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2.  Security advice

• 

Persons operating, maintaining or servicing the cutting head should always 
read and understand the operating manual in particular the safety inst-
ructions. Persons under the influence of alcohol and /or drugs may cause 
accidents! 

• 

Take into account the weight of the thread cutting head upon installation. If 
necessary lift it with a lifting gear.

• 

Please take note that the cutting sites between tool and machine are kept 
clean. Should they be fouled the accuracy of the workpiece is affected. 

• 

When installing the tools switch off the machine at the line switch. When 
changing the chaser holders and chasers take note that the tool shaft isn’t 
starting unexpectedly.

• 

Remove all tools and testing equipment from the workspace of the machine 
before activating it. Risk of injury arises through tools and testing equipment 
which are flung about! 

• 

Close guard door or protection case before machining. Flying chipping and 
damaged tools or workpieces can cause damage to persons or mechanical 
breakdown. 

• 

Make sure that the thread cutting head isn’t loosening when machining.

• 

Don’t touch the cutting head upon closing. Don’t touch rotating tools: Risk of 
injury!

• 

Be very careful when dealing with the chasers. The edges of the chasers are 
very sharp. Wear safety gloves if necessary!

• 

Please ensure that the thread cutting head is properly secured and attached 
whilst transporting. 

Operating Manual ZR 26-I 

 5

Security advice

Summary of Contents for ZR26-I

Page 1: ...Operating Manual Thread Cutting Head ZR26 I Article No 74424300 ...

Page 2: ...f the chasers 21 8 Installation of the chaser holders 22 9 Presetting of the thread diameter 23 10 Mounting of the cutting head onto the machine 24 11 Operation sequence of the thread holders 25 12 Control paths 26 13 Thread cutting and diameter fine adjustment 28 14 Cutting speed 29 14 1 Choice of the cutting speed 29 14 2 Calculation 29 14 3 Choice of the infeed 29 15 The coolant 30 16 Maintenan...

Page 3: ...ing Systems Baublies GmbH reserves the right to technical amendments regar ding the improvement of this product However the Wagner Tooling Systems Bau blies GmbH cannot held liable for any faults damages failures and production loss resulting thereof caused by disregarding of some aspects mentioned in this manual Due to copyright reasons we would like to point out that this operating manual is for...

Page 4: ...se you will cause damages to the cutting head or the machine Initial operation Check the function of the thread cutting head before initial operation Limitation of liability Please note Use this pro duct only for the purpose it is manufactured for Please take notice of the safety instructions and ha zard warnings The thread cutting head ZR 26 I should only be used by trained technical staff Otherw...

Page 5: ...nd chasers take note that the tool shaft isn t starting unexpectedly Remove all tools and testing equipment from the workspace of the machine before activating it Risk of injury arises through tools and testing equipment which are flung about Close guard door or protection case before machining Flying chipping and damaged tools or workpieces can cause damage to persons or mechanical breakdown Make...

Page 6: ...luding run out isn t longer than the width of the chasers As the load of the tool is quite high this method can be used for fine threads only Four axial marks can t be avoided here 3 2 Mode of operation The Thread Cutting Head ZR 26 I with internal control is designed for the fast and effective production of external threads on machine tools with connecting rod All required mechanical movements li...

Page 7: ... excentric ring and the sli ding pieces of the chaser holders The four bores of the base body are the die of the chaser holders whose axial guidance adopts the central support guidance of the base body The chaser holders will be pressed outwards up to the installation of the excentric ring by means of the spring mounted pressure sockets Figure 2 Mode of operation sliding piece chamfer Unit Guide a...

Page 8: ...and the lead angle of the thread Please note that the core diameter of the thread and the angle of the holder should approximately correspond to the lead angle of the thread Lead angle angle of the holder lead angle 1 Please note Only chaser holders with the same serial number may be used in one set of holders Due to manufacturing reasons chaser holders are not available separate but as a set 4 2 ...

Page 9: ...ndrical threads and short conical threads size of chaser S09 22 x 7 x 32 Mainly for conical threads Please refer to the holder table in the annex for the required size of the chasers Chaser profile The chaser profile consists as mentioned before of parallel grooves which correspond to the profile of the thread to be cut Example Metric profile with lead angle of 60 according to DIN 13 or Whitworth ...

Page 10: ...ber of the chaser 1 4 within a set is engraved Examples for thread labelling on the chaser M 0 7 P Chaser for all metric ISO threads according to DIN 13 with lead of 0 7 mm W 28 GG Chasers for all Whitworth threads according to ISO 228 resp B S 84 for threads according to DIN 11 with lead of 28 movements per inch and all cylindrical Whit worth pipe threads according to DIN 259 with lead of 28 move...

Page 11: ...et the relevant angles Should you not be in possession of a tool grinding machine we recommend you use a WAGNER chaser skiving machine As cup wheels we do recommend conical cup wheels EKW 60 Jot with edge reinforce ment They are available from WAGNER When grinding chasers with low thread profiles it is very useful to adjust an illumina ted magnifier at the grinding device The choice of the chip an...

