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HYDROK – Disassembly

7.2.4 Disassembly of the hydraulic stationary chuck SPANNTOP

9. x

Two people are required.
Special tools required:



Allen wrench



Crane and eye bolts from weight 15 kg

WARNING!
Risk of injury due to leaking hydraulic oil!

The stationary chuck may contain spring as-
semblies.



Move the clamping device into reserve
stroke!

Fig. 31

1. Loosen and remove the mounting screws.
2. Disconnect the hydraulic connection at the station-

ary chuck.

3. Remove the stationary chuck from the machine ta-

ble.

Clean the mounting surfaces of the stationary
chuck and the machine table after each disas-
sembly!

7.3 Subsequent storage of the clamping device

The clamping device must be cleaned and treated
with corrosion protection for subsequent storage [see
section »Cleaning«].

NOTE!

The storage conditions are specified in the
section »Transport, packaging and storage«.

Order h49 7144.907-333

Summary of Contents for HYDROK

Page 1: ...Installation manual HYDROK HYDROK 40 SE HYDROK 32 RD Hydraulic stationary chuck SPANNTOP force operated...

Page 2: ...gate 37 2 11 1Clamping and release flow at HYDROK 37 2 11 2Clamping and release times at 2 liter hydraulic aggregate 37 2 11 3Clamping and release times at 4 liter hydraulic aggregate 37 2 11 4Clampin...

Page 3: ...dem cylinder 58 4 7 7 Hydraulic base plate 58 4 7 8 Multiple clamping pallet 59 5 Transporting packaging and storing 60 5 1 Safety instructions for transporting 60 5 2 Symbols on the packaging 60 5 3...

Page 4: ...d HYDROK 40 SE 84 8 3 Preservation 85 8 4 Use of lubricant 85 8 5 Maintenance schedule 86 8 6 Bolt torque 87 9 Trouble shooting 88 9 1 Safety 88 9 2 Trouble shooting table 89 9 3 Start up after correc...

Page 5: ...mping device It is assumed that the reader is familiar with standard procedures such as cleaning the mounting surfaces 1 2 Explanation of symbols Safety instructions Safety instructions are indicated...

Page 6: ...approved spare parts The actual scope of delivery can vary from the expla nations and graphic representations provided in this manual in the case of special versions if supplemental order options are...

Page 7: ...s dupli cation in any form including excerpts as well as ex ploitation and or communication of the content are not permitted except for internal use without written ap proval from the manufacturer Act...

Page 8: ...lfunction or total failure they can also impair safety Only use manufacturer s original spare parts Only purchase spare parts from authorized dealers or direct from the manufacturer Addresses are in t...

Page 9: ...plementation of the device Note in particular that the status scans of the machine must be adjusted to the respective product DANGER Risk of injury due to thrown out parts Incorrect machine settings m...

Page 10: ...as well as knowledge of the applicable regulations are capable of executing the tasks assigned to them and of recognizing and avoiding possible hazards on their own Hydraulic specialist The hydraulic...

Page 11: ...evice is to be used for the case of applica tion contractually agreed between the producer deliverer and the user as well as such cases of application de scribed in the product description which are a...

Page 12: ...Follow the instructions that have been posted in the work area Always wear For all tasks always wear Protective work clothing is tight fitting work clothing with low resistance to tear ing with tight...

Page 13: ...e in a machine tool In each case the residual risks that have been determined based on a risk analysis of the machine must be specified by the customer Follow the safety instructions listed here and t...

Page 14: ...in projecting compo nents Only use approved hoists and sling gear with sufficient bearing capacity Do not use rope and belts that are torn or frayed Moving parts WARNING Danger of injury due to movin...

Page 15: ...imensional accuracy Missing changing parts WARNING Danger of injury due to missing changing parts When operating the clamping device without changing parts segmented clamping bushing clamping heads wo...

Page 16: ...ping device while the spindle is rotating Before starting to work on the mandrel make sure the machine spindle cannot be put in motion WARNING Risk of injury Falling down of the clamping device or its...

Page 17: ...or pneumatic connections are available and undamaged WARNING Damage of clamping device The clamping device may be released exclu sively in the standing condition 2 7 Clamping force The achieved clampi...

Page 18: ...the product itself near the screw or threaded pin and or given in chapter Bolt torque All screws or stud screws that are not marked with a tightening torque specification are tightened with the prescr...

