E V7 GRINDING 15E

Transcription

1 E V7 GRINDING 15E

2 SMW-AUTOBLOK worldwide Headquarters / Production Plants Subsidiaries Representations SMW-AUTOBLOK manufacturing plant Meckenbeuren AUTOBLOK manufacturing plant Caprie-Torino Visit our website for more information Latest product catalog Newest product innovations Worldwide contact data Tutor: new customer section* Free web applications JAW FINDER free application to search for jaws very quick and easy D-Vario Configurator free application to configurate your set up Update GFT-X online firmware update available Free application to search for jaws quick and easy Covers all coon chuck manufacturers 3D models for all standard jaws available * Registration required Free application to configurate your set up Save and quick configuration for different gears Export of configuration to your computer possible Free update software for the firmware of the Gripping force meter GFT-X* Firmware update to download from website* Takes only a few minutes for a complete update

3 Overview Grinding Applications SRG Workpieces High precision grinding Steady Rests Grinding diameter Ø Camshafts Crankshafts Shafts Fine adjustment of the grinding center Retractable arms Suitable for follow-down grinding High rigidity Chapter 1 AcuGrind Workpieces High precision air chucks Chuck sizes Ø For OD and ID clamping Built-in pneumatic actuation For universal grinding applications Bearing rings Bearing parts Bolts Camshafts Shafts Chapter 2 Diaphragm Technology Diaphragm chucks Chuck sizes Ø Diaphragm technology for highest precision External or pitchline clamping With or without open center Workpieces Gears Gear shafts Chapter 3 FDG Workpieces High precision face drivers for machining between center pins Camshafts Gear shafts Shafts Machining of the entire surface of the workpiece with one single operation Power operated on the side of the spindle Highest run-out accuracy Chapter 4 CPG Pneumatic pancake cylinder for diaphragm chuck D-VARIO and face driver FDG Easy installation for grinding and turning machines without hydraulic unit Operating pressure 2-8 bar Medium feed for air / coolant Chapter 5 EM-S Segment sleeve mandrel Clamping diameter Ø For ID clamping Very rigid design Workpieces Bearing rings Bearing parts Chapter 6

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5 SRG Chapter 1 SRG High precision grinding Steady Rests Grinding diameter Ø Fine adjustment of the grinding center Retractable arms Suitable for follow down grinding High rigidity SMW-AUTOBLOK 5

6 Application / customer benefits Application / customer benefits Support of shaft type workpieces on grinding machines Particularly suitable for the machining of crankshafts and camshafts Rapid set up of the Steady Rest to the grinding center with the fine adjustment Suitable for Follow down grinding Standard equipment Basic Grinding Steady Rest SRG Delivery in transport box (Padholder for the middle piece, Clamping Kit and Pad Kits are not scope of delivery. See therefor the overview for the confi gurations below.) Technical Features Horizontal fine adjustment of the grinding center 2. Vertical fine adjustment of the grinding center 3. Retractable Steady Rest arms 4. Port for compressed air against dust and coolant 3 5. Monitoring of end positions with proximity switches (switches not included) Overview Configuration Select padholder for the middle piece (SRG 1 / 1 S / 2) Select clamping kit (SRG 2 F / 4 F / 5.1 FS; SRG-B 4 F / 5 F) Select Pad Kit Padholder for the middle piece (*) Clamping Kit for the arms (**) Pad Kit (***) Consisting of padholder middle piece Consisting of 2 nests for the arms and 1 Consisting of 3 pads incl. 3 mounting (incl. mounting material) 3 versions available: 0 degree, ± 5 degree, ± 7 degree Can be rotated by 180 degrees padholder for the middle piece (incl. mounting material) The different clamping ranges can be covered by different clamping kits screws Standard for clamping range as shown on the Steady Rest Special for shifting of the clamping range -5 * Consisting of padholder for the middle piece incl. mounting material ** Consisting of padholder for the middle piece and the nests for the arms incl. mounting material *** Consisting of 3 pads and 3 mounting bolts 6 SMW-AUTOBLOK

7 SRG/ SRG-B Grinding Steady Rests SMW-AUTOBLOK Type Basic Steady Rest Clamping range Padholder 0 degree* Padholder ± 5 degree* Padholder ± 7 degree* Pad Kit Standard Pad Kit Special *** SRG SRG SRG 1 S SRG Working pressure bar Follow down grinding Yes Yes Yes Yes SMW-AUTOBLOK Type Basic Steady Rest Clamping range Clamping kit Clamping range Clamping kit 0 degree** Clamping kit -2 degree** Clamping kit -3 degree** Clamping kit -5 degree** Clamping kit -7 degree** Pad Kit Standard Pad Kit Special*** SRG 2 F Ordering review SRG 4 F SRG 5.1 FS I II III I II III IV V VI I II III IV V Working pressure bar Follow down grinding Yes Yes Yes SMW-AUTOBLOK Type Basic Steady Rest Clamping range Clamping kit Clamping range Clamping kit 0 degree** Clamping kit -2 degree** Clamping kit -3 degree** Pad Kit Standard Pad Kit Special*** SRG-B 4 F SRG-B 5 F I II III IV V VI I II III IV Working pressure bar Follow down grinding Yes Yes * Consisting of padholder for the middle piece incl. mounting material ** Consisting of padholder for the middle piece and the nests for the arms incl. mounting material *** Clamping range -5 SRG-B Side mounted cylinder SMW-AUTOBLOK 7

8 SRG 0.8 Dimensions and technical data Grinding Steady Rests For prox. switches Ø 8 A G1/8 Port for compressed air E1 P1 P2 A B U1 U2 U3 F1 F2 O1 O2 S2 S1 V D4 D3 D2 D1 C X Y T K G U4/U5 Cylinder port G 1/8 close Cylinder port G 1/8 open Drain G 1/8 Port for centralized lubrication Vertical fine adjustment Horizontal fine adjustment Subjected to technical changes. For more detailed information please ask our customer service. SMW-AUTOBLOK Type Minimum clamping diameter Maximum clamping diameter Max. loading diameter (vertical, steady open) Max. axial clearance diameter (steady open) Max. swing diameter Horizontal adjustment range Vertical adjustment range Cylinder stroke Piston area Operating pressure max. Working pressure Repeatability accuracy Mass SRG U1 3 U2 18 U3 58 U4 58 U5 58 ± 0.05 ± 0.05 A C 45 D1 25 D2 25 D3 25 D4 25 E1 60 F1 70 F2 50 G 30 K 10 O1 4 O P1 35 P2 35 S1 9 (4x) S (1x) T 30 V 30 X 10 Y cm² bar bar kg ± SMW-AUTOBLOK

