MQL Shrinkfit holders

Transcription

1 Technical Sales Guide MQL Shrinkfit holders Release for sales: Publication: SN Internal use only 1

2 Internal use only 2

3 1 Contents 2 Executive summary / Introduction What is MQL? Advantages of MQL Requirements to implement MQL MQL1 and MQL Background History Market trends Potential EPB 5403/EPB 5403M/EPB 5403M1/EPB 5403M Tool holders: range summary and delivery content EPB 5403 DIN type Shrinkfit holders EPB 5403M: DIN type Shrinkfit holders, designed for MQL EPB 5403M1: DIN type Shrinkfit holders, equipped for MQL EPB 5403M2: DIN type Shrinkfit holders, equipped for MQL Key codes Tool holders and accessories for MQL Selection of accessories for MQL Coolant tube E930x Stop screw 19MQL1xxx Tool holders: EPB 5403M or EPB 5403M Tool holders and accessories for MQL Selection of accessories for MQL Advice: refer to the Machining Navigator Coolant tube 20E930xM2xxx Stop screw 19MQL2xxx Selection of MQL2 accessories: principle Tool holders: EPB 5403M or EPB 5403M Transmittable torque to the tool shank and Max RPM FAQ What is the difference between an EPB 5603 and an EPB 5403 holder? Can I use an EPB 5603 or an EPB 5403 Shrinkfit holders for MQL? What does the transformation of an EPB 5403 into an MQL holder consists in? Can DIN, BT, CAT holders be equipped for MQL? What are the main differences between MQL1 and MQL2? Internal use only 3

4 2 Executive summary / Introduction 2.1 What is MQL? MQL stands for Minimum Quantity Lubrication. This near-dry coolant solution consists in a mix of air and oil, generating sort of an emulsion. It is an alternative to flood coolant systems. MQL coats the interface cutting edge/workpiece with a thin film of lubricant and prevents heat build up through friction reduction. 2.2 Advantages of MQL This solution significantly reduces the volume of coolant used to lubricate machining operations: overall coolant costs reduced, keeps the machine environment and workpiece clean, reducing the need to clean workpieces, reduces the need for recycling coolant floods, as the volume used is very low compared to conventional flood coolants and as it is mostly consumed in the cutting process, makes the recycling of chips easier, as no cleaning is needed, reduces the exposition of operators to chemicals. 2.3 Requirements to implement MQL MQL needs a specific equipment to produce and deliver the emulsion: - machine equipped with a MQL full equipment, - suitable tool holders, equipped with specific coolant tubes and stop screws. - tools with specific coolant channels and tapered tool shank designed according to standard DIN The standard DIN defines specific requirements for MQL1 standard holders, accessories and tool shank shapes. Internal use only 4

5 2.4 MQL1 and MQL2 MQL exists in 2 versions: - MQL1: the air and oil mix is produced before entering the spindle and delivered to the tool through one channel (hence MQL1) that goes through the spindle, the tool holder and the tool. HSK-A63: Conventional coolant tubes and MQL1 stop screws are needed. HSK-A100: Specific MQL1 coolant tubes and MQL1 stop screws are needed. MQL1 COOLANT SUPPLY Oil and air mixture externally One channel Oil + Air MQL Shrinkfit holder Rotary union Spindle Coolant tube MQL1 Stop screw MQL1 - MQL2: the air and oil mix is produced in the tool holder; The air and the oil are delivered through 2 distinct channels (hence MQL2) and are mixed in a chamber, in the MQL2 coolant tube. MQL2 coolant tubes, featuring a connecting pipe, and MQL2 stop screws are needed. MQL2 COOLANT SUPPLY Oil and air supply through 2 independent channels Oil Air Mixing chamber MQL Shrinkfit holder Rotary union Spindle Coolant tube MQL2 Stop screw MQL2 Internal use only 5

6 3 Background 3.1 History MQL exists since 1990 and has grown mostly in the automotive industry. It is now growing in the aeronautic industry. 3.2 Market trends The machining trend is in some areas moving in direction of dry machining, completely dry is not always possible that s the reason of using MQL. The market is slowly growing nevertheless there is a clear direction started by automotive industry now overlapping in the aerospace application. We are losing market share against competitors having these products (mainly Guhring, Mapal ). 3.3 Potential Even though competitors are well installed in the automotive industry, Seco is well positioned in the aerospace industry, where the demand for MQL solutions is growing. In a first stage, Seco will offer a range of MQL1 and MQL2 tool holders only. On the long run, Seco is aiming at offering full MQL solutions (tool holders and tools). The potential for MQL solutions is probably around 10% of the current sales of equivalent conventional Shrinkfit holders. Internal use only 6