Page 12: ... the most common cutting angles from 20 to 25 Cutting angle Supplementary angle for long throat medium throat short throat 20 3 0 3 5 5 0 25 3 8 4 5 6 5 In order to calculate the additional angle for other cutting angles and special first cuts the following alignment chart applies Figure 8 All you have to do is to read off the first cut or the correspondent first cut angle on the right scale Then ...

Page 13: ...ional cases to have a grinding angle of minus degree Whereas we would not recommend to increase its size Grinding of the chasers After choosing the matching angles the chasers can be grinded Please heat the chasers reasonably when dry grinding On no account should they be cooled in water after grinding Please note to supply water sufficiently when wet grinding Non observance can lead to fissures a...

Page 14: ...ond complete cutting sprocket It is most important to cut the nook sharply edged as when grinding the flank of the first sprocket of the guiding presser foot a chip pocket is formed which can lead to cobbling of the sprocket Moreover it can create very uneven thread flanks The cutting sprockets are cut this deep that the length of the guiding presser foot amounts to 0 5 to 1 x lead Please be infor...

Page 15: ...he chasers 6 2 The setting device The setting device is used to set the chasers in the chaser holder to the value needed for the thread to be cut Please refer to the holder tables for the exact setting values Figure 11 Fixture for chasers Figure 12 The setting device Operating Manual ZR 26 I 15 Equipment ...

Page 16: ... are converted into setting values which are laid down in the holder and thread tables Using the setting device the setting values are transmitted onto the chasers In order to establish the setting value please refer to the left column of the holder and setting table for the thread to be cut Thread and holder tables see page 19 20 To the very right you will come upon the column setting values In t...

Page 17: ... 1 2 Construction steel up to 500 N m 1 Construction steel after 500 N m 0 5 1 High alloyed steel stainless steel 0 0 5 Pipes cylindrical threads 0 5 2 Pipes conical threads 1 2 Grey and cast iron 1 2 MS 58 2 MS 63 bronze 0 5 2 Copper 0 5 1 Aluminium alloy 0 5 1 Example ad diameters Figure 13 Setting value and length of the chaser Figure 15 Setting of the chasers Operating Manual ZR 26 I 17 Settin...

Page 18: ...note Adjust the chasers carefully Set them up to that point until you won t notice the brinelling of the thread anymore If you set the chasers too far there will be higher friction between the tool and the workpiece This will result in in tense heating and abrasion 18 Operating Manual ZR 26 I Setting of the chasers in the chaser holder ...

Page 19: ...2 844 22 128 21 930 ZR 26 D 1 5 KD 21 8 29 2 744 274 00 S 02 2 59 M26x1 5 1 50 25 968 25 732 24 994 24 844 24 128 23 920 ZR 26 D 1 5 KD 21 8 29 2 744 274 00 S 02 2 23 Metric threads conical DIN 158 1 External threads tolerance 6g Tools setting value Thread indica tion Pitch mm External diameter Flank dia meter Minor dia meter Chaser holder Chaser size maximum size maximum size maximum size Type Ar...

Page 20: ... 7x 28 2 50 NPT threads ANSI ASME B1 20 1 External threads tolerance 6g Tools setting value Thread indication Lead turn 1 inch External diameter Flank diameter Minor dia meter useable th read length Chaser holder Chaser size Type Article number Gauge Ø 48 mm At the pipe end NPT 1 8 27 10 287 9 233 8 481 6 632 ZR 26 D 2 5 KD 6 9 14 7 744 270 00 S 02 4 08 NPT 1 4 18 13 716 12 125 10 996 10 206 ZR 26...

Page 21: ...r holders aren t numbered there is no need yet to pay attention of their order when inserting them After you have inserted them tight the clamp screw slight ly Thus the chaser is slightly clamped but can be moved with the setting screw The two needles of the flowmeter are set to zero on the setting gauge Please note to choose the right diameter of the gauge Afterwards the setting gauge will be rem...

Page 22: ...elled in holders have to be pressed outwards by the pressure sleeves An efficient functioning of the cutting head is dependent hereof You can now push forward the components guiding and excentric ring In doing so the chaser holders are pressed together by means of the clamping ring Annotation Contrary to the other cutting heads the ZR 26 I does not have any inner stop bolt which engages automatica...

Page 23: ...nated bore hole and twist the excentric ring 110 thus far that the sample part resp the bolt can be only just turned by hand Remove the bolt resp the sample part and scale the excentric ring again down to 1 to 2 tick marks One tick mark complies with ca 0 1 mm setting of the diameter This is necessary for the position cutting head closed completely so that the minimum size of the diameter can be a...