9 SRG 1 A R C1 E3 E P2 P1 E2 E1 U1 U2 U3 F1 F2 O1 S2 S1 O2 D5 D4 D3 D2 D1 J V C Vertical fine adjustment Horizontal fine adjustment Y X T K G I Grinding Steady Rests Dimensions and technical data For prox. switsches Ø 12 G1/8 Port for compressed air A B U4 / U5 Cylinder port G 1/4 close Cylinder port G 1/4 open Drain Lift thread M8 H Subjected to technical changes. For more detailed information please ask our customer service. SMW-AUTOBLOK Type Minimum clamping diameter Maximum clamping diameter Max. loading diameter (vertical, steady open) Max. axial clearance diameter (steady open) Max. swing diameter Horizontal adjustment range Vertical adjustment range Cylinder stroke Piston area Operating pressure max. Working pressure Repeatability accuracy Mass G 1/8 Port centralized lubrication SRG U1 20 U2 35 U3 72 U4 72 U5 72 ± 0.20 ± 0.10 A C 55.9 C D D D D D E E E E F F G 39 H 5 I 13 J 121 K 16.1 O1 4.5 O P1 41 P2 35 R 82.8 S1 11 (5x) S (1x) T 39 V 37 X 19.5 Y cm² bar bar kg ± SMW-AUTOBLOK 9

10 SRG 1 S Dimensions and technical data For prox. switches Ø 12 A Grinding Steady Rests G1/8 Port for compressed air E1 E2 P2 P1 A B U1 U2 U3 U4/U5 F1 F2 O1 O2 S2 S1 D5 D4 D3 D2 D1 C V X Y T K G G 1/8 Port for centralized lubrication Cylinder port G 1/8 close Drain Cylinder port G 1/8 open Vertical fine adjustment Horizontal fine adjustment Subjected to technical changes. For more detailed information please ask our customer service. SMW-AUTOBLOK Type Minimum clamping diameter Maximum clamping diameter Max. loading diameter (vertical, steady open) Max. axial clearance diameter (steady open) Max. swing diameter Horizontal adjustment range Vertical adjustment range Cylinder stroke Piston area Operating pressure max. Working pressure Repeatability accuracy Mass SRG 1 S U1 20 U2 35 U3 62 U4 72 U5 72 ± 0.20 ± 0.10 A 280 C 55.8 D D D D D E E F F G 25 K 10 O1 4.5 O P1 35 P2 35 S1 9 (5x) S (1x) T 25 V 36.7 X 7.5 Y cm² bar bar kg ± SMW-AUTOBLOK

11 SRG 2 A R C1 E2 I Grinding Steady Rests Dimensions and technical data For prox. switches Ø 12 G1/8 Port for compressed air E E1 P2 P1 A B U1 U2 U3 F1 F2 U4/U5 Cylinder port G 1/4 close Cylinder port G 1/4 open O1 Drain O2 S D4 D3 D2 D1 C J V X Y H T K G Lift thread M8 Vertical fine adjustment Horizontal fine adjustment Subjected to technical changes. For more detailed information please ask our customer service. SMW-AUTOBLOK Type Minimum clamping diameter Maximum clamping diameter Max. loading diameter (vertical, steady open) Max. axial clearance diameter (steady open) Max. swing diameter Horizontal adjustment range Vertical adjustment range Cylinder stroke Piston area Operating pressure max. Working pressure Repeatability accuracy Mass G 1/8 Port centralized lubrication SRG U1 30 U2 60 U3 82 U4 95 U5 95 ± 0.20 ± 0.14 A C 79 C D D D D E E E F F2 71 G 45 H 5 I 13 J K 19 O1 4.5 O P1 42 P2 35 R 94.7 S (5x) T 44 V 42 X 13 Y cm² bar bar kg , ± SMW-AUTOBLOK 11

12 SRG 2 F A R C1 E2 E P2 P1 F1 U1 U2 U3 E1 F2 I Dimensions and technical data Grinding Steady Rests For prox. switches Ø 12 G1/8 Port for compressed air A B O1 O2 S D4 D3 D2 D1 J V C Vertical fine adjustment Horizontal fine adjustment X Y H T K G U4 U5 Cylinder port G 1/4 close Cylinder port G 1/4 open Drain Lift thread M8 Subjected to technical changes. For more detailed information please ask our customer service. SMW-AUTOBLOK Type Clamping kit Minimum clamping diameter Maximum clamping diameter Max. loading diameter (vertical, steady open) Max. axial clearance diameter (steady open) Max. swing diameter Horizontal adjustment range Vertical adjustment range Cylinder stroke Piston area Operating pressure max. Working pressure Repeatability accuracy Mass G 1/8 Port centralized lubrication SRG 2 F I II III U U U U U5 94 ± 0.20 ± 0.14 A C 79 C D D D D E E E F F2 71 G 45 H 5 I 13 J K 19 O1 4.5 O P1 42 P2 35 R 94.7 S (5x) T 44 V 42 X 13 Y cm² bar bar kg ± SMW-AUTOBLOK