7 4 EPB 5403/EPB 5403M/EPB 5403M1/EPB 5403M2 4.1 Tool holders: range summary and delivery content The range will consist of three MQL types, declined from conventional DIN type Shrinkfit holders (according to standard DIN ): EPB 5403/EPB 5603: Shrinkfit holders, not adapted to MQL (according to standard DIN ) EPB 5403M : Shrinkfit holders designed for MQL1 and 2, delivered without MQL accessories (according to standard DIN ) EPB 5403M1 : Shrinkfit holders ready for MQL1, delivered with MQL accessories mounted (according to standard DIN ) EPB 5403M2 : Shrinkfit holders (according to standard DIN ), ready for MQL2, delivered with MQL2 accessories mounted EPB 5603 EPB 5403 EPB 5403M EPB 5403M1 EPB 5403M2 According to standard DIN (Shrinkfit holders) X X Pre-adapted to MQL X According to standard DIN (MQL) X X X Coolant channels according to MQL norm X X X MQL thread X X X MQL laser marking X X X Delivered with a stop end screw (DIN ) X (spare part) X (spare part) Mounted with coolant tube for MQL1 No (accessories) X (spare part) Mounted with a stop end screw for MQL1 No (accessories) X (spare part) Mounted with coolant tube for MQL2 No (accessories) X (spare part) Mounted with stop end screw for MQL2 No (accessories) X (spare part) Delivered with user instructions X X X Details about the different types are explained further in this document. Internal use only 7

8 4.2 EPB 5403 DIN type Shrinkfit holders Description Example: E (substitution to former E ) EPB 5403 Shrinkfit holders are very close to our range of EPB 5603 Shrinkfit holders. Both are according to standard DIN % same external shape, - 100% same grip length and same transmittable torque. Minor modifications have been made to the internal coolant channels (diameter modifications, chamfers...), however, a new EPB 5403 can be substituted to a former EPB 5603, without any influence on the customer s process. EPB 5403 can be shrunk on a Shrinkfit device with the same program as for EPB To allow easy transformation of EPB 5403 Shrinkfit holders into MQL holders, the specification of HSK-A63 and HSK-A100 DIN type Shrinkfit holders have been slightly modified, resulting in the creation of a new sub-family EPB 5403, very similar to the existing EPB 5603 type. Note: only HSK-A63 and HSK-A100 EPB 5603 are replaced by EPB 5403 holders. Other tapers (HSK-A32, HSK-A40, DIN, BT ) remain unchanged. Examples of changes between EPB 5603 and EPB 5403 E Addition of a chamfer at the entrance of the coolant channel E E Slight changes in internal dimensions (coolant channels). E Internal use only 8

9 4.3 EPB 5403M: DIN type Shrinkfit holders, designed for MQL Example: E M (similar to E , with specific MQL characteristics) M versions are DIN type Shrinkfit holders according to the norm DIN , adapted for MQL1 and 2. They are delivered without coolant tube nor stop screw. These accessories must be ordered separately. E M). A MQL laser marking is added in their HSK V-flange, to differentiate them MQL types Shrinkfit holders from DIN type Shrinkfit holders (according to standard ). The M designation is engraved on the tool holder (eg. 4.4 EPB 5403M1: DIN type Shrinkfit holders, equipped for MQL1 Example: E M1 (similar to E M,equipped with a MQL1 stop screw and MQL1 coolant tube) M1 versions are DIN type Shrinkfit holders according to the norm DIN , designed for MQL1. It is a full solution, composed of a MQL1 toolholder along with suitable MQL1 accessories (coolant tube and stop screw), mounted on the toolholder when delivered. Only one combination tool holder + stop screw + coolant tube possible per workpiece side diameter. A MQL laser marking is added in their HSK V-flange, to differentiate them MQL types Shrinkfit holders from DIN type Shrinkfit holders (according to standard ). The M1 designation is engraved on the tool holder (eg. E M1). 4.5 EPB 5403M2: DIN type Shrinkfit holders, equipped for MQL2 Example: E M2-1.9 (similar to E M,equipped with a MQL2 stop screw and MQL2 coolant tube) M2 versions are DIN type Shrinkfit holders according to the norm DIN It is a full solution, composed of a toolholder along with suitable MQL2 accessories (coolant tube and stop screw), mounted on the toolholder when delivered. Several combinations tool holder + stop screw + coolant tube : the selection is depending on the cutting tool (shank diameter, number and cross-section of the coolant channels). See 7.1. A MQL laser marking is added in their HSK V-flange, to differentiate them MQL types Shrinkfit holders from DIN type Shrinkfit holders (according to standard ). The M2 designation is engraved on the tool holder (eg. E M2-1.9). Internal use only 9

