 Coolants and lubricants: Recommended coolants and lubricants are those, which are also used for cutting operations, i. e. solutions with diluted ratio of 1:10 up to 1:20 perhaps with high pressure additives and thin cutting oils. Possible errors to be made: 1. Starting diameter selected too large or head setting was too small, that means an overload is generated, which in most cases may be seen at the thread end by building up a bead at the thread crests over approx. the width of the rolls. 2. Chamfering (also at the undercut) is not in line with the rolling instructions. 3. Setting for length selected Incorrect or component length variating (rolls are running against a shoulder).. Jamming of the rolls or evidence of wear on the eccentric spindles caused be heavy dirt accumulated in the coolant. 5. Unclean thread start and perhaps damage of the rolls caused by incorrect feed approach.. amage on the Rolls or rolling of two-start threads caused by incorrect assembly of the Rolls. 7. Premature opening of the Rolling Head caused by wear on the Wedges for the Coupling (9) or the og Coupling (2). Wedges for the Coupling (9) can be used several times more by turning them around. Fig. 3 LMT FETTE Werkzeugtechnik GmbH & Co. KG Grabauer St Schwarzenbek Germany Phone Fax Rolling Head-Hotline Hotline teamrollen@lmt-tools.com Printed in Germany, No G ( M/H)

10 IMPORTANT: In the case of re-ordering of Spare Parts, please state Rolling Head Type and Serial-No. Please note marking on the Front Plate! S = Special angle (example FU 5-1 S) L = esign for Left Hand Threads (example FU 5-1 L) SL = Special angle for Left Hand Threads (example FU 5-1 SL) X... = Special design (example FU 5-1 X101) Ke = Rolling Head for rolling of Serrations (example FU 5-1 Ke) In case of re-ordering of Rolls, please state the Roll-Code-No., which is marked on the letter side of the Roll in addition to the dimension (e. g. for rolling head FU 5-1 e. g. FU 5-1/...)! 8a a Spare Parts No. Pcs. escription 1 1 Flange 2 1 Clutch 3 1 Operating ring 1 Spring housing 5 1 Gear ring 3 Gear sectors 7 1 Centre plate 7a 3 Centre plate bushing 8 1 Front plate 8a 3 Front plate bushing 9 1 Sleeve 10 3 Pin 11 1 Coil spring 12 1 Brake ring 13 Spring pin 1 3 Eccentric spindles 15 3 Spacer studs 1 1 Bearing cage 17 2) 3 Washer 18 3 Thread roll Steel ball 21 3 Carbide bushing 22 3 Fitting key 23 3 Pressure spring 2 3 Front plate screw 25 3 Cap screw 2 Cap screw 27 Stud 28 8 Cap screw 29 Hexagon nut 30 Washer 31 3 Lock washer 33 3 Shear pins 3 3 Roll pins 35 1 Stop screw body 3 1 Stop screw 37 1 Hexagon nut 38 3) 1 Ball 39 1)3) 3 Cap screw 0 3) 1 Handle 1 3 Fitting key 2 2 Fitting key 3 1) 2 Shear pins Circlip 5 2)3) 1 Hexagon nut 2) 3 Set screw 8 3 Cover plate 9 3 Clutch wedge 51 2) Centering ring 52 2) Thrust bearings 53 3 Set screw 1) for FU 5-1 2) for FU 5-1 3) only for fixed application Rolling Heads FU 5-1, FU 5-1 (for fixed and rotating application) Assembly of Thread RolIs: Remove Front Plate (8), apply Molykote or similar lubricating agents to the Roll Bearing surfaces if possible. For type FU 5-1: Assemble thrust Bearings (52) together with the Centering Plates (51) and fix them to both sides of the Rolls. Assemble Rolls in the sequence as marke-2-3 or A-B-C in clockwise direction (for left hand threads in counter-clockwise direction). Insert Needle Roller Bearings (21), put on Front Plate and screw down tight. Setting of the Rolling Head to thread diameter: The Rolling Head has to be set to thread diameter when it is in closed position, that means this is done by turning the Gear Ring by means of Ball Handle (38) and the og Coupling (2) gets into locking position and there will be a wide gap between Flange (1) and og Coupling (2). The Hexagon Nuts (29) have to be loosened. By using a Setting Gauge, a Thread Sample or a Plain Plug having the root diameter of the thread to be rolled, the Gear Ring (5) is turned by means of Ball Handle (38) in such a way until the outside diameter of the Rolls touch in Setting Gauge. After that the Hexagon Nuts (29) are tightened up in some cases it may be necessary when setting that a slight correction has to be made on the guide scale towards minus. The accurate setting should be determined by test rolling! If the effective diameter reached is too big or too small then the head setting has to be corrected towards minus or plus. A rolled thread should never be overrolled a second time. Setting of the Rolling Head to thread length: The thread length is set basically when the Rolling Head is in opened position, to do this it is necessary that the Operating Ring (3) is pushed towards Flange (1). Between Flange (1) and og Coupling (2) there is now only a very small gap to be noted. a) Opening by means of Internal End Stop: Stop Screw (3) is to be set to the required thread length and is locked by Hexagon Nut (37). In doing this the length of the component extending beyond the clamped portion is of no importance in this case. b) Opening by means of External End Stop over Operating Ring: The thread length is set by an End Stop for use with an additional yoke, keeping the length of component extending beyond the clamped portion uniform. When the yoke touches the End Stop, the Rolling Head opens automatically. Important: As opposed to opening by means of Internal End Stop it is in this case absolutely necessary to maintain uniform component length extending beyond the clamped portion, in case rolling is done against a shoulder or similar. Closing of Head: In case of fixed application the Rolling Head is closed by means of Ball Handle (38) and turning of the Gear Ring (5). In case of revolving application closing of the Rolling Head is accomplished by quick brake action in split second time, this is done by pushing the operating ring by means of the additional yoke against the Brake Ring (12). Machining of the component: Starting diameter to be thread rolled must be equivalent to the effective diameter. eviations are possible, depending upon type of component material being used. The starting diameter arrived at now should never be increased. The components have to be chamfered under) = against the axis and must be concentric. An undercut at the thread run-out is not required. If an undercut is called for, the same should be chamfered according to sketch below. The width of the undercut depends upon the lead