13 SRG 4 F A J U3 G1/8 Port for compressed air H E E1 P2 P1 U1 U2 F1 F2 U5 O1 O2 D2 D1 C V T K G I Grinding Steady Rests Dimensions and technical data For prox. switches Ø 12 A B U3 U4 S Cylinder port G 1/4 close Drain Cylinder port G 1/4 open Lift thread M10 Vertical fine adjustment Horizontal fine adjustment Subjected to technical changes. For more detailed information please ask our customer service. SMW-AUTOBLOK Type Clamping kit Minimum clamping diameter Maximum clamping diameter Max. loading diameter (vertical, steady open) Max. axial clearance diameter (steady open) Max. swing diameter Horizontal adjustment range Vertical adjustment range Cylinder stroke Piston area Operating pressure max. Working pressure Repeatability accuracy Mass G 1/8 Port centralized lubrication SRG 4 F I II III IV V VI U U U U U5 228 ± 0.20 ± 0.14 A C D D E E F1 108 F2 108 G 55 H 6 I 16 J K 18.2 O1 4.5 O P1 48 P2 43 S M12 (6x) T 54.5 V cm² bar bar kg ± SMW-AUTOBLOK 13

14 S SRG-B 4 F A J U3 H E E1 P2 P1 U1 U2 F1 F2 U5 O2 D2 D1 C O For prox. switches Lift thread M10 Ø 12 V V1 K1 K G T U3 U4 I Grinding Steady Rests Dimensions and technical data G1/8 Port for compressed air Drain Vertical fine adjustment Horizontal fine adjustment Cylinder port G 1/4 close (A) Cylinder port G 1/4 open (B) Subjected to technical changes. For more detailed information please ask our customer service. SMW-AUTOBLOK Type Clamping kit Minimum clamping diameter Maximum clamping diameter Max. loading diameter (vertical, steady open) Max. axial clearance diameter (steady open) Max. swing diameter Horizontal adjustment range Vertical adjustment range Cylinder stroke Piston area Operating pressure max. Working pressure Repeatability accuracy Mass G 1/8 Port centralized lubrication SRG-B 4 F I II III IV V VI U U U U U5 228 ± 0.20 ± 0.14 A 465 C D D E E F1 108 F2 108 G 55 H 5 I 13 J K 18.2 K1 9 O O2 57 P1 48 P2 43 S M12 (6x) T 106 V 106 V1 cm² bar bar kg ± SMW-AUTOBLOK

15 SRG-B 5 F D3 A J C1 U3 H P2 E U1 U2 U5 P1 E1 F2 I Dimensions and technical data Grinding Steady Rests G1/8 Port for compressed air S F1 V O2 D2 D1 C V1 T K1 K G U3 U4 G1/8 Port for compressed air Drain For prox. switches Ø 12 G 1/8 Port centralized lubrication Lift thread M10 Cylinder port G 1/4 close (A) Cylinder port G 1/4 open (B) O Horizontal fine adjustment Vertical fine adjustment Subjected to technical changes. For more detailed information please ask our customer service. SMW-AUTOBLOK Type Clamping kit Minimum clamping diameter Maximum clamping diameter Max. loading diameter (vertical, steady open) Max. axial clearance diameter (steady open) Max. swing diameter Horizontal adjustment range Vertical adjustment range Cylinder stroke Piston area Operating pressure max. Working pressure Repeatability accuracy Mass SRG-B 5 F I II III IV U U U U U5 310 ± 0.20 ± 0.14 A 624 C C D D2 71 D E E F1 149 F2 149 G 65.3 H 9 I 24 J K 22.9 K O 468 O2 29 P1 45 P2 45 S M16 (5x) T V 154 V1 cm² bar bar kg ± SMW-AUTOBLOK 15

16 SRG 5.1 FS A E1 F2 F1 P2 E U1 U2 U3 U5 P1 I Dimensions and technical data Grinding Steady Rests G1/8 Port for compressed air For prox. switches Ø12 A B S O2 D2 D1 V C J Vertical fine adjustment Horizontal fine adjustment H K1 T K G U4 Cylinder port G 1/4 close Cylinder port G 1/4 open Drain Lift thread M10 G 1/8 Port centralized lubrication Subjected to technical changes. For more detailed information please ask our customer service. SMW-AUTOBLOK Type Clamping kit Minimum clamping diameter Maximum clamping diameter Max. loading diameter (vertical, steady open) Max. axial clearance diameter (steady open) Max. swing diameter Horizontal adjustment range Vertical adjustment range Cylinder stroke Piston area Operating pressure max. Working pressure Repeatability accuracy Mass SRG 5.1 FS I II III IV V U U U U U5 320 ± 0.22 ± 0.17 A C 190 D D E E F F G 64.3 H 6 I 16 J K K1 10 O P1 48 P2 47 S 17 (5x) T 64 V cm² bar bar kg ± SMW-AUTOBLOK

17 AcuGrind Chapter 2 AcuGrind High precision air chucks Chuck sizes Ø For OD and ID clamping Built-in pneumatic actuation, no hydraulic cylinder required For universal grinding applications SMW-AUTOBLOK 17

18 AcuGrind proofline series fully sealed low maintenance High precision air chuck Ø AcuGrind with built-in pneumatic actuating cylinder fully sealed Application/customers benefits Sealed standard chuck for high-precision turning and grinding Highest accuracy - runout and repeatability Built-in pneumatic actuation, no hydraulic cylinder required Technical features Base jaws case hardened Repeatability < proofline chucks = fully sealed - low maintenance Standard equipment Odering example Power chuck AcuGrind 150, Id.No Boring ring for I.D. clamping Boring ring for O.D. clamping Lubricating oil Tapped holes in the face are optional. β Master jaw AcuGrind 80 E F I H Master jaw AcuGrind α M A C D L J N M K J K J Master jaw AcuGrind 125 N M M M M N M K Connection AcuGrind 200 E L L M M K N M L J 36 D Master jaw AcuGrind 150 Master jaw AcuGrind 200 N M M J K M M H 6,6 T G L Subject to technical changes. For more detailed information please ask for customer drawing. Technical data SMW-AUTOBLOK Type AcuGrind 80 AcuGrind 100 AcuGrind 125 AcuGrind 150 AcuGrind 200 AcuGrind 250 Order number Outside Ø A Centering Ø C Distributor Ø D min. / max. E 9.5 / / / / 18-3 / / Height F Chuck mounting bolts G 6 x M5 6 x M5 6 x M6 6 x M6 6 x M10 6 x M10 H I Pin Ø J Jaw mounting bolts K M5 M5 M5 M5 3/8" - 24 UNF 3/8" - 24 UNF Distance to 1. pin max. / min. L / / / / / / M N Bolt circle Ø T α 30 6 x 60 6 x 60 6 x 60 6 x 60 6 x 60 β Repeatability < < < < < < Radial jaw stroke Speed max. min Clamping force at 6 bar kn Operating pressure bar Weight kg jaw and 4-jaw power chucks available on request. 18 SMW-AUTOBLOK