Page 19: ...rning operation Feed cutting edge drilling operation FB N Feed force drilling operation Fc N Cutting force turning operation Fc max N Max cutting force turning operation Ffz N Clamping force contingen...

Page 20: ...g head mw kg Workpiece mass MB Nmm Torque drilling operation Mq Nm Moment due transverse force relative to the chuck axis Mqmax Nm Max moment due to transverse force relative to the chuck axis n 1 min...

Page 21: ...irst limit workpiece length The max unclamping length that can be machined without the aid of steady rest or tailstock is specified at max 6x the clamping diameter 2 10 3 Second limit workpiece mass T...

Page 22: ...etely unconsidered General Lsp 0 08 dsp Moreover the following also applies Fig 2 Lsp 2 8 mm Use of clamping heads with smooth clamping bore Lsp 13 mm Use of clamping heads with longitudinal and radia...

Page 23: ...s Principles for the forces acting on the workpiece from the outside NOTE For safe machining2 the following must apply at all times 1st principle Frad Fraderf AND 2nd principle Ft Ftmax AND 3rd princi...

Page 24: ...ng procedures must be added However axial drilling and turning jobs are rarely over laid because as a rule they cannot run simultaneous ly due to opposite directions of rotation For the calculation th...

Page 25: ...ter of the clamping head is greater than the clamping diameter on the workpiece Edge seat The clamping diameter of the clamping head is less than the clamping diameter on the workpiece 3 These values...

Page 26: ...ces kc N mm Corresponding to the relatively imprecise classifica tion of the materials these are guide values Thus in some cases greater deviations relative to the real val ues can be present For devi...

Page 27: ...ol steels unhardened C105W1 1 1545 3100 2100 1690 Machining steels 35S20 1 0726 60S20 1 0728 1700 1480 1400 Stainless steels 3600 2450 2100 Hardened steels 4800 Aluminum wrought alloy 16 Si 1340 900 7...

Page 28: ...d lose their capacity of achieving higher co efficients of friction with soft materials Workpiece surface Jaw clamping surface Smooth clamping head Clamping head with longitu dinal and trans verse ser...

Page 29: ...mass m kg and distance rs from the center of mass of clamping head segments to the axis of rotation m S c kc a t rs m From table 2 From table 3 From table 4 From table 5 From table 6 I F raderf S c 1...

Page 30: ...rce Fraderf in order to execute this machin ing task using the chuck If this condition is not satisfied then the chuck is not suitable The machining task must not be executed in this manner For clampi...

Page 31: ...2 10 5 2For principle 2 Ft Ftmax 14 Tailstock force Due to the additional spreading force on the chuck the max permissible tailstock force is limited to the following values in accordance with the ch...

Page 32: ...0 100 8 000 125 12 000 140 12 500 160 14 000 Table 8 Maximum permissible cutting force 2 10 5 4For principle 4 Fq Fqmax For drilling tasks radial to the workpiece axis due to the feed force of the too...

Page 33: ...n the clamping head or on the chuck This moment as well must not limitlessly increase without the chuck being damaged although perhaps the clamping set up would nonetheless still securely clamp the wo...

Page 34: ...ping length Lsp 20mm Chuck SPANNTOP pull back size 65 Clamping head used D 60 mm smooth extension length 3 mm Detailed consideration The first condition namely that the workpiece length may equal up t...

Page 35: ...ing F C 1 3 1 5mm 0 25mm 2515 N mm2 F C 1226N Drilling Here not relevant because drilling is not intended Consequently M B 0Nmm F B 0N F sk 0 27 Lz dsp 0 63 F c Lz F G Lg 2 F c p 2 0 5 0 67 1 9 Lsp 4...

Page 36: ...tting force of Fc 1226 N is far below the limit of 4500 N In this example principles 4 and 5 are again irrele vant because both principles must only be considered for radial drilling work Result of th...

Page 37: ...size 65 size 80 size 100 Clamping volume 1 Clamping device 0 013 0 01 0 022 0 022 0 028 0 031 0 080 Release volume 1 Clamping device 0 013 0 01 0 022 0 022 0 028 0 031 0 080 2 11 2 Clamping and relea...

Page 38: ...ubstances particularly improper dis posal can cause significant environmental damage Always comply with the instructions cited be low If environmentally harmful substances should inadvertently get int...

