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J630D

26.7.02

5

0.1

Safety of the machine

The J630D machine has been designed in line with the present state of the art in
engineering as well as generally recognized safety rules and regulations. It com-
plies with the EU Machinery Directive. The X-radiation generated by the monitor
is adequately shielded in accordance with statutory requirements. Nevertheless,
the risk of personal injury (or in extreme cases death) to the operator or third par-
ties as well as damage to the machine or other equipment cannot be ruled out
completely.

The machine is equipped with various safety devices intended to protect the user
and other persons. Safe operation is not dependent on mechanical / electrical
functions alone however, but also on

•

Your own sense of personal responsibility

•

Correct handling in accordance with regulations

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Содержание J630D

Страница 1: ...2 Technical data transportation commissioning 25 2 1 Technical data 25 2 2 Noise measurement 27 2 3 Floor space drawing 29 2 4 Transport dimensions machine only 31 2 5 Transport instructions 33 2 5 1...

Страница 2: ...tting up and semi auto matic mode 73 5 1 3 Function tree structure of the Machine Jung module in automatic mode 75 5 1 4 Machine Jung module 76 5 1 4 1 System data 78 5 1 4 2 Statistics 79 5 1 4 3 Sim...

Страница 3: ...ocedure with an MA65 optional 174 5 6 8 Dressing procedure with a Diaform DG 5 1 grinding wheel profile dresser optional 175 5 7 Dressing contours created in Grips 177 5 7 1 Creating a contour saving...

Страница 4: ...9 7 6 Grinding wheel flange optional 231 7 6 1 Flanging and balancing a grinding wheel 232 7 6 1 1 Flanging a grinding wheel 232 7 6 1 2 Balancing a flanged grinding wheel statically 233 7 7 Grinding...

Страница 5: ...e unit for optional equipment 282 9 3 9 Lubricating points on the PA 31K optional 283 9 4 Hydraulic plan 285 9 4 1 Charging extracting the hydraulic oill 287 9 5 Pneumatic plan 289 9 6 Grinding spindl...

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Страница 7: ...Operating Instructions J630D...

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Страница 9: ...7161 612 213 Spare parts and customer service See address above Service Department Telephone 49 0 7161 612 224 Telefax 49 0 7161 612 169 Hotline 49 0 7161 612 131 or 49 0 7161 612 207 Spare parts 49 0...

Страница 10: ...172 Safety Through Instructions taking account of the technical docu mentation and all statutory requirements The descriptions and specifications contained in these Operating Instructions are subject...

Страница 11: ...n accordance with statutory requirements Nevertheless the risk of personal injury or in extreme cases death to the operator or third par ties as well as damage to the machine or other equipment cannot...

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Страница 13: ...the machine system is accepted and reported immedi ately to the insurer and K Jung GmbH In the event of damage that has occurred not being detected until the machine system is unpacked leave the mach...

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Страница 15: ...nditions for new machines We furnish a full 12 month warranty on all new JUNG grinding machines delivered for one shift operation up to a maximum of 2000 operating hours The warranty period shall term...

Страница 16: ...servicing appropriate to the specific use made of the machinery The customer be ars sole responsibility for selecting the correct machining technology as well as for high quality machining results Ot...

Страница 17: ...to a potentially dangerous situation which could result in minor personal injury This symbol is also used if there is a risk of damage to the machine or equipment Draws attention to a potentially pro...

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Страница 19: ...of any kind on or with the machine Observance of all servicing and maintenance intervals All other forms of use which deviate from the above and in particular failure to heed the information contained...

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Страница 21: ...heels Fastening and dressing grinding wheels Entering workpiece machining data and optimizing the machining process Special hazard precautions and safety requirements Any special procedures or machini...

Страница 22: ...he Operating Instructions is not heeded Moreover the recognized rules practices and legislation relating to occupational safety must be studied and heeded The Operating Instructions must be kept close...

Страница 23: ...ntion regulations Study and heed the original instructions provided by the manufacturer before transporting accessories or other items of equipment e g coolant systems clam ping fixtures extraction de...

Страница 24: ...our particular machine is not fitted with the necessary fire and explosion protection de vices Aluminium and all alloys with at least 70 percent aluminium by weight Magnesium and all alloys with at le...

Страница 25: ...grips steps railings floors windows and safety devices free from dirt and other forms of contamination such as coolant residues oil or grinding dust Failure to do so may cause your view to be obstruc...