19 Top jaws for AcuGrind power chucks AcuGrind Top jaws for AcuGrind WAK Soft top jaws SBK Segment jaws 120º Chuck type Material Height Height AcuGrind 80 Aluminium Steel Aluminium AcuGrind Steel Aluminium AcuGrind Steel Aluminium AcuGrind Steel Aluminium AcuGrind Steel AcuGrind 250 Aluminium Steel Top jaws in special version on request. SMW-AUTOBLOK 19

20 AcuGrind Air feed tubes fix (AP) SMW-AUTOBLOK Speed Type max. (min -1 ) AP2S AP3S AP2S/AP3S = with serration Version 2 airways 3 airways AP2S AP3S S = 5 C D LS E G Chuck type LS E C D S F G Spindle length Chuck adaptor Bushing (included in scope of delivery of the air feed tubes type AP) Adaptor (mounting ring manufactured by the customer) Safety distance AcuGrind chuck Support ring for tube bundle longer 600 Ordering example NOTE In case of an order of the air feed tubes type AP, the length of the air feed tube is necessary. For calculating the correct length of the air feed tube (LR) are the following dimensions necessary: LS, E, C, D and the chuck type! NOTE Use only with clean and oiled air. 20 SMW-AUTOBLOK

21 Air feed tubes flex (APFL) AcuGrind SMW-AUTOBLOK Speed Type max. (min -1 ) APFL APFL Version 2 airways 3 airways APFL2 APFL3 PH 6-2 / PH 6-3 SMW-AUTOBLOK Typ PH 6-2 PH 6-3 Id.-Nr Number of airways 2 3 Airways outside Ø () 6 6 Airways inside Ø () 4 4 Medium air air Max. operating pressure (MPa) at 20 C Operating temperature -20 C C -20 C C Length () Max. working distance () Outside Ø coil () Material Polyurethan Polyurethan Colour black black Rotary joint APFL Aluminium bushing Air feed tube adaptor Spindle Adaptor plate Power chuck AcuGrind SMW-AUTOBLOK 21

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23 Diaphragm Chapter 3 Diaphragm Technology Diaphragm chuck Chuck sizes Ø Diaphragm technology for highest precision Pitch line clamping or O.D. clamping With or without open center SMW-AUTOBLOK 23

24 Clamping jaws Closed center rotating cylinder Installation D Diaphragm chuck QUICK JAW CHANGE SYSTEMS Jaws Type A Jaws Type B Jaws Type C External clamping Pitchline clamping with roller cage Pitchline clamping with clamping pin Clamping jaws Rotating double piston cylinder Installation D-KOMBI Radial-axial clamping QUICK JAW CHANGE SYSTEMS Jaws Type A Jaws Type B Jaws Type C External clamping Pitchline clamping with roller cage Pitchline clamping with clamping pin 24 SMW-AUTOBLOK

25 Radial O.D. or pitch line clamping With central bore Centrifugal force compensation D-PLUS Diaphragm chuck QUICK JAW CHANGE SYSTEMS Jaws Type A Jaws Type B Jaws Type C External clamping Pitchline clamping with roller cage Pitchline clamping with clamping pin SMW-AUTOBLOK 25

26 D Diaphragm chuck QUICK JAW CHANGE SYSTEMS Main dimensions and technical data N C1 K C H M Stroke S F1 F2 A Ø E Ø F Ø P G1 Ø D Ø D1 G Q R Subject to technical changes. For more detailed information please ask for customer drawing. J B SMW-AUTOBLOK Type D-210 D-260 D-315 Mounting Size A5 A6 A6 A8 A8 A B C C Clamping range min./max. D D E F G M10 M12 M12 M16 M16 G1 M26 x 1.5 M26 x 1.5 M30 x 1.5 Jaw height H J K M N P H Q R Piston stroke min./max. S Jaw stroke at distance H Draw pull min./max.* F1 kn Draw push for chuck open F2 kn Moment of inertia kg m Weight without top tooling kg Recoended actuating cylinders Type SIN-DFR SIN-DFR SIN-DFR * Additional actuation force to the diaphragm spring clamping force applied by the clamping cylinder Advice: The max. allowed speed for the application is permanently marked on the corresponding top jaws and must not be exceeded. Advice: Please note, that it is important, that the cylinder force for pushing and pulling can be set to different values independently. Important: Never rotate the chuck without inserted jaws, otherwise the centrifugal force compensation mechanism will get damaged. 26 SMW-AUTOBLOK

27 D-KOMBI Radial-axial clamping QUICK JAW CHANGE SYSTEMS Main dimensions and technical data N K M C C1 H Ø A Ø E V Ø D1 FD FC U T stroke S FB FA Ø D G2 Ø D2 G1 S1 ø F G Subject to technical changes. For more detailed information please ask for customer drawing. J B SMW-AUTOBLOK Type D-210 KOMBI D-260 KOMBI D-315 KOMBI D-400 KOMBI Mounting Size A5 A6 A6 A8 A8 A8 A11 A B C C Clamping range without fingers D D Clamping range with fingers D E F G M10 M12 M12 M16 M16 M16 M20 G1 M28 x 1.5 M28 x 1.5 M28 x 1.5 M28 x 1.5 G2 M14 x 1.0 M14 x 1.0 M14 x 1.0 M14 x 1.0 Jaw height H J K M N Piston stroke S Axial stroke swing clamps S T U V Jaw stroke at distance H Draw pull min./max.* FD kn Draw push for chuck open FC kn Draw pull swing clamps max. FB kn Draw push swing clamps open FA kn Moment of inertia kg m Weight without top tooling kg Recoended actuating cylinder Type ZHVD-DFR ZHVD-DFR ZHVD-DFR ZHVD-DFR * Additional draw pull to the diaphragme force actuated by the actuating cylinder Advice: The max. allowed speed for the application is permanently marked on the corresponding top jaws and must not be exceeded. Important: Never rotate the chuck without inserted jaws, otherwise the centrifugal force compensation mechanism will get damaged. SMW-AUTOBLOK 27