Page 39: ...94 46 65 16 4 174 x 174 x 130 105 40 80 17 5 186 x 186 x 130 115 40 100 30 9 229 x 229 x 140 150 40 RD Alu 100 13 5 229 x 229 x 130 143 40 SE 40 2 7 79 8 x 79 8 x 95 75 63 110 52 11 8 154 x 154 x 120...

Page 40: ...8 150 40 Stationary chuck SPANNTOP SE 32 12 3 134 x 134 x 118 148 x 8 70 40 42 12 3 154 x 154 x 120 170 x 8 80 40 65 16 4 174 x 174 x 140 196 x 8 105 40 80 17 5 186 x 186 x 140 210 x 8 115 40 100 30...

Page 41: ...g forces are outside the allowed range the maintenance is mandatory to perform After servicing the clamping forces have to be re examined If the clamping force even after the mainte nance is not in th...

Page 42: ...kN Given values pmax HYDROK 40 bar Fax max HYDROK 35 kN Fax adaptation clamping device 20 kN Example Requested value p HYDROK if Fax adaptation clamping device 20kN Calculation p HYDROK pmax HYDROK F...

Page 43: ...HYDROK Technical data 3 3 1 Clamping force diagram HYDROK size 32 RD Fig 4 Order hotline 49 7144 907 333 43 nom inal...

Page 44: ...HYDROK Technical data 3 3 2 Clamping force diagram hydraulic stationary chuck size 32 RD Fig 5 44 Order hotline 49 7144 907 333 n o m i n a l...

Page 45: ...HYDROK Technical data 3 3 3 Clamping force diagram HYDROK size 40 SE Fig 6 Order hotline 49 7144 907 333 45 nom inal...

Page 46: ...HYDROK Technical data 3 3 4 Clamping force diagram HYDROK and hydraulic stationary chuck size 42 52 RD SE Fig 7 46 Order hotline 49 7144 907 333 n o m i n a l...

Page 47: ...HYDROK Technical data 3 3 5 Clamping force diagram HYDROK and hydraulic stationary chuck size 65 RD SE Fig 8 Order hotline 49 7144 907 333 47 n o m i n a l...

Page 48: ...HYDROK Technical data 3 3 6 Clamping force diagram HYDROK and hydraulic stationary chuck size 80 RD Fig 9 48 Order hotline 49 7144 907 333 n o m i n a l...

Page 49: ...HYDROK Technical data 3 3 7 Clamping force diagram HYDROK and hydraulic stationary chuck size 100 RD SE Fig 10 Order hotline 49 7144 907 333 49 n o m i n a l...

Page 50: ...ifications of clamping device machine adapter and machine do not agree severe damage extending to total damage can occur Only operate clamping devices and adapters in machines with the same power spec...

Page 51: ...nction 4 Structure and function 4 1 Overview HYDROK 3 x Fig 12 1 Clamping head optional 2 Housing 3 Piston coupling 4 Locking ring 5 Cylinder cover 6 Fitting 7 Mounting screws Order hotline 49 7144 90...

Page 52: ...Clamping head optional 2 Mounting screws 4x 3 HYDROK 32 4 Tandem cylinder optional 5 Cylindrical screws 4x 6 Hydraulic base plate optional 7 Hydraulic connection 8 Hydraulic connection optional for th...

Page 53: ...hydraulically actuated sta tionary chuck that provides even more implementa tion possibilities It can be used with all clamping de vice adaptations such as the MANDO Adapt man drel in the clamping de...

Page 54: ...nnection to base plate or table 5 Media supply from side or through the base plate 6 Positioning for front end stop 7 Radial positioning 8 Mounting screws 9 Safety ring 10 Mounting thread for frond co...

Page 55: ...hining or rational multiple clamping wit h the HYDROK we offer a hydraulically actuated sta tionary chuck that provides even more implementa tion possibilities It can be used with all clamping de vice...

Page 56: ...e not included in the scope of delivery Specially developed segmented clamping bushings match to the respective maximum RPM are available for each clamping device Trouble free and precise function of...

Page 57: ...nging fixture and can be inserted into the mounted clamping device with the aid of the changing fixture 4 7 2 Clamping head Fig 19 The clamping heads are used to accommodate the workpiece that will be...

Page 58: ...m cylinder Fig 23 By adapting the tandem cylinder to the HYDROK 32 RD you can reach a clamping pressure of 70 kN by only 50 bar By adapting the tandem cylinder to the HYDROK 40 SE you can reach a clam...