Страница 26: ...s Always adjust the dressing diamond and or your follower to the diameter of your actual grinding wheel for all machines Caution If the dressing diamond follower is not adjusted correctly or if the gr...

Страница 27: ...hether or not persons with active implants or ferromagnetic foreign bodies should be allowed to work in this area must be decided on a case to case basis Persons wearing a pacemaker are not allowed to...

Страница 28: ...accessories work equipment As the owner of the machine you must fit an extraction device if the quantity of dust and or smoke and or mist produced during grinding is such that it could rep resent a he...

Страница 29: ...atutory and general requirements valid in the country in which the machine is to be used All persons who have not yet received the appropriate training or instruction or who have not yet completed the...

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Страница 31: ...r 9 84 inch inch 14 41 Maximum load including magnetic chuck kg 130 Height above floor inch 42 72 Main spindle drive Speed range RPM 800 4200 Others on request Motor power KW 5 at max RPM 10 at max RP...

Страница 32: ...limit switches with JC JCE guard inch 10 63 10 43 Resolution of measuring system mm 0 0002 Installation data Width inch 133 86 Depth without machine controller inch 106 3 Height depending on equipment...

Страница 33: ...h DIN 45 635 Parts 1 and 16 is less than 70 dB A when the machine is idling idle reciprocating motion with grinding spindle motor active The value may increase to 75 dB A during grinding if the machin...

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Страница 35: ...J630D 2 Technical data transportation commissioning 26 7 02 29 2 3 Floor space drawing...

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Страница 37: ...J630D 2 Technical data transportation commissioning 26 7 02 31 2 4 Transport dimensions machine only...

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Страница 39: ...statutory requirements must be observed when the machine is transported e g accident prevention regulations Drain off all liquids e g coolants and oils before transporting the machine The machine must...

Страница 40: ...sories necessary for crane transport 4 threaded bolts 1 HF 50 1624 4 ring nuts M 30 x 2 DIN 582 2 steel pipes or rods outside diameter 1 97 x 0 2 x 51 18 inch 4 continuous poly hoisting slings 196 85...

Страница 41: ...e bed Screw in the threaded bolts Insert the steel pipes rods through the eyes of the threaded bolts Take steps to prevent the steel pipes rods from being moved accidentally Suspend the machine as sho...

Страница 42: ...lift truck Transport the machine as shown in the Transport by fork lift truck dia gram The maximum carrying capacity of the fork lift truck must be greater than the weight of the machine plus the wei...

Страница 43: ...electrical connectors and connect the power supply This step must always be carried out by a qualified electrician in accordance with the generally recognized rules of sound electrical practice See s...

Страница 44: ...ssioning Transportation safeguards Mount the enclosed accessories on the machine after studying the original in structions provided by the manufacturers These accessories include Magnetic chuck Coolan...

Страница 45: ...ling the dresser To do so unscrew the two hexagon socket bolts in each safeguard and remove the locking elements Keep the locking elements in a safe place in case you need to transport the dres ser ag...

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Страница 47: ...ion requirements Note the permissible floor load Connection and installation requirements See section 2 1 Technical data on page 25 Make sure sufficient floor space is available See section 2 3 Floor...

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Страница 49: ...e from a second person who can then press the EMERGENCY STOP button or the main switch to release the voltage in an emergency Cordon off the working area with a red and white chain and a war ning sign...

Страница 50: ...ans that direct currents can flow in the event of a fault Consequently safe ope ration cannot be guaranteed with conventional residual current operated circuit breakers Connection of the r c c b circu...

Страница 51: ...wnwards towards the grinding wheel upwards away from the grinding wheel E axis Rotary motion of the dressing arm PA 31K forward backwards U axis Infeed motion of the dressing diamond PA 31K toeards th...

Страница 52: ...and Z axes The tool reference point is located on the front edge of the grinding wheel Please remember when you program the positioning paths in the X axis that from the point of view of the operator...

Страница 53: ...to main screen 2 Key for returning one screen at a time 3 10 Horizontal softkey row 11 Shift key for activating second horizontal softkey row 12 Dual function key Change module key click this key once...

Страница 54: ...48 26 7 02 3 Machine control unit remot control panel C Alphanumeric key block Keys Function 1 7 A 2 8 B 3 9 C 4 D 5 E 6 4 F 7 5 G 8 6 H 9 I 10 J 11 1 K 12 2 L 13 3 M 14 N 15 O 16 P 17 0 Q 18 R 19 S...

