Forkardt 3QLCLM Operating Manual Download

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3QLCLM

POWER CHUCKS

E R MA N

O P E R A T I N G M A N U A L

Summary of Contents for 3QLCLM

Page 1: ...3QLCLM POWER CHUCKS GERMAN O P E R A T I N G M A N U A L ...

Page 2: ...l information 18 4 3 2 Centrifugal force compensation 19 4 3 3 Lubrication 19 4 3 4 Sealing of the power chuck 19 4 4 Chuck jaw 20 4 4 1 General information 20 4 4 2 Safety instructions for top jaws 20 4 5 General safety instructions 21 5 0 Clamping force 22 5 1 General information 22 5 2 Clamping force FSp0 22 5 3 Dynamic gripping force 23 5 4 Clamping force calculation 24 5 5 Determination of gr...

Page 3: ...5 Behavior in case of faults 38 7 6 Measures during longer standstill 39 7 7 Measures after longer standstill 39 7 8 Oil selection 40 8 0 Maintenance 41 8 1 Lubrication 41 8 2 Maintenance plan 42 8 3 Disassembly of the power chuck 42 9 0 Spare parts and customer service 46 9 1 Spare parts 46 9 2 Tools and accessories 46 9 3 Customer service 47 10 0 Declaration of incorporation 48 ...

Page 4: ...t be reproduced or copied either in full or in part utilized for the purposes of competition FORKARDT DEUTSCHLAND GMBH retains the copyright for this operating manual The operating manual prepared based on DIN V 8418 must be read understood and followed by the responsible operating staff Important details for the use of power chuck are pointed out in this operating manual Faults in the power chuck...

Page 5: ...ted operational states Indicates an important information for handling or additional information 1 3 Copyright This operating manual is meant for the assembly operating and monitoring staff It contains specifications and drawings of technical nature which may not be copied reproduced either in full or in part or utilized for the purposes of competition without authorization The company retains the...

Page 6: ...n this manual may result in mortal danger severe bodily injury or severe material damages Only qualified staff are allowed to work with the power chuck Unauthorized modifications and changes to the power chuck are not allowed Use the power chuck only in perfect condition Switch off the machine before working on the chuck and secure the machine against unintentional restart Only use original compon...

Page 7: ...th the applicable technical rules e g VDI 3106 In case of doubt or accessories not provided by the manufacturer the threshold values must be approved by the manufacturer or redefined The following factors must be taken into consideration Variable friction coefficient between work piece and top jaw Proportion of clamping diameter and working diameter Magnitude of the cutting force on the cutting to...

Page 8: ...4 Maintenance and repair In case of maintenance work or inspection work on the power chuck stop the machine and switch off power supply to the clamping cylinder The power chuck is exposed to high loads when it is subject to speeds that are normal on rotary machines In case of occasional collisions between the tool and power chuck e g faults in program sequence the power chuck can be damaged After ...

Page 9: ...ped up to spindle standstill if there is failure of clamping energy Non return check valve in the actuation cylinder There will not be any change to the switch position in case of electricity failure and return Impulse controlled way valve with locked end positions A signal will be sent for automatic or manual spindle stop in case of failure of clamping energy Pressure switch in the clamping line ...

Page 10: ... condition intermediate or chuck flange separately 3 2 Transport handling and storage Report transport damages to the freight forwarder Please report missing parts to the manufacturer immediately by phone and in writing If the power chuck is not mounted immediately after delivery it must be stored in a safe location In such case cover the parts properly and protect against dust and moisture All bl...

Page 11: ...Large through hole for rod works Selected material pairing all force transmitting parts are hardened and polished Simplified form through piston connection in the chuck and not sliding in the rear side Base jaw connections based on European and international standard Developed and manufactured under ISO 9001 Thanks to suitable accessories actuation cylinder hard or soft top jaws matching the work ...

Page 12: ...Table of contents 3QLCLM Edition 04 2014 12 4 2 Constructive design 4 2 1 Technical data main dimensions power chuck type 3QLCLM 3QLC 315 LM Z11 KDIN max 4000 U min Fmax 60KN ...

Page 13: ...x110 M20x90 Thread connection drawbar G1 M45x2 M68x2 M82x2 M100x2 M140x2 Jacking screw standard sleeve G2 M4 M5 M6 M6 M6 Chuck height H 101 101 111 111 141 Chuck height up to jaw support H1 111 124 124 Mounting depth H2 5 6 6 Cover height H3 6 8 8 Thread length mounting bolt J 20 23 6 30 Thread length actuator J1 17 5 24 24 Pull length actuator J2 23 5 34 34 Actuator stroke K 20 20 20 Actuator pos...