28 D-PLUS Diaphragm chuck QUICK JAW CHANGE SYSTEMS Open center diaphragm chuck Main dimensions and technical data jaws and clamping ranges see chuck type D C G S A E F D G1 T D1 Subject to technical changes. For more detailed information please ask for customer drawing. J B SMW-AUTOBLOK Type D-PLUS-260 D-PLUS-315 Mounting Size A B C D E F G M16 M16 G1 M42x1.5 M60x1.5 J 6 6 P H Piston stroke S Through hole T Draw pull min./max.* F1 kn Draw push for chuck open F2 kn Moment of inertia kg m Weight without top tooling kg Recoended actuating cylinders Type SIN-DFR SIN-DFR * Additional actuation force to the diaphragm spring clamping force applied by the clamping cylinder. Advice: The max. allowed speed for the application is permanently marked on the corresponding top jaws and must not be exceeded. Advice: Please note, that it is important, that the cylinder force for pushing and pulling can be set to different values independently! Important: Never rotate the chuck without inserted jaws, otherwise the centrifugal force compensation mechanism will get damaged. 28 SMW-AUTOBLOK

29 D-VARIO Diaphragm chuck FLEXIBLE MODULAR SYSTEM proofline series fully sealed low maintenance Main dimensions and technical data Application/customer benefits Flexible solution for grinding with quick adjustment for short set up times Technical features Adjustable, modular jaw system for clamping different work pieces with the same jaws Key Lock System for quick positioning of the pitch of different work pieces Micrometer fine adjustment of the center line For small, medium and large batch sizes Workstop with medium feed for air sensing and integrated coolant nozzles optional Jaws for O.D. clamping (Type A) optional D-Vario Configurator: free application to configurate your set up ( Standard equipment Diaphragm chuck D-Vario (with mounting bolts) Optional accessories in the modular system: Pitch line clamping 6 different jaw sets for different outside diameters Key Lock System for different pitches of gears (see figure A, B and C) Clamping pins for different modules (Dia. of ball Ø 3,0 to 6,0 ) Locators O.D. clamping (Type A) 4 different jaw blanks for different outside diameters Factory finished jaws Locators D-VARIO Configurator Software: Safe and quick configuration of all set-ups for different gears Web-APP: from anywhere with any device feasible (internet access needed) Data export possible With this free of charge D-Vario configurator a complete top jaw and the corresponding locator with the locator pins can be configured for your gears. The export function allows you to safe your results on your PC. Start Web-App: A: Number of teeth is divisible by 3 Example of application: gear with number of teeth [z] = 30 B: Number of teeth is not divisible by 3 Example of application: gear with number of teeth [z] = 31 C: Number of teeth is not divisible by 3 Example of application: gear with number of teeth [z] = , , ,75 123, , , Specification of Key Lock System: 3x Key straight Specification of Key Lock System: 1x Key straight, 2x Key for number of teeth 31 Specification of Key Lock System: 1x Key straight, 2x Key for number of teeth 32 SMW-AUTOBLOK 29

30 D-VARIO Main dimensions and technical data Diaphragm chuck FLEXIBLE MODULAR SYSTEM Top jaws and locator base are optional. Subject to technical changes. For more detailed information please ask for customer drawing. SMW-AUTOBLOK Type Mounting Locating Face for Locator Clamping range min./max. Swing min. Swing max. D-VARIO 215 Z A 215 B 49.5 C 68.5 D D1 215 D2 264 E 170 F G G1 M12 M24x1.5 Jaw height H 40.5 J 6 P H8 25 Q 7 R 20 Piston stroke Jaw stroke at distance H Draw pull min./max.* Draw push for chuck open Moment of inertia Weight without top tooling S kn kn kg m 2 kg Recoended actuating cylinders Type * Additional draw pull to the diaphragme force actuated by the actuating cylinder SIN-DFR Advice: Please note: It is important, that the cylinder force for pushing and pulling can be set to different values independently. 30 SMW-AUTOBLOK

31 D-VARIO Diaphragm chuck FLEXIBLE MODULAR SYSTEM Overview clamping kit Configuration of the set up for pitch line clamping within only 5 steps: I II III IV V First you have to choose your matching top jaw (size 1-6) for the outside diameter [da] of the gear to be machined. Each size of top jaw can cover 20 outside diameter using two different types of clamping pins (Type A and B). One set of top jaw consists of 3 pieces including 1 straight Key Lock insert. The determination of the spherical clamping pins is made according to the ball dimension of the gear. There are 2 types of clamping pins: Type A for the first 10 of the clamping range of the top jaws. Type B for the second 10 of the clamping range of the top jaws. Optionally prelocator pins are available. Prelocator pins are used at automatic loading. The determination is made according to the clamping pins used. One set of Key Lock insert consists of 2 keys. Gears, which number of teeth that is divisible by 3 can be machined with 3 of the same type Key Lock insert (straight). For all gears, which number of teeth is not divisible by 3, there are different key insert sets available according to the number of teeth. The Key Lock inserts are the same for all 6 sizes of top jaws. The following types of locator bases are available: Type A: without air sensing / without nozzle for coolant Type B: without air sensing/with nozzle for coolant Type C: with air sensing / with nozzle for coolant The height of the locator posts is depending on the gear. Overview of the clamping kit: Top jaws (1 set = 3 pcs.) available in 6 sizes for different outside diameters [da] 1 pcs. key insert straight contained in the set of the top jaws Gear Parameter for the configuration of the clamping kit: Outside diameter [d a ] Gear Clamping pin (1 set = 3 pcs.) Ball diameter 3-6 for different ball dimensions Gear Key Lock inserts (1 set = 2 pcs.) for different numer of teeth [z] Number of teeth [z] Ball dimension D-Vario Configurator free application to configurate your set up SMW-AUTOBLOK 31