Page 59: ...sult in serious injury Connect the rapid action coupling only with extreme vigilance 4 7 8 Multiple clamping pallet Fig 25 For size 65 a special multiple clamping pallet has been developed Connecting...

Page 60: ...in such a manner that it is located above the center of gravity Carefully lift and see if the load tilts If neces sary change the attachment Transport For transport always use a suitable clamping mean...

Page 61: ...packed vertically and has threaded bores in the end face From about weight 15 kg there are also thread ed holes in the circumference of the clamping device Lifting eye bolts can be screwed into these...

Page 62: ...just before installation The packed goods are sealed in foil airtight and packed in cartons See the Technical Data section for the specific weight of the re spective sizes Handling packaging material...

Page 63: ...midity max 60 For storage periods longer than 3 months Check the general condition of all parts and the packaging at regular intervals Touch up or re apply anti corrosion agents as needed Subsequent s...

Page 64: ...ces see Mainte nance The ex works wetting of the plate surfaces and the clamping element is only corrosion protection It s not functionally lubricated The insertion of lubricant is provided only on th...

Page 65: ...injury and material damage Two people are always required for this task Use a crane WARNING Risk of injury due to stored energy The clamping device can be designed with disc springs These disc spring...

Page 66: ...de Always remove immediately all the tools and wrenches from the clamping device after use WARNING Risk of injury By operating the clamping device without changing parts clamping head segmented clampi...

Page 67: ...e may be thrown out If the clamping pressure is too high severe damages of the components of the clamping device may occur the throwing out of the work piece Before operation set the operation pressur...

Page 68: ...main in the stationary chuck 1 Remove the plug from the rear side of the clamp ing device Property danger due to not fitting hydraulic connections With not fitting of the hydraulic connections of bas...

Page 69: ...tationary chuck is carried out via the base plate The stationary chuck can be centered either on an outer diameter or on an inner diameter Fig 27 Caution Property damage due to missing seal rings By r...

Page 70: ...the rear side on the HYDROK 32 RD HYDROK 40 SE till end stop Use the Index holes for positioning 6 Turn back the tandem cylinder till the Index holes fit 7 Put the ring in the base plate 8 Put the ta...

Page 71: ...ition Make sure that the clamping device is empty and leakage of hydraulic fluid is avoided 6 3 3 Installation of the clamping head 12 x The changing of the clamping head is only possible in release p...

Page 72: ...mensional requirements in this regard pay attention to the maximum utilization of the clamping reserve reserve stroke see chapter 2 5 Faulty workpiece clamping Only clamp workpieces with a minimum cl...

Page 73: ...ents must be intact this means that they are neither torn nor are they porous at any point All edges and bearing surfaces are intact this means that they are neither broken nor do they show any signs...

Page 74: ...nto moving parts or handle moving parts during operation Note the gap dimensions of moving parts Wearing of gloves PSA is required 6 7 Activities after production is concluded 5 x 1 Move the clamping...

Page 75: ...afeguarding against restart DANGER Life threatening danger if restarted without authorization When disassembling there is danger of the en ergy supply being switched on inadvertently This poses a life...

Page 76: ...ding screws they have to be operated continuously alternately to reduce the clamping pressure to a mini mum Particularly cautious approach is required For cleaning and maintenance disassemble the clam...

Page 77: ...ead is squeezed at the coupling area 2 Remove the clamping head out of the clamping el ement reception and or the housing 3 Loosen the changing fixture by light pressure in ax ial direction and pull i...

Page 78: ...each disassembly 4 Remove the ring from the base plate and clean it 5 Move the tandem cylinder into front end position 6 Move the coupling of the H HYDROK 32 RD HY DROK 40 SE into reserve stroke down...

Page 79: ...Loosen and remove the mounting screws 2 Disconnect the hydraulic connection at the station ary chuck 3 Remove the stationary chuck from the machine ta ble Clean the mounting surfaces of the stationar...

Page 80: ...f screw and drain re maining liquid Discard the liquid NOTE Improper disposal causes environmental damage Lubricants and other auxiliary materials are subject to treatment as special waste and should...

Page 81: ...ity and perpendicularity tolerances Clean these surfaces with an appropriate cleaner CAUTION Danger of injury due to improper handling of cleaners Improper handling of cleaners can cause health impair...