Page 14: ...ce accessories Chuck Ø Centrifugal force weight Lever 160 200 191062009 156122010 250 191216009 156584010 315 190476009 156584010 400 CHUCK BODY JAW COMPLETE CHUCK COVER COMPLETE 4 2 2 1 Complete chuck CENTRIFUGAL FORCE ACCESSORIES ACTUATOR COMPLETE CHUCK FIXING SCREWS Lever Centrifugal force weight ...

Page 15: ...7 711A030193 190476004 703D004030 400 Chuck Ø O Ring 3 O Ring 4 Frame Locking screw Sealing disc Actuator O Ring 5 160 200 711A020849 191062001 709C212150 171594044 191062003 711A020055 250 711A015050 711A015033 191216001 177821008 191216002 711A030112 315 711A015123 711A015123 190476001 709C212150 171594044 190476002 711A030127 400 4 2 2 3 Chuck body complete COUNTERSUNK SCREW ACTUATOR O RING 5 L...

Page 16: ...nder screws Chuck cover O Ring 1 O Ring 2 O Ring 3 160 200 701B010360 191204001 711A020107 711A015015 711A015014 250 701B010380 191216005 711A030191 711A025075 711A025012 315 701B010380 190476005 711A030198 711A025026 711A025012 400 CYLINDER SCREW CHUCK COVER O RING 3 O RING 2 O RING 1 ...

Page 17: ... 200 701B012340 191064002 711A015028 191203001 711A020047 701C005320 191064003 191064001 250 701B016360 701C008360 191216008 711A178051 701B004340 190476010 191216003 315 701B016360 701C008360 190476011 711A020055 190476008 711B178054 701B004340 190476010 190476003 400 CYLINDER SCREW O RING A O RING B ADAPTER JAW CYLINDER SCREWS FOR TOP JAWS BASE JAW SLIDING BLOCK SEALING FRAME CYLINDER SCREWS FOR...

Page 18: ...y the clamping cylinder The pressure at the clamping cylinder must be adjusted such that the max permissible actuation force of the power chuck is not exceeded The axial actuation force of the clamping cylinder which is spread on the actuator surface through pressure is transferred to the corresponding wedge guides of the master jaw through the wedge surfaces laid out in the chuck actuator and the...

Page 19: ...tated it uses its centrifugal force to balance the centrifugal force of the base and top jaw which otherwise may result in significant loss of gripping force This simple robust and direct centrifugal force compensation system ensures high gripping force of the 3QLCLM power chuck in the entire speed range on the one hand and allows selective processing with reduced gripping force on the other hand ...

Page 20: ...k and the top jaw which is positively attached by serrations to the master jaw and can thus be exactly positioned The chuck jaws have to be changed to suit the type of machining or the differences in size and shape of the work pieces The chuck jaws must be trained separately for optimal use and to prevent run outs For the type QLCLM power chuck the top jaw may have different holders for fixing to ...

Page 21: ...pressure exceeds an adequate minimum value The pressure at the clamping cylinder must be adjusted such that the max permissible actuation force of the power chuck is not exceeded The test regulations of the industrial safety authority demands that not only a pressure monitor but also a stroke monitor is provided for the actuating cylinder The stroke monitor must ensure that the spindle and feed dr...

Page 22: ...ork holding equipment is subject to centrifugal forces that increase with the square of the speed of rotation The centrifugal force opposes the gripping force in the case of external chucking and increases it in the case of internal chucking The residual dynamic gripping force at high spindle speeds depends on the static gripping force the mass of the chuck jaws and the radius of their center of g...

Page 23: ... to suit the specific application The gripping jaws effect the gripping force and hence the maximum permissible speed The centrifugal force of the jaws of power chucks can have such a significant effect on the gripping force that this effect has to be taken into consideration at higher spindle speeds The centrifugal force generated by the master jaws and top jaws which reduces the gripping force o...

Page 24: ...tuated counterbalancing weights The dynamic gripping force Fsp is thus The total centrifugal moment can be calculated as Terms used in the formulas Fsp Dynamic gripping force daN the total dynamic gripping force applied by the jaws C1 C2 C3 C4 chuck constants Fax Max actuating force daN n Spindle speed min 1 Ma Total centrifugal moment of the jaws kgm Dsp Gripping diameter mm YAB Distance of cente...

Page 25: ...dequate for the machining operation then the spindle speed or the weight of top jaws must be reduced The permissible spindle speed for the power chuck equipped with appropriate top jaws or the variation of gripping force with speed has to be calculated for each application Safety instructions Check that the gripping force of the chuck is adequate for the machining operation under the chosen operat...