10 5 Key codes DIN type Shrinkfit holders (same family as EPB 5603 holders) Workpiece side diameter Workpiece side gauge length E9304=HSK-A63 E9306=HSK-A100 E E M Designed for MQL1 and MQL2 E M1 Equipped for MQL1 (one combinaison «tool holder +MQL1 accessories» possible) E M2-1.9 Equipped for MQL2 (several combinations «tool holder +MQL2 accessories» possible) External diameter of the coolant Tube* *see explanations in paragraph Tool holders and accessories for MQL2 Internal use only 10

11 6 Tool holders and accessories for MQL1 6.1 Selection of accessories for MQL1 The selection of the appropriate MQL1 coolant tube and stop screw is easy: One possible combination per tool holders Coolant tube E930x HSK-A63, MQL1 Shrinkfit holders use a conventional coolant tube 20E9304: conventional Ø8 internal diameter is suitable for MQL solutions. HSK-A100, MQL1 Shrinkfit holders use a specific coolant tube 20E9306M1: the internal diameter is adapted to optimize the MQL flow (tapered from diameter 12 to diameter 8mm) Stop screw 19MQL1xxx Stop screw for MQL1 are adapted to MQL tool shank, according to DIN For each tool shank diameters, 2 stop screws are available: Short version 19MQL1xxS Long version 19MQL1xxL The choice between the short and the long version depends on the gauge length of the tool holder. See correspondence tables in catalogue pages. 6.2 Tool holders: EPB 5403M or EPB 5403M1 Customers have the possibility to order MQL1 tool holders as: EPB 5403M: The appropriate stop screw and coolant tube must be ordered separately. o already owns MQL1 accessories, o wants to manage MQL1 accessories separately, o wants to run test with one holder and several combination of accessories, before investing in his final equipment. o Content delivery: E M EPB 5403M1: The tool holder is delivered, assembled with the appropriate stop screw and coolant tube. o Easier solution. o Content delivery: E M + 19MQL112S + 20E9306M1 Internal use only 11

12 7 Tool holders and accessories for MQL2 7.1 Selection of accessories for MQL2 An MQL2 solution is built up from a MQL tool holder equipped with MQL2 coolant tube and MQL2 stop screw Advice: refer to the Machining Navigator An appropriate selection of the accessories is required to guaranty an efficient delivery of the coolant mixture to the cutting edges. This chapter explain you the principle of the selection of accessories for MQL2. Note that a table is available in the Machining Navigator to make this selection easier. This table features a list of tool holders along with coolant tubes and stop screws, and contains a ADIF1 attribute providing the section of the MQL coolant channel (see explanations in 7.1.4). Internal use only 12

13 7.1.2 Coolant tube 20E930xM2xxx MQL2 coolant tubes feature a tube, that is fitted in the stop screw to warranty an optimal delivery of the MQL2 mix to the tool. A variety of MQL2 coolant tubes is available, with different coolant channels diameters and different pipe lengths. See more details in 7.1 Code key coolant tubes E9304=HSK-A63 E9306=HSK-A100 For MQL2 20E9304 M2A 01 Code corresponding to the internal diameter of the pipe A=smallest diameter D=widest diameter Code corresponding to the length of the pipe 1=short 16=longest Stop screw 19MQL2xxx A variety of stop screws is available, with different coolant channels diameters for each tool diameter. Code key stop screws Note: the code key by itself does not allow you to select the appropriate stop screw. You must refer to the table in the machining navigator to match the appropriate coolant tube and stop screw. 19MQL2A01 For MQL2 Code corresponding to the tool shank diameter 1=smallest shank diameter 2=second smallest shank diameter 9=widest shank diameter Code corresponding to the internal diameter of the pipe A=Ø2mm C=Ø4.1mm B=Ø2.9mm D=Ø5.4mm Internal use only 13

14 7.1.4 Selection of MQL2 accessories: principle Basic principle The selection of the appropriate MQL2 coolant tube and stop screw is based on the tool that is mounted on the toolholder, and precisely on the dimension and number of coolant channels in the tool. Step 1: Selection of the appropriate MQL2 coolant tube To guaranty an optimal MQL flow delivery to the cutting edge, a cross-sectional ratio of 1:1 to 4:1 between the section of the tool coolant channels (A tool ) and the section of the coolant tube s pipe (A tube ) is required. A tool A tube 4 x A tool If several combinations are possible, it is recommended to privilege the combination with the ratio the closest to 1:1, to optimize the MQL flow. BD2 CND Section area ADIF1 1.9 mm 1.6 mm 2.01 mm² 2.8 mm 2.3 mm 4.15 mm² 4.0 mm 3.4 mm 9.08 mm² 5.3 mm 4.6 mm mm² Internal use only 14