32 D-VARIO Configuration of the clamping kit Diaphragm chuck FLEXIBLE MODULAR SYSTEM I. Determination of the top jaws Top Jaws Size Outside diameter of gear d a Number of teeth z number Inside clearance diameter of jaws Swing diameter Weight / set kg Order number / set of 3 pieces Clamping pin Type Clamping range A B A B A B A B A B A B II. / III. Determination of the clamping pins (and optional prelocator pins) Clamping pin type Set Type A Available prelocator pins Ball diameter Ø 3,0 Ball diameter Ø 3,5 Ball diameter Ø 4,0 Ball diameter Ø 4,5 Ball diameter Ø 5,0 Ball diameter Ø 5,5 Ball diameter Ø 6,0 Type B Available prelocator pins B B B B B B B B B B B B B B Clamping pins Clamping pin type A Ball diameter Ø 3; 3,5; 4; 4,5; 5; 5,5; 6 [ Top jaw 1 Top jaw 2 Top jaw 3 Top jaw 4 Top jaw 5 Top jaw 6 Ø Ø Ø Ø Ø Ø Clamping pin type A For the first 10 of the clamping range of the top jaws. Clamping pin type B For the second 10 of the clamping range of the top jaws. Clamping pin type B [ Top jaw 1 Top jaw 2 Top jaw 3 Top jaw 4 Ø Ø Ø Ø Compatibility All types and sizes of clamping pins are compatible to all top jaws. Top jaw 5 Ø Ball diameter Ø 3; 3,5; 4; 4,5; 5; 5,5; 6 Top jaw 6 Ø SMW-AUTOBLOK

33 D-VARIO Diaphragm chuck FLEXIBLE MODULAR SYSTEM Configuration of the clamping kit IV. Key Lock inserts for different number of teeth of gears Key Lock insert for gears which number of teeths is not divisible by 3 (1 set = 2 pcs.) z = 10 z = 11 z = 13 z = 14 z = 16 z = 17 z = 19 z = 20 z = 22 z = z = 25 z = 26 z = 28 z = 29 z = 31 z = 32 z = 34 z = 35 z = 37 z = z = 40 z = 41 z = 43 z = 44 z = 46 z = 47 z = 49 z = 50 z = 52 z = z = 55 z = 56 z = 58 z = 59 z = 61 z = 62 z = 64 z = 65 z = 67 z = z = 70 z = 71 z = 73 z = 74 z = 76 z = 77 z = 79 z = 80 z = 82 z = z = 85 z = Key Lock insert for gears which number of teeths is divisible by 3 (1 set = 2 pcs.) straight Order Example: Gear with number of teeth 32 not divisible by (1 set = 2 pcs.) Gear with number of teeth 33 divisible by (1 set = 2 pcs.) 1 straight Key Look that comes with the chuck always remains in use. Key Lock insert (1 set = 2 pcs.) [ Top jaw 1 Top jaw 2 Top jaw 3 Top jaw 4 Compatibility All Key Lock inserts are compatible to all top jaws. Top jaw 5 Top jaw 6 SMW-AUTOBLOK 33

34 D-VARIO Configuration of the clamping kit Diaphragm chuck FLEXIBLE MODULAR SYSTEM V. Locator base Locator base Clamping pin Top jaw Workpiece Locator post Ø 10 Locator base Determination of height of locator posts: = Distance between clamping position and locating face Height of locator posts [H] = 32,5 - Clamping position = 1/2 serration length / at longer serrations it is the requested clamping position. In case the lowest face is not the locating face, please ask our customer service. Locator base Type A Type B Type C Medium feed for air sensing - - X Noozle for coolant - X X Locating diameter min. D min Locating diameter max. D1 max Width B Order Number Locator posts with contact face diameter [E] 2.5 Height [H] = Height [H] = Height [H] = Height [H] = Height [H] = Height [H] = Height [H] = Height [H] = Height [H] = Height [H] = Height [H] = Height [H] = Height [H] = Height [H] = Height [H] = Height [H] = I.D. Number is for one set (=3 pieces) Locator posts with contact face diameter [E] 4.5 Height [H] = Height [H] = Height [H] = Height [H] = Height [H] = Height [H] = Height [H] = Height [H] = Height [H] = Height [H] = Height [H] = Height [H] = Height [H] = Height [H] = Height [H] = Height [H] = I.D. Number is for one set (=3 pieces) 34 SMW-AUTOBLOK

35 D-VARIO Diaphragm chuck FLEXIBLE MODULAR SYSTEM Jaws type A Jaws type A for O.D. clamping D max. Clamping diameter range D min. Jaws type A Clamping Range Ø D min. - D max. Weight / set Blank jaws (set of 3 pcs.) kg Jaws factory finished* (set of 3 pcs.) * Jaws are factory finished according to the specified clamping diameter. Note: The clamping diameter must be specified in case of order. Device Grinding rings (1 Set = 2 pcs.) Device for machining of the blank jaws type A Recoended grinding rings (1 Set = 2 pcs.) Jaws type A sizes Jaws type A sizes The device is needed to pre-machine the blank jaws type A. Then, the jaws must be finish ground to the clamping diameter on the D-Vario chuck. For this operation, the jaws have to be clamped with the grinding rings. Grinding data: 1. Grinding A1 D = residual jaw stroke Grinding A2 D = residual jaw stroke Grinding A3 D = residual jaw stroke Grinding A4 D = residual jaw stroke 0.10 The clamping diameter A1 is used for the first finish grinding process. The smaller clamping diameter of the grinding rings (A2-A4) are used to regrind worn or damaged existing jaws. SMW-AUTOBLOK 35

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37 FDG Chapter 4 FDG High precision face drivers for machining between center pins Machining of the entire surface of the workpiece with one single operation Power operated on the side of the spindle Highest rund-out accuracy SMW-AUTOBLOK 37