Page 26: ...the turning diameter dz 60mm and the cut requires a tangential cutting force Fs 1200daN at a spindle speed of 2760 rpm Soft jaws turned to the gripping diameter are used to avoid damaging the work piece This gives a gripping coefficient of isp 0 1 A safety factor Sz is allowed for the cutting data with Sz 2 The reduction in gripping force ΔFsp amounts to 2000daN This example shows When taking into...

Page 27: ...mula 1 0501 C35G 490 100 2577 2237 1927 1668 1441 1241 1 0532 St50 2 559 100 2561 2248 1959 1716 1499 1307 1 0632 St70 2 624 100 2877 2492 2142 1851 1595 1371 1 0711 9S20 371 100 1609 1553 1497 1444 1393 1342 1 1181 Ck35V 622 100 2574 2266 1962 1741 1527 1339 1 1191 Ck45V 765 100 2524 2253 1999 1781 1584 1405 1 1221 Ck60V 673 100 2548 2296 2058 1851 1662 1490 1 3505 100Cr6G 624 100 2904 2551 2239 ...

Page 28: ...he work piece flying out of the chuck from the cutting force component P is ensured when the friction force isp x Fsp 3 and P are in equilibrium The gripping force required to prevent tilting out of the chuck The gripping force required for driving The gripping force required S safety factor Permissible overhang length with given gripping force ...

Page 29: ...ppropriate mounting flange see also Section 5 8 1 is attached to the spindle nose of the lathe for direct mounting of the power chuck on the machine spindle with short taper to DIN ISO and ASA standards If the adapter flange is manufactured by the user it must be finish turned on the machine spindle and balanced before the power chuck is mounted After fitting of the mounting flange the radial and ...

Page 30: ...ing points when fitting a draw tube The draw tube dimensions have to be adequate for the loads imposed The draw tube must be turned all over to avoid imbalance Manufacture the draw tube from a material with a tensile strength of at least 1000N mm2 e g 42CrMo4V The draw tube has to be balanced dynamically in two planes so that the residual imbalance in each plane is not equivalent to more than a ma...

Page 31: ...uality Since the centrifugal forces per unit of weight increase with the square of the spindle speed the demands on the precision of balancing increase with increasing speed of the parts For this reason the lathe spindle the actuating cylinder the power chuck the cylinder flange the chuck mounting flange or adapter plate and the draw tube must be balanced The power chuck is balanced dynamically wh...

Page 32: ...unting hook to mount the power chuck on the hoist and level it with the spindle The mounting hook must correspond to the conditions in accordance with DIN 6890 Attention Remove any chips from the machine spindle before mounting the power chuck Clean the register and locating faces of the adapter flange adapter disc However in case the machine s chucking equipment is frequently changed the draw tub...

Page 33: ...nting spigot of the chuck flange When doing this make sure the mounting bolts are at the correct angle to the threaded bore holes in the chuck flange Tightly screw the power chuck on the chuck flange with the socket head screws Before finally tightening the socket head screws in a clockwise direction align the power chuck so that after completing mounting the run out at the test surfaces of the po...

Page 34: ... 8 M 10 M 12 Tightening torque Nm 8 7 12 25 43 56 Preload Fv N 9300 10560 16940 23100 25200 Thread M 16 M 20 M 24 M 30 Tightening torque Nm 124 244 420 840 Preload Fv N 42400 66400 95600 154000 6 4 2 Tightening torques of jaw mounting bolts Bolts in accordance with DIN 912 Quality 10 9 Manufactured in accordance with DIN 267 Thread M 6 M 8 M 10 M 12 M 16 Tightening torque Nm 15 29 50 75 155 Preloa...

Page 35: ...inder or on the body of the power chuck must not be used for this purpose as the exact dynamic balancing of the actuating cylinder or power chuck will be lost Check the proper mounting using a dial gage on the test faces of the power chuck The chuck body may be distorted if the chuck without gripping jaws does not operate freely In that case remove the chuck from the spindle of the machine and che...

Page 36: ...ssure monitor but also a stroke monitor is provided for the actuating cylinder The stroke monitor must ensure that the spindle and feed drives cannot be started or are automatically stopped if the power chuck is opened or the actuating cylinder reaches the end of its stroke Use limit switches to VDE 0113 12 with mechanically operated positive acting NC contacts to monitor the actuating cylinder st...

Page 37: ...nical data The power chuck must open and close at approx 1 10 of the permissible actuating force Binding of the power chuck may be the result of strained master jaws or top jaws Unbolt the top jaws and inspect the cross tenon If the power chuck binds without top jaws the chuck body may be strained Check the flatness of the chuck mounting flange Check the jaw movement and chuck piston stroke Check ...