Страница 55: ...channel W 4 Acknowledge alarm X 5 Help Y 6 Z 7 Change input area 8 Cursor up 9 Scroll up 10 Delete to left 11 Blank space bar 12 Cursor left 13 Select key advance through marked area select 14 Cursor...

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Страница 57: ...e in steps 5 8 S3 Magnetic gripping force OFF 6 8 S2 Magnetic gripping force ON 7 0 S3 EMERGENCY STOP button 8 0 S2 Control unit OFF 9 0 S1 Control unit ON 10 12 S30 Override switch for the sum of the...

Страница 58: ...hining at breakpoint 27 12 S7 Cancels a function 28 12 S6 Measurement 29 12 S5 Traverses to the grinding wheel change position 30 12 S4 Traverses to the workpiece change position 31 12 S20 Key operate...

Страница 59: ...les e g traverse to reference point are started with this key 38 12 S21 Key operated switch for control unit 1 position not relevant for the operator 39 Key operated switch for control unit 2 position...

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Страница 61: ...tion in selec ted axis 3 not activ 4 Handwheel increments of 0 00001 inch 5 Rapid traverse key in combination with a direction key or 7 Handwheel increments of 0 0001 inch 8 not activ 9 Handwheel incr...

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Страница 63: ...ode Exception If a guard door is fitted and you close it before changing the operating mode the function or program is not interrupted Safety regulations There is a risk of collision when the axes are...

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Страница 65: ...n on the remote control panel Select the infeed value per handwheel increment on the remote control panel 4 0 00001 inch 7 0 0001 inch or 9 0 001 inch See section 3 3 Remote control panel on page 55 T...

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Страница 67: ...should remain aware of the risks of working in this mode at all times Please bear the potential hazards and the safety regulations in mind while working on the machine When you probe a workpiece do no...

Страница 68: ...u release the rapid traverse key 5 the axis will continue po sitioning at the normal feed rate If you release the direction key or the axis will stop immediately 4 3 1 4 Positioning the axes increment...

Страница 69: ...6 NC reset See section 3 2 Machine control unit on page 51 position 36 The reciprocating motion in the X Z axis stops immediately The reciprocating W axis traverses to the start position before stoppi...

Страница 70: ...op pos softkeys Alternatively you can set the values for the reciprocating X axis using the scroll bars Set the right hand reversing position X with the top slider control Set the left hand reversing...

Страница 71: ...axis directly Press the Recip Value Z Axis softkey You can enter the current position values for the reciprocating Z axis in the input boxes directly by pressing the Teach Pos Teach Pos and Teach Sto...

Страница 72: ...s reversing position with the remote control panel Traverse to a future reversing position with the X or Z axis Press the teach key See section 3 3 Remote control panel on page 55 po sition 12 on the...

Страница 73: ...tomatic program cycle The program is interrupted immediately The Y axis grinding head is traversed to the safety position If you want to continue machining at the breakpoint you must press key start a...

Страница 74: ...rogram start dressing program See section 3 2 Machine control unit on page 51 posi tion 35 Until you do so you will not be able to continue machining at the breakpoint and complete the program This op...

Страница 75: ...nt If you do not want to correct the measurement click on the End softkey 4 4 2 Sequence of operations in an automatic program cycle Example You want to grind a groove with a profile in a workpiece of...

Страница 76: ...Dressing function Create the dressing technology Start the dressing program a contour negative is created for the grinding wheel Measure the workpiece in order to enter the grinding geometry Fix the...

Страница 77: ...47 D17 The active input line has a yellow background while the value field in this line has a blue background The dialog line of the display contains a short description of the selected input line So...

Страница 78: ...ns of the machine 5 1 1 Important warning for all programs Moving axes are dangerous Keep workpieces and other objects of all kinds clear of the axis traverse paths Keep your hands well away while the...

Страница 79: ...ble Set X axis Set Y axis Set Z axis AT Y axis NC Start AT Z axis NC Start AT ON Select dia station Set dress head Chapter5 4 1 Chapter 5 4 3 Chapter 5 4 2 Nominal pos indication MCS System Data Set d...

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Страница 81: ...C Start AT Z axis NC Start AT ON Teach current value Set dress table Set X axis Set Y axis Set Z axis AT Y axis NC Start AT Z axis NC Start AT ON Select dia station Set dress head Nominal pos indicati...