38 FDG Face drivers for grinding between center pins Power operated on the side of the spindle Application/cutomers benefits Machining of the entire surface of the workpiece in one single operation For the machining of the surface of soft and hardened workpieces Center pin with carbide insert for highest running accuracy Technical features Highest run-out accuracy < Compensating drive elements Retractable drive pins in case of on- or off-loading Fine adjustment at face drivers for highest run-out requirements Standard euipment Ordering example Face driver FDG Pneumatic pancake cylinder CPG-FDG without changeable parts A Cylindrical retainer Z140 on flange adapter total stroke 6 Ø165 Ø Ø160 Ø133,4 (3x M12) Ø106,375 (KK Gr.6) d5 Ø6 d8 D1 D2 D3 d7 d9 d Short taper retainer DIN size 6 directly onto machine spindle A 92 Subject to technical changes. For more detailed information please ask for customer drawing. Technical Data Type d Center d5 d7 d8 d9 Clamping-Ø Z140 KK Gr. 6 Ø D1 D2 D FDG , FDG FDG , , FDG , , FDG , FDG , FDG , Face drivers with morse taper retainer according to DIN 228 available on request. NOTE Pancake cylinder CPG for the pneumatic actuation of face drivers FDG available. 38 SMW-AUTOBLOK

39 FDG d8 d1 60 d1 d7 60 I I I Face drivers for grinding between center pins Changeable parts Center heads / Center pins Application/customer benefits Center pin with carbide insert Maximum rigidity Highest change accuracy Fixed safely via set screw and plane surface inside the face driver Center heads Type FDG 0 and FDG 1 60 center with carbide coating. Center pins Type FDG 2 to FDG 6 carbide design. A 28 Center heads Type FDG 0 / FDG 1 Center pins Type FDG 2 - FDG 6 A d8 d4 d9 Ø6 Id.-No. Center pin Type d1 d4 Center Ø d7 d8 d FDG FDG FDG FDG FDG FDG FDG Drive pins with diamond coating Model A Ø6 Ø6 Ø6 Model B Model C Drive pins diamond drive pin diamond D1 1.5 C diamond D2 3 B diamond D3 3 A Further dimensions on request. Type Clamping diameter I Model Drive pins for torque transmission onto the workpiece Drive pins with diamond coating High frictional coefficient Clamping diameter D1/D2/D3 see technical data. SMW-AUTOBLOK 39

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41 CPG Chapter 5 Example: CPG with D-VARIO diaphragm chuck CPG Pneumatic pancake cylinder for diaphragm chuck D-VARIO and face driver FDG Easy installation for grinding and turning machines without hydraulic unit Operating pressure 2-8 bar Medium feed for air / coolant SMW-AUTOBLOK 41

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43 J CPG Application example: CPG with D-VARIO diaphragm chuck Pneumatic pancake cylinder D-VARIO / FDG Pneumatic actuation (2-8 bar) Easy installation for grinding and turning machines Application/customer benefits For the actuation of diaphragm chuck D-VARIO and face driver FDG Easy installation for grinding and turning machines without hydraulic unit Compact design Technical features Operating pressure 2-8 bar Maximum axial piston force push 21 kn and pull 7 kn 1 additional medium feed for air / coolant Air service unit with water separator and oil feed necessary Air feed tube necessary Standard equipment Odering example Pneumatic pancake cylinder Version D-VARIO Id.No (without air feed tube) Version FDG Id.No APFL3 Id.No H M W N Accessory S O A С D E P Q Actuation pull APFL3 Air feed tube R G F K B Additional medium Actuation push 3 Connections: 1x Actuation push 1x Actuation pull 1x Additional medium channel for air/coolant U Subject to technical changes. For more detailed information please ask for customer drawing. A Technical Data SMW-AUTOBLOK Type CPG 215 A 215 B 170 C 195 D E 30 F M25x1.5 G 16 H 54.5 J 116 K L 2 M 46.3 N 6.2 O 3 P 3x M12x120 Q M6 R M14 S 16 Piston stroke Axial force 6 bar (pull) Axial force at 6 bar (push) Moment of inertia Max. speed Piston area (piston pull) Piston area (piston push) Operating pressure (**) Weight U kn kn kg m² r.p.m. cm² cm² bar kg (*) Version FDG contains reducing fl ange Z140. Total stroke max. 4. (**) Operating pressure for opening the D-VARIO chuck min. 6 bar SMW-AUTOBLOK 43

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45 EM-S Chapter 6 EM-S Segment sleeve mandrels Clamping diameter Ø For ID clamping Rigid design SMW-AUTOBLOK 45

46 EM-S Segment sleeve mandrel Ø Segment sleeve mandrel power operated L4 L6 L9 L3 L2 L1 Size 1-4 Large expansibility Application/ customer benefits Ideal for volume production and hard turning / grinding with wear resistant, case hardened and vulcanised clamping sleeves Highest accuracy and high torque transmission by means of fixed mandrel body Axial pull down by the axial clamping movement of the clamping sleeve = best face run out Clamping sleeve quick change for short setup times Preparation for air sensing Technical details Large expansibilty depending on the size (The clamping sleeves have a max. radial expansibility in diameter of ± 0.4 S2 or ± 0.6 from the nominal diameter.) Power operated S3 Rigid design with flange mounting Tapped holes in the face for axial stops Standard equipment Base mandrel with mounting bolts K L4 L6 L9 L3 L2 L1 air sensing S2 S3 A2 D6 A1 D5 D4 K S1 D3 D2 D1 D7 L5 L7 Bayonet quick change S1 D3 D2 D1 L8 L5 A2 D6 A1 D5 D4 L5 L7 D7 L8 L5 Attention: Sleeve mandrel in open position = right end position! Gap L8 must remain open when using airsensing! Subject to technical L6changes. L4 L2 For more detailed information please ask for customer drawing. L1 L3 SMW-AUTOBLOK Type EM-S-1 L9 EM-S-2 EM-S-3 EM-S-4 Mounting A5 A6 L2 Z140 A5 A6 Z140 A5 A6 A08 Z140 Z170 A5 A6 A8 Z140 Z L1 Short taper mounting A1 A5 A6 - A5 A6 - A5 A6 A8 - - A5 A6 A8 - - DIN Center mounting Gap Technical data Type Clamping range max. clamping length min. clamping length Axial stroke Expansibilty in dia. max. actuating force max. speed max. transmittable torque Nm rec. actuating cylinders A2 H D D D D4 M30x1.5 M30x1.5 M30x1.5 M30x1.5 M30x1.5 M30x1.5 M30x1.5 M30x1.5 M30x1.5 M30x1.5 M30x1.5 M30x1.5 M30x1.5 M30x1.5 M30x1.5 M30x1.5 D5 H D D7 4 x M10 4 x M12 3 x M10 4 x M10 4 x M12 3 x M10 4 x M10 4 x M12 4 x M16 3 x M10 6 x M12 4 x M10 4 x M12 4 x M16 3 x M10 6 x M12 L L L L L L L L L EM-S-1 EM-S-2 EM-S-3 EM-S-4 S S S K kn r.p.m SIN-S 70 SIN-S 85 SIN-S 85 SIN-S 85 L6 L4 L3 L9