Page 38: ...g If the center of the gripping cross section deviates from the lathe centerline beyond the specified tolerance this will result in faulty work pieces and consequently to scrap 7 3 Unauthorized operation In the event of system imbalance at the actuating cylinder or power chuck eliminate the imbalance immediately 7 4 Safety instructions During rotation of the power chuck use a dynamic gripping forc...

Page 39: ... not attained Master jaws incorrectly mounted or reversed Check and replace if necessary Wrong length of draw tubes Check setting dimension E No gripping force Master jaws strained Inspect locating faces possibly use of jaws from a different manufacturer Top jaw cannot be adjusted Serrations of master jaw soiled Clean Possibly difference in pitch with self manufactured top jaws Run out error with ...

Page 40: ...linder see also operating manual of the manufacturer of chucking cylinder Recommended oil Operating temperature Viscosity Viscosity Viscosity Viscosity Viscosity CSt at CSt at CSt at CSt at CSt at 50 C 50 C 50 C 50 C 50 C 25 54 cSt At working condition Heat 60 80 C Aral oil GFY Aral oil TU 524 Aral oil TU 528 49 0 49 0 68 0 Energol HLP 150 Energol HLP 175 49 0 65 0 Esstic 55 Teresso 56 Hydraulic o...

Page 41: ...th fresh lubricant Filling through the oil holes in the chuck body see above Oil quantity max 75 of the cavity volume This will ensure uniform chucking force accuracy and high service life The lubrication of the actuated by the hydraulic oil cylinder power check must be done at regular intervals Due to this reason carry out many empty runs without work piece to distribute the lubricant evenly 8 0 ...

Page 42: ...mi annual Check the master jaw chuck actuator lever and sealings for wear Depending on the load of the power chuck Use new sealings if required during assembly disassembly of the power chuck and fill actuator and jaw guides with PF2 grease and fill power chuck with Mobil Vactra Oil No 4 8 3 Disassembling the power chuck Open the locking screws on the body and discharge lubricant oil Loosen the fix...

Page 43: ...diate jaw mounting bolts Now you can remove the intermediate jaw and the O rings Remove screws for cover bolts Now you can removed the cover and O ring Note O ring will not be present in certain chuck variants Here the chuck is sealed with a sealant e g Hylomar Universal Blue When assembling note that the sealing areas are cleaned off grease and the area between cover and body has sealant ...

Page 44: ...ing blocks Now the sliding bolts can be removed Even the sealing frames at the master jaw and associated O rings can be removed as next step Remove the cylinder screws for chuck cover Remove chuck cover including all O rings and centrifugal weights from the body of the chuck You can now remove the centrifugal weights and O rings from the chuck cover and lever from the chuck body ...

Page 45: ...e center of the chuck When the actuators are removed the master jaws can be pushed into the center one after another and then removed from top Pull the covers of QLC guides only in case of repairs Auxiliary threads can be used in this case The removal requires certain force because the covers are used with a sealant ...

Page 46: ...n our products relieves us from our obligations regarding product liability in so far as any damage can be attributed directly or indirectly to the use of such parts Our warranty only extends to ORIGINAL spare parts supplied by us Please note that special specifications frequently exist for parts manufactured or bought out by us and that we always supply spare parts that meet the latest technical ...

Page 47: ...ition 04 2014 9 3 Customer service Following data must be specified when ordering spare parts Description Quantity Ident No FORKARDT DEUTSCHLAND GMBH Lachenhauweg 12 72766 Reutlingen Telephone Fax 49 7127 5812 0 49 7127 5812 122 ...

Page 48: ...d observed The special technical documents according to Appendix VII B have been prepared The aforementioned special technical documents will be submitted to the responsible authority as required Commissioning is forbidden until it has been verified that the machine in which the aforementioned machines are to be incorporated comply with the specifications of the machinery directive Responsible for...

Page 49: ...Table of contents 3QLCLM Edition 04 2014 49 ...

Page 50: ...ORKARDT INDIA LLP Plot No 39 D No 5 5 35 Ayyanna Ind Park IE Prasanthnagar Kukatpally Hyderabad 500 072 India Phone 91 40 400 20571 Fax 91 40 400 20576 Email info forkardtindia com FORKARDT FRANCE S A R L 28 Avenue de Bobigny F 93135 Noisy le Sec Cédex Phone 33 1 4183 1240 Fax 33 1 4840 4759 Email forkardt france forkardt com FORKARDT CHINA Precision Machinery Shanghai Co Ltd 1F 45 Building No 209...

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