15 Step 2: Selection of the appropriate MQL2 stop screw Select the stop screw according to: - the tool shank diameter, - the selected coolant tube (see above): both the coolant tube and the stop screw must have the same value for the attribute ADIF1 (referred to as A tube ). Four ADIF1 values are available: 2.01 mm², 4.15 mm², 9.08 mm², mm². Beware: - for coolant tube, ADIF1 (indicated in the catalogue) corresponds to the cross section of the internal diameter of the pipe of the coolant tube. - for stop screw, ADIF1 (indicated in the catalogue) correspond to the cross section of the internal diameter of pipe of the corresponding coolant tube, and NOT to the cross section of the stop screw s coolant channel. CND coolant tube (mm) => ADIF1 (mm²) Internal use only 15

16 7.2 Tool holders: EPB 5403M or EPB 5403M2 Customers have the possibility to order MQL2 tool holders as: EPB 5403M: The appropriate stop screw and coolant tube are meant to be ordered separately. o Suitable for a customer who: already owns MQL2 accessories, wants to manage MQL2 accessories separately, wants to run test with one holder and several combination of accessories, before investing in his final equipment. o Content delivery: E M EPB 5403M2: The tool holder is delivered with the appropriate stop screw and coolant tube. o Easier solution. o Content delivery: E M2-1.9 (= E M + 19MQL2A05 +20E9306M2A01) Transmittable torque and max rpm see Shrinkfit holders EPB 5603/ Transmittable torque to the tool shank and Max RPM The coolant mixture efficiency limits the maximum RPM for holders equipped for MQL1 and MQL2. Transmittable torque to the tool shank (Nm) are the same for all types of EPB 5603 and EPB 5403 Shrinkfit holders, including MQL versions. Transmittable torque are defined by the standard DIN Clamp Ø (mm) Min static transmittable torque (Nm) DIN Shrinkfit clamping system Shrinkfit clamping system Max RPM* EPB EPB 5603/EPB 5403 EPB 5403M1 5403M * The maximum RPM for holders equipped with this clamping system is often restricted by the holder s machine side taper type and size. Internal use only 16

17 9 FAQ 9.1 What is the difference between an EPB 5603 and an EPB 5403 holder? Both are designed according to the standard DIN An EPB 5603 can be directly replaced by an EPB 5403 (exact same external shape). EPB 5403 are pre-adapted to make it easier for Seco-EPB to transform them into MQL holders. Some internal dimensions, not imposed by the standard DIN , have directly been adapted to the MQL standard DIN Can I use an EPB 5603 or an EPB 5403 Shrinkfit holders for MQL? EPB 5603/EPB 5403 are not designed according to the standard DIN for MQL. We can not guaranty EPB 5603/EPB 5403 will work for MQL. 9.3 What does the transformation of an EPB 5403 into an MQL holder consists in? Internal modifications are made to the tool holder, eg. thread dimensions, to allow the mounting of the MQL accessories. In addition to the changes mentioned in 9.1, modifications are made to make the EPB 5403M fully according to the MQL standard DIN A laser marking is added in the HSK-A flange to differentiate MQL holders from conventional holders. The laser marking of the designation of the product is changed into the final designation of the product: o EPB 5403M : eg. E into E M, o EPB 5403M1 : eg. E into E M1, o EPB 5403M1 : eg. E into E M In the case of EPB 5403M, no stop screw is delivered with the tool holder (the one delivered with the EPB 5403 is removed from the packaging). In the case EPB 5403M1 and EPB 5403M2, required MQL coolant tube and MQL stop screw are assembled on the holder before delivery. MQL user instructions are added to the delivery content. 9.4 Can DIN, BT, CAT holders be equipped for MQL? The standard DIN for MQL only applies to HSK-A holders. Market demand for DIN/BT/CAT solutions remain anecdotic and would require an adaptation of the whole chain MQL unit/spindle/tool holder/tool. Internal use only 17

18 9.5 What are the main differences between MQL1 and MQL2? Aside the difference of equipment, each technologies has specific advantages: MQL 1 MQL 2 Possible to change from a conventional coolant system to a MQL1 system. Can be implemented on multi-spindle machines. The rotational speed influences the quality of the flow (the flow must be adapted to the speed). Modification of the coolant parameters (quantity of coolant, ratio oil/air ) is very slow. Not convenient when quick tool changes are necessary. Limited volumes/min of coolant can be delivered to the tool (150ml/min). Pressure 5 bars minimum required. Does not allow to switch from a conventional coolant system to a MQL2 system. Very complicated to implement on multi-spindle machines. The rotational speed does not influence the quality of the flow (same flow quality, dependless of the speed). Fast adaptation to parameter changes. Suitable when quick tool changes are needed. Higher volumes/min can be delivered to the tool (400ml/min). Pressure 4 bars minimum required. EPB 5403M EPB 5403M1 EPB 5403M2 Internal use only 18