Page 82: ...By loosening the corresponding screws they have to be operated continuously alternately to reduce the clamping pressure to a mini mum Particularly cautious approach is required For cleaning and mainte...

Page 83: ...partly disassembling of the stationary chuck for cleaning service the seal rings will be damaged Keep a new set of seal rings ready for re assembling Fig 32 1 Disassembled the clamping device see cha...

Page 84: ...RD HYDROK 40 SE from the machine table see chapter Disassem bly of the HYDROK 32 RD HYDROK 40 SE CAUTION Risk of injury by not allowed partly disas sembly of the HYDROK 32 RD HYDROK 40 SE When partly...

Page 85: ...ge location and safeguard it from falling 8 4 Use of lubricant With the usage of lubricant you may only use grease that corresponds to the requirements concerning bond pressure stability and solubilit...

Page 86: ...ack if you have questions concerning mainte nance tasks and intervals Interval Maintenance task Daily Visual inspection and complete cleaning in case of heavy contamination see section Cleaning Weekly...

Page 87: ...d in Nm in the table Total friction coefficient tot 0 12 Diameter mm mm Torque for screw quality 10 9 Nm M 4 7 3 4 M 5 8 4 7 M 6 10 5 12 M 8 13 6 25 M 10 17 8 50 M 12 19 10 100 M 16 24 14 220 M 20 30...

Page 88: ...vice address on the back of this operating instruction 9 1 Safety Trouble shooting The following always applies 5 xx 1 Determine the cause of the fault 2 Depending on the type of fault either have aut...

Page 89: ...ection Cleaning Specialist Contaminated clamping taper Remove the clamping head and clean the clamping taper see section Cleaning Specialist Formal defect on the work piece Elastic deformation of feed...

Page 90: ...correcting the fault execute the following steps to start up again 4 xxx 1 Reset the emergency stop device 2 Acknowledge the fault on the machine tool con troller 3 Ensure that no one is in the dange...

Page 91: ...f hainbuch at Internet www hainbuch at Belgium BIS Technics bvba sprl Zevenputtenstraat 20 3690 Zutendaal Phone 32 89518890 Fax 32 89518899 E mail info bistechnics com Internet www bistechnics com Bul...

Page 92: ...e 30 210 2753725 Fax 30 210 2753725 E mail info cncmechanics gr Internet www cncmechanics gr Hungary GIMEX Hydraulik GmbH Selyem utca 1 9025 Gy r Phone 36 96525588 Fax 36 96427239 E mail info gimex hu...

Page 93: ...tns tnssro sk Internet www tnssro eu Slovakia TMC CR s r o Masn 27 9 60200 Brno Phone 420 533433722 Fax 420 548217219 E mail info tmccr cz Internet www tmccr cz Slovenia Elmetool d o o Prvomajska uli...

Page 94: ...hone 1 4143589550 Fax 1 4143589560 E mail sales hainbuchamerica com Internet www hainbuchamerica com Brasil Sanposs Tecnologia Suprimentos e Consultoria Internacional Ltda Rua C ndia n 65 Jardim do Ma...

Page 95: ...om Taiwan GSTC Technology Co Ltd No 418 Youn Chun East 1st Rd Taichung City 40877 Taiwan Phone 88 6423805678 Fax 88 6423805511 E mail gstc seed net tw Internet www gstctech com tw Thailand HAINBUCH Th...

Page 96: ...ementation limits 19 Inspections 73 Installation Clamping head 71 Hydraulic stationary chuck SPANNTOP 68 HYDROK 68 HYDROK 32 RD HYDROK 40 SE 69 Preparations 65 Intended use 11 M Maintenance schedule 8...

Page 97: ...Symbols on the packaging 60 T Tandem cylinder 58 Transport inspection 61 Transport inner company 61 Trouble shooting 88 Trouble shooting table 89 Type designation 50 U Unpacking 61 Order hotline 49 7...

Page 98: ...HYDROK Appendix 98 Order hotline 49 7144 907 333...

Page 99: ...rried out subse quently by the final user The declaration is no more valid if the product is modified without agreement Hiermit erkl ren wir dass die nachstehend beschriebene Maschine Herewith we decl...

Page 100: ...1262 71667 Marbach Erdmannhauser Strasse 57 71672 Marbach Germany Phone 49 7144 907 0 Fax 49 7144 18826 sales hainbuch de www hainbuch com 24h Emergency call 49 7144 907 444 06 2016 Part no 80001 008...

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