Страница 82: ...ction 5 10 Batch mode on page 185 Warm up follow up see section 5 11 Warm up follow up program on page 189 Settings change positions Recip value X axis see section 4 3 Semi automatic mode on page 61 T...

Страница 83: ...oordinate system the distance from the reference point of the NC axes is displayed as an absolute value If you press the WCS softkey workpiece coordinate system the distance from the zero point after...

Страница 84: ...the current axis if the softkey Teach cur rent value is actual Finally press the Accept values softkey The values you have entered are now transferred to the NCU 5 1 4 1 System data You can set the da...

Страница 85: ...s values e g the wheel number to their defaults If you press the Software version softkey the current software version is dis played 5 1 4 2 Statistics Press the Statistic softkey in the Machine Jung...

Страница 86: ...as well as the total time and reset them again by pressing the Clear old data softkey 5 1 4 3 Simulation If you press the Simulation OFF ON softkey the dressing operation defined by the currently act...

Страница 87: ...mulation OFF ON soft key again 5 1 4 4 Program overview You can select a machining program on the program overview screen It is active if it appears above in the program overview Press the Program ove...

Страница 88: ...J630D 82 26 7 02 5 Functions of the machine To reload the overview press the Load overview softkey Select a machining program and press the Program selection softkey The selected program is now active...

Страница 89: ...ure of the Program Jung module File Software Version Read NCU data Write NCU data Dressing program Grinding program Program Jung The various subordinate branches of the Grinding program Dressing progr...

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Страница 91: ...active program data in the MMC is copied to the NCU All the data you enter via the programming interface is thus transferred to the NCU This is also possible during a machining operation in other word...

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Страница 93: ...ructure of the File Manager File File new Value to clipboard Value from clipboard Filemanag open Filemanag save Load NCU Unload NCU Cancel Open Load NCU Unload NCU Cancel Save Software Version Read NC...

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Страница 95: ...n open files and save them Files can be de leted in the Services menu Press the File softkey in the Program Jung module Create a new file Press the File new softkey If you want to make changes to a fi...

Страница 96: ...e active grinding and dressing programs are reset set to 0 You can also enter a comment for the new file if you wish Opening a file Press the Filemanag open softkey Select either NCU or Hard disk MMC...

Страница 97: ...en softkey Saving a file in BATCH 1 Press the Filemanag save softkey Select either NCU or Hard disk MMC here A list of the files stored in the NCU or on the hard disk MMC then appears If you select a...

Страница 98: ...iece in which you want to save the file and enter a file name program Press the Save softkey Please adhere to the following rule in order to prevent name con flicts use an _ underline as the third cha...

Страница 99: ...chine 26 7 02 93 5 1 7 Bereich Dienste Bedienbaum Struktur Services Archiv Disk PG V24 Interface Data selection Manage data Data in Data out Clip board Disk Programs data Log Copy Proper ties Delete U...

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Страница 101: ...anage data softkey Open the Workpieces folder Then open the STD_GEO folder You can load unload delete or copy existing files here and create new ones The Unload key only removes the standard geometrie...

Страница 102: ...elect Subprogram SPF here in the Type box 2 Press the OK softkey Then press the Load softkey on the Manage data screen This geometry program is now saved as a loaded SPF program and you can select and...

Страница 103: ...to the reference point Switch the master switch on the machine on Wait until the control unit has booted up approx 2 3 min The message Important Traverse to machine reference point then ap pears on t...

Страница 104: ...sing the OK softkey If a guard door is fitted close it Press the RESET key see section 3 2 Machine control unit on page 51 position 36 Press NC Start see section 3 2 Machine control unit on page 51 po...

Страница 105: ...OK Start change Cancel change Cancel OK Cancel OK Actual New Cancel OK Tool Management Grinding wheels Dresser New Copy Delete Selection OK Cancel OK Start change Cancel change Cancel OK OK Structure...

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Страница 107: ...y The main tool management screen is then displayed You can select either grinding wheel or dresser management here 5 3 3 Grinding wheel management You can manage up to 100 different grinding wheels i...

Страница 108: ...n is displayed when you press the Selection OK softkey in the grinding wheel management mask The data of the selected grinding wheel and the active grinding wheel is dis played here You can modify thi...

Страница 109: ...lected in the grinding wheel management mask is not necessarily the same as the wheel that is active in the pro gram You can make the selected grinding wheel the active grin ding wheel by pressing the...

Страница 110: ...ways proceed in the order described above After you have changed the grinding wheel the SUG confirmation screen should be displayed If it is not please press the Confirm SUG softkey You can only chang...

Страница 111: ...ain 5 3 4 Dresser management You can manage up to 30 different dressers in the dresser management mask Select dresser management in the tool management menu The correction values you enter in the dres...

Страница 112: ...oftkey if you want to create a new dresser record You can copy or delete records with the Copy and Delete softkeys The Parameter dresser screen is displayed when you press the Selection OK softkey You...

Страница 113: ...you enter here must never be higher than the diamond values entered in the Grips program for calculating the swi vel angle If you ignore this warning a collision will occur It is best to use the same...

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Страница 115: ...eset state i e no pro grams must be executing The function tree structure for setting actual values is shown in chapters 5 1 1 and 5 1 2 for all operating variants The full actual value setting functi...

Страница 116: ...while the numeric field inside it containing the dresser has a blue background Select the dressing tool you want to set Confirm your choice of dressing tool by pressing the Select diamond sta tion so...

Страница 117: ...s you must probe it with the front edge of the grinding wheel Now press the Set Z Axis softkey Now select Diamond 2 Confirm your choice of dressing tool by pressing the Select diamond sta tion softkey...

Страница 118: ...oing so trip the probing signal the colour of the box in the Status probing control field will change from green to red Now set the actual values for the axis in which you have just probed You can dea...

Страница 119: ...e key see section 3 1 Control unit on page 47 po sition 12 Press the Services softkey Press the Manage data softkey The Subprograms directory contains two programs called AT_Y SPF and AT_Z SPF AT_Y SP...

Страница 120: ...the grinding wheel and the dressing diamond The dressing di amond is positioned to the grinding wheel before the actual values are set This is a basic prerequisite of all automatic program cycles Acti...

Страница 121: ...V axis You can deactivate the Status probing control field again by pressing the AT OFF softkey 5 4 3 Setting actual values for the PA 31K dressing head optional The Actual values dressing head PA 31...

Страница 122: ...ound while the numeric field inside it for selecting the dressing tool has a blue background Select the required dressing tool PA 31K D7 D8 D9 or D10 Station1 Confirm your chosen dressing tool by pres...

Страница 123: ...the same as the machining area you selected on the main Grinding pro gram screen This input selects the actual value system for grinding Select either the front or the back wheel edge using one of th...

Страница 124: ...there is a probing travel of 0 079 inch You must receive the probing signal during these 0 079 inch or an error message will be output You can carry out the probing operation manually using the electr...

Страница 125: ...you have just probed Proceed to the next axis To change the default values for probing with the machine before setting ac tual values Press the Change module key see section 3 1 Control unit on page...

Страница 126: ...a value is entered the grinding head positions upwards by this amount value in m as soon as a probing signal is received RS 133 2 Maximum probing travel Important The sign determines the direc tion i...

Страница 127: ...rregular spacing If you change the geometry or technology data during a program cycle you can cause it to take effect immediately in the active program by pressing the Write act data softkey 5 5 1 Gri...

Страница 128: ...in the grinding program select Automati cally with probing cont Enter the required Prob feed rate in inch min and if necessary a suitable Probing correction value in 0 00001 inch Then press the Write...

Страница 129: ...regular spacing Uniform spacing Plunge grinding Dressing program Value to clipboard Value from clipboard Write act data Main screen Selection Face grinding Stat Plunge grinding Programm functions Writ...

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Страница 131: ...table cams The infeed motion is control led via the Y axis vertical axis of the grinding head It is effected at the cams in the Z axis Activating surface grinding Set the key switch to the automatic p...

Страница 132: ...gy r surface softkey If you activate the check box for Change reference edge the reference edge of the grinding wheel changes automatically between the front and back reversing positions during recipr...

Страница 133: ...Now press the Write act data softkey Meaning of the Dr after N input field Input 0 Dressing in the roughing area according to the roughing depth Dressing at the roughing finishing transition accordin...

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Страница 135: ...acing Irregular spacing Irregular spacing Uniform spacing Dressing program Value to clipboard Value from clipboard Write act data Main screen Selection Program Jung back to Program Jung Chapter 5 5 Ch...

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Страница 137: ...then ground in the workpiece by means of a relatively slow ta ble motion in the X axis longitudinal axis An optimum coolant supply is essenti al This method permits a relatively large quantity of mate...

Страница 138: ...tion softkey Now press the Write act data softkey Now select the required grinding technology namely reciprocating plunge grinding or creep feed grinding optional 5 5 5 1 Reciprocating plunge grinding...

Страница 139: ...Input 0 Dressing in the roughing area according to the roughing depth Dressing at the roughing finishing transition according to the Y S allowance Input 1 Dressing after every groove Input 2 Dressing...

Страница 140: ...proportionally up to the preselected maximum limit The roughing feed is in other words controlled as a function of the preselected power limit of the grinding spindle motor Description of the most im...

Страница 141: ...Press the Change module key 12 on the control unit Press the Machine Jung softkey Press the AC correction softkey You can change the nominal value for the current consumption in increments by pressing...

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Страница 143: ...ce grinding Technology r face Dressing program Value to clipboard Value from clipboard Write act data Main screen Selection Stat Plunge grinding Programm functions Write act data Dressing program Act...

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Страница 145: ...ol unit on page 51 position 33 Press the change module key see section 3 1 Control unit on page 47 position 12 Press the Program Jung softkey Press the Grinding program softkey Press the Face grinding...

Страница 146: ...nology data Press the Selection softkey Now press the Write act data softkey Meaning of the Dr after N input field Input 0 Dressing in the roughing area according to the roughing depth Dressing at the...

Страница 147: ...ding Technology plunge Uniform spacing Irregular spacing Uniform spacing Irregular spacing Dressing program Value to clipboard Value from clipboard Write act data Main screen Selection Programm functi...

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Страница 149: ...al values for X and X Activating stationary plunge grinding Set the key switch to the automatic position see section 3 2 Machine control unit on page 51 position 33 Press the change module key see sec...

Страница 150: ...he Plunge N unif spacing or Plun ge N irregular spacing screen You can also teach the current value for a selected axis if the Teach current va lue softkey is active black lettering Press the Selectio...

Страница 151: ...ent values for X and X in the geometry data a cor responding oscillating reciprocating motion will be effected in the X axis In this case you are not allowed to enter values for Fy finishing and Fy ro...

Страница 152: ...ite act data softkey Meaning of the Dr after N input field Input 0 Dressing in the roughing area according to the roughing depth Dressing at the roughing finishing transition according to the Y S allo...

Страница 153: ...ding Face grinding Stat Plunge grinding Technology r path Z Y Dressing program Value to clipboard Value from clipboard Write act data Main screen Selection Programm functions Write act data Dressing p...

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Страница 155: ...ition 33 Press the change module key see section 3 1 Control unit on page 47 position 12 Press the Program Jung softkey Press the Grinding program softkey Press the Recip path Z Y softkey The Z Y path...

Страница 156: ...d in the Y axis either to the relative relief value or to the workpiece change position depending on the settings in the Grinding program functions menu It is always positioned via the maximum workpie...

Страница 157: ...Fb finishing Path infeed during the finishing cycle outside the workpiece in the region of the reversing position Tx Tx Precision stop at the X or X reciprocating position 2 OFF Value Dwell time in se...

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Страница 159: ...grinding Stat Plunge grinding Technology r path X Y Dressing program Value to clipboard Value from clipboard Write act data Main screen Selection Programm functions Write act data Dressing program Ac...

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Страница 161: ...nit on page 51 position 33 Press the change module key see section 3 1 Control unit on page 47 position 12 Press the Program Jung softkey Press the Grinding program softkey Press the Recip path X Y so...

Страница 162: ...our direc tory or unload a loaded file Press the Selection softkey Then press the Write act data softkey Press the Technology r path X Y softkey Enter the required technology data Description of the m...

Страница 163: ...ammed feed rate Both The path is machined in both directions starting in down cut mode CD dressing selected If CD dressing is activated the dressed value is compensated outside the path before the nex...

Страница 164: ...Selection softkey Then press the Write act data softkey 5 5 14 Special programs optional Activating special programs Press the Special programs softkey in the Machine Jung module Press the softkey for...

Страница 165: ...g wheel several parallel recesses are plunge ground in order to cut as much material as possible within a short period Second program step finish grinding The machined surface is then reground in a re...

Страница 166: ...other things The true overlap value may be slightly higher than the value pro grammed here The control unit calculates an equivalent overlap value on the basis of the surface to be ground and the num...

Страница 167: ...logy data here Dr Tech No This input technology appears for both plunge grinding and reci procating surface grinding You can thus assign a suitable dres sing technology to each of these program steps...

Страница 168: ...echnologies in just one program Advantages of the program You can write a program with up to four different areas This is easier and quicker than writing a batch program You can also optimize the chro...

Страница 169: ...nge grinding Press the Special programs softkey in the Machine Jung module Mark the check box for Activate multiple plunge grinding If your machine has two or more special programs you will now see a...

Страница 170: ...xis if the Teach current va lue softkey is active black lettering After you have entered all the data press the Accept values softkey This option allows you to machine areas with different heights At...

Страница 171: ...from clipboard Tool and geometry Write act data Main screen Write act data Selection Geometry circumfer Geometry freefrm 01 Grinding program Value to clipboard Value from clipboard Write act data Mai...

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Страница 173: ...key see section 3 1 Control unit on page 47 position 12 Press the Program Jung softkey Press the Dressing program softkey Press the Program functions softkey Position the grinding wheel over the work...

Страница 174: ...ta softkey 5 6 4 Setting up PA 31K optional You can display the setting up mask for the PA 31K by pressing the Settings change positions key on the extended Machine Jung screen see section 5 1 4 Machi...

Страница 175: ...in the U axis is relative to the workpiece depending on the diameter of the grinding wheel while in the W and E axes it is an absolute value based on the reference point Press the Change Dia number s...

Страница 176: ...ntrol unit on page 51 position 33 Press the change module key see section 3 1 Control unit on page 47 position 12 Press the Program Jung softkey Press the Dressing program softkey You can create and s...

Страница 177: ...peed relation dressing roll grinding wheel Feed rate Dressing speed in inch min Press the Selection softkey Now press the Write act data Selecting the dressing tools and the dressing technology Press...

Страница 178: ...during plunge grinding reciprocating plunge grinding creep feed grinding or continuous path grinding In CD mode the wheel is dressed without interrupting the grinding process The CD option is there f...

Страница 179: ...D mode Select a dressing technology on the Dressing Technology screen Enter your technology data in the CD line 5 6 6 Selecting a geometry for face dressing Select the required face dressing option on...

Страница 180: ...rupted at the programmed point The dressing sleeve effects the programmed dressing infeed motion The message Operate MA65 manually press Cancel key appears on the display Operate the dressing lever on...

Страница 181: ...ing the Diaform DG 5 1 grinding wheel profile dresser Set the key switch to the automatic position see section 3 2 Machine control unit on page 51 position 33 Press the change module key see section 3...

Страница 182: ...ge 51 position 35 By pressing the Start dressing program see section 3 2 Machine con trol unit on page 51 position 35 at any time during a grinding program If a grinding program is already active it i...

Страница 183: ...SPF You must then copy this contour paste it into the Workpieces STD_GEO folder and load it 5 7 1 Creating a contour saving it and transferring it to the NC by means of a postprocessor run 1 Grips 2 F...

Страница 184: ...er to dress a loaded contour program you must enter it on the Tool and geometry screen see section 5 6 5 Dressing technology input on page 170 The contour program which is entered there can then be st...

Страница 185: ...dressing in the Setups menu enter your dressing data and press OK Select V24 in the Setups menu Then select To NC check the setups you have entered and press OK Setups Baud rate 9600 Data bits 7 Stop...

Страница 186: ...ed Press the Yes softkey The message Job is ready appears at the bottom of the display Press the Log softkey Press the Delete log softkey Press the Manage data softkey Mark the transferred contour e g...

Страница 187: ...e 95 Press the Manage data softkey Mark a contour e g TEST SPF in the Workpieces STD_GEO folder and then press the Delete softkey Press the Yes softkey Press the Delete log softkey If you do not have...

Страница 188: ......

Страница 189: ...e contours you create to be accepted by the machine control unit Open the Settings menu in GRIPS 32 and select Directories If your GRIPS 32 directories are not already defined automatically as shown a...

Страница 190: ......

Страница 191: ...gram under any name To prevent name conflicts please use an _ underline as the third character of all batch program names Load all the programs you want to combine in your batch program in the NCU To...

Страница 192: ...am and press the Value to clipboard softkey Then select the position 1 5 in the Machining cy cles at which you want to insert the program and press the Value from clipboard softkey The program is inse...

Страница 193: ...e program in the Batch folder More steps for both programs Select Batch mode in the Machine Jung module Activate batch mode Enter 1 as the Start no and 2 as the End no Select your program 1 from the l...

Страница 194: ...e selected program is opened Press the Previous key see section 3 1 Control unit on page 47 position 2 The main Program Jung screen is opened Please also refer chapter file manager see section 5 1 6 2...

Страница 195: ...me after the end of the program before switching off Select the Machine Jung screen see section 3 1 Control unit on page 47 position 12 an Press the Warm up follow up softkey Select the warm up progra...

Страница 196: ...am Press NC Reset see section 3 2 Machine control unit on page 51 position 36 This terminates the warm up program and you can then activate any other programs or functions Activating the warm up progr...

Страница 197: ...grinding wheels are being dressed The reason for this is to prevent wheel particles from flying off and coolant from spattering and cau sing injuries If an extraction device is installed it must be ac...

Страница 198: ......

Страница 199: ...depending on the application It is usually mounted on the left hand side of the magnet You should adjust its height either to your particular ma gnet or if necessary to the workpiece you want to grin...

Страница 200: ......

Страница 201: ...gle of 45 You can use these diamonds to dress the outer contours of the grinding wheel You must remove the no 3 diamonds of the roughing and finishing station including the diamond blocks beforehand T...

Страница 202: ...0 25 mm 54 25 mm The best way to set this value accurately is to use an optical setting device If you cannot set it exactly you must reset the actual values again every time you change the diamond Mou...

Страница 203: ...maintained at a constant value also automatically as the grinding wheel radius decreases If you traverse the dressing sleeve V axis manually key on the remote con trol panel there will be no compensat...

Страница 204: ...nit on page 51 Position 37 Starting a dressing program during a grinding program Press the Start automatic program key see section 3 2 Machine control unit on page 51 position 37 The configured grindi...

Страница 205: ...ntograph ratio 10 1 Maximum profile width 32 mm Maximum profile depth 13 mm Please study the manufacturer s original operating manual enclosed with the Diaform profiling tool carefully before starting...

Страница 206: ...sing technology input on page 170 This is necessary to ensure that the dressed value is calculated and compensated in the Y axis The procedure for dressing with the Diaform DG 5 1 is described in chap...

Страница 207: ...r s original operating manual enclosed with the Mafra profiling system carefully before starting up the machine If you dress using the Optidress E you must open the right hand side of the machine cove...

Страница 208: ......

Страница 209: ...axis Maximum dressing stroke approx 65 mm The dresser axes can also be positioned using the mobile remote control panel Exceptions Before you start a dressing program the dressing diamond must be posi...

Страница 210: ......

Страница 211: ...hnical data Working envelope Profile width 50 mm Profile depth inside outside 15 20 mm Contour precision 0 0025 mm Traverse paths W axis 55 mm U axis 60 mm E axis 60 Max dressing speed 2000 mm Max dia...

Страница 212: ...ndicates a deviation you must correct it by means of the single diamond holder If it is not possible to adjust the single diamond holder so that it is exactly concentric the calibrated ball insert is...

Страница 213: ...adjustment by inserting the dividing head into the turret head of the PA 31K again and swivelling it 2 x 90 as described above 6 8 5 Adjusting the diamond reference dimension Swivel the dividing head...

Страница 214: ...ing edge must always be perpendicular Fasten the diamond with the two screws provided 6 8 7 Adjusting and mounting the single diamond holders with the dia monds Mount the dividing head with diamond no...

Страница 215: ...p the holder When the single diamond holder is aligned exactly in position tighten the clam ping screws again carefully Now re check the diamond Adjust the other three diamonds in the same way Adjust...

Страница 216: ...ssage will appear on the display 5115 Important Dia mond holder clamped After reading off the diamond number mount the diamond holder at the centre point of the swivel axis of the PA 31K arm and press...

Страница 217: ...J630D 6 Dressers 26 7 02 211 6 8 10 Changing the Erowa plate If you change the Erowa plate you must also readjust the diamonds in the preset ting device...

Страница 218: ......

Страница 219: ...ke sure that magnets with 210 V DC voltage are always connected to a 210 V DC supply Magnets with 360 V DC voltage are only allo wed to be connected to a 360 V DC supply If you ignore this war ning it...

Страница 220: ...y new magnetic chucks supplied by K Jung GmbH They have already been ground in the factory so that they are slightly concave They must simply be cleaned and possibly honed with a