Page 24: ...e connecting rod A machine requirement is a connectable connecting rod which is resistant to tension and pressure The cutting head can be mounted completely assembled and preset on the drive screw The connector is coupled via a left handed thread with the connecting rod and the flange is mounted on the shaft The nature of mounting is machine dependent and is done either by a screw connec tion or a...

Page 25: ...head closed min and cutting head closed max This enables a fine adjustment of the thread diameter via the adjusted position of the connecting rod Replacement of the thread holders The position holder replacement has to be reached in order to install or remove the chaser holders During that position the chaser holders can be swivelled out from the holder guidance and taken out The new holders are p...

Page 26: ...ever this isn t a permanent position Please be notified not to use up more than 8 mm of the axial lift to guarantee sufficient support of the chaser holders Position Head opened During this position the cutting head is opened which allows the chasers to lift from the workpiece This is a permanent position which has to be always approached by the connecting rod immediately after the thread is cut P...

Page 27: ...Control chart 00366569 Operating Manual ZR 26 I 27 Control paths ...

Page 28: ...05 Ø adjustment Having cut the first thread the thread diameter ideally the flank diameter has to be checked resp measured This necessary adjustment is again done by the connecting rod Should the diameter of the cut thread be too small it has to be adjusted in the section Z As mentioned before 1 mm connecting rod path amounts to about 0 05mm adjust ment of the diameter This means that the position...

Page 29: ...on 10 30 Grey cast iron 10 25 Short chipping brass 30 60 Long chipping brass 30 50 Bronze 20 50 Copper 15 50 Aluminium alloy 20 60 14 2 Calculation The cutting speed is calculated according to this formula vc d π n 1000 vc cutting speed m min d thread diameter mm n rotation speed min 1 Referring to the given cutting speed the rotation speed is calculated according to this formula n vc 1000 d π 14 ...

Page 30: ...s it enhances the cutting process and the thread surface In special cases we recommend to contact the manufacturing company The cooling lubricant can be applied on the cutting edges from outside However we recommend the inner coolant supply The coolant is connected via the flank or the connecting rod 30 Operating Manual ZR 26 I The coolant ...

Page 31: ...uide ring 70 Unscrew the two cylinder head screws 170 the gear segment 150 and the clam ping piece 160 can now be removed The four cylinder head screws 130 can be unscrewed by the four holder boreholes of the base body 10 The flank 400 and the guide ring 70 with the attached parts can now be separated dressed backwards from the base body 10 Please take note that the two o rings 420 of the flank 40...

Page 32: ...t the insert plates 120 into the notches of the excentric ring Screw in the cylinder head screws but don t tighten them By using the match code 310 the excentric ring is brought into the right position refer to scale Insert the gear segment 150 and the clamping piece 160 and screw them together by means of the two cylinder head screws 170 and tighten the cylinder head screws 140 16 3 Verifying of ...

Page 33: ...16 4 Exploded assembly drawing ZR 26 I Operating Manual ZR 26 I 33 Maintenance ...

Page 34: ...60 1 724 913 00 clamping piece 170 2 020 160 52 cylinder head screw M5x10 DIN6912 180 1 743 701 00 guide bail 190 2 020 161 04 cylinder head screw 200 2 020 610 05 hexagonal nut 210 1 on request connector 220 1 020 151 65 cylinder head screw 300 1 705 215 00 clamping ring 310 1 731 040 00 match code 320 1 036 972 01 screwdriver SW4 330 1 026 770 04 screwdriver 4 DIN 911 340 1 036 972 02 screwdrive...

Page 35: ...wdriver 2 5 Flank complete article no on request Part No Quantity Article No Designation 400 1 on request flank ZR26 I 410 2 020 451 01 threaded pin M5x4 DIN 913 420 2 5822001111 o ring 430 1 737 267 00 locating bolt levelled Setting device article no 70535600 Part No Quantity Article No Designation 710 1 705 259 00 setting bearing 720 1 705 261 00 headless screw 721 1 705 264 00 control 722 1 021...

Page 36: ...right handed threads clockwise left handed threads anti clockwise The infeed speed is too fast while pres sing on Chaser or chaser holders from different sets have been used Please check the set number Chaser for conical threads have been used Please check the marking Chasers set too far over centre Chasers haven t been grinded properly the radius in the nook between cutting sprocket and guide spr...

Page 37: ...er angle and lead angle are too unequal The feed unit runs too heavily or at the wrong speed The chaser is blunt or the cutting angle is too small Setting value is too big Unsuitable coolant Material requires coating of the chasers Operating Manual ZR 26 I 37 Defects and causes thereof ...

Page 38: ...ormation in this catalog is current as of publication date and subject to change All rights reserved Date 10 2018 Wagner Toling Systems Baublies GmbH Gutenbergstraße 4 1 D 72124 Pliezhausen phone 49 0 71 27 97 33 00 fax 49 0 71 27 97 33 90 email info wagner werkzeug de web www wagner werkzeug de ...

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