47 I Segment sleeve mandrel Ø Size 1-4 Large expansibility Technical design 1. Basic body EM-S with spindle adapter 2. Segment sleeve mandrel (case hardened + vulcanized) with bayonet quick change. Clamping sleeves size EM-S-1 with three segments, clamping sleeves from size EM-S-2 on with six segments for better gripping force distribution. 3. Workstop 1 EM-S Segment sleeve mandrel power operated 2 3 Overview clamping ranges EM-S-4 Clamping range EM-S-3 Clamping range EM-S-2 Clamping range EM-S-1 Clamping range EM-S-1* Ø Ø EM-S-2** Ø Ø EM-S-3** Ø Ø Ø EM-S-4** Ø Ø Ø Clamping sleeves Type EM-S-1 EM-S-2 EM-S-3 EM-S A C D E F H I K M N O M5 M5 M5 M EM-S * The clamping sleeves have a max. radial expansibility in diameter of ± 0.4 from the nominal diameter. ** The clamping sleeves have a max. radial expansibility in diameter of ± 0.6 from the nominal diameter. Soft work stop blank EM-S-2 / EM-S-3 / EM-S A D N O H F C E M K

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51 SMW-AUTOBLOK Service Benefits Service hotline Hotline +49 (0) Worldwide Service and support on site Rapid task force Global reach in less time, technical problem-solving skills Repair Quick Repair, express service on request Original spare parts Relevant spare parts are available from stock Training Individual training courses Run-off Run-off and support at the point of use Maintenance Scheduled maintenance, at SMW-AUTOBLOK or at the customer Warranty Warranty of 24 month on request Contact SMW-AUTOBLOK Serviceteam Tel.: +49 (0) Fax: +49 (0) service@smw-autoblok.de refers to Registered Trademarks in Germany and/or other countries

52 SMW-AUTOBLOK Spannsysteme GmbH Postfach 1151 D Meckenbeuren Wiesentalstraße 28 D Meckenbeuren Tel.: +49 (0) Vertrieb Inland vertrieb@smw-autoblok.de Fax: +49 (0) Sales International sales@smw-autoblok.de Fax: +49 (0) U.S.A. SMW-AUTOBLOK Corporation 285 Egidi Drive - Wheeling, IL Tel Fax autoblok@smwautoblok.com Japan SMW-AUTOBLOK Japan Inc Hira, Nishi-Ku 461-Nagoya Tel. +81 (0) Fax +81 (0) japan@smwautoblok.co.jp China SMW-AUTOBLOK (Shanghai) Work Holding Co.,Ltd. Building 6, No.72, JinWen Road, KongGang Industrial Zone, ZhuQiao Town, Pudong District , Shanghai P.R. China Tel Fax china@smwautoblok.cn Mexico SMW-AUTOBLOK Mexico, S.A. de C.V. Pirineos No. 515-B, Nave 16 Col. Industrial Benito Juarez Micro Parque Industrial Santiago Queretaro, Qro. C.P Tel. +52 (442) Fax +52 (442) smwmex@smwautoblok.mx India SMW-AUTOBLOK Workholding Pvt. Ltd., Plot No. 4, Weikfield Industrial Estate, Gat No. 1251, Sanaswadi, Tal Shirur, Dist Pune Tel Fax info@smwautoblok.in Brazil SYSTEC METALÚRGICA LTDA R. Luiz Brisque, Vinhedo - SP Tel. +55 (0) Fax +55 (0) systec@systecmetal.com.br Argentina SMW-AUTOBLOK Argentina Rio Pilcomay Bella Vista RA Bella Vista Buenos Aires Tel. +54 (0) Fax +54 (0) autoblok@ciudad.com.ar AUTOBLOK s.p.a. Via Duca D Aosta n.24 Fraz. Novaretto I Caprie - Torino Tel Tel Fax info@smwautoblok.it France SMW-AUTOBLOK 17, Avenue des Frères Montgolfier - Z.I. Mi-Plaine F Chassieu Tel. +33 (0) Fax +33 (0) autoblok@smwautoblok.fr Great Britain SMW-AUTOBLOK Workholding Ltd. 8, The Metro Centre GB-Peterborough, PE2 7UH Tel. +44 (0) Fax +44 (0) sales@smwautoblok.co.uk Spain SMW-AUTOBLOK IBERICA, S.L. Ursalto 10 - Nave 2, Pol Mateo Gaina San Sebastián (Guipúzcoa) (Spain) Tel.: Fax: info@smwautoblok.es Russia SMW-AUTOBLOK Russia B.Tulskaya str., 10, bld.3,off.3203, Moscow (Russia) Tel Fax info@smw-autoblok.ru Taiwan AUTOBLOK Company Ltd. NO.6, SHUYI RD., SOUTH DIST., TAICHUNG, TAIWAN Tel Fax taiwan@smwautoblok.tw Czech Republic / Slovakia SMW-AUTOBLOK s.r.o. Merhautova 20 CZ BRNO Tel Fax info@smw-autoblok.cz Sweden / Norway SMW-AUTOBLOK Scandinavia AB Kasernvägen 2 SE Hässleholm Tel. +46 (0) info@smw-autoblok.se Korea SMW-AUTOBLOK KOREA CO., LTD ho, Baeksang Startower 1st, 65, Digital-ro 9-gil, Geumcheon-gu Seoul, ROK-08511, Korea Tel Fax info-korea@smw-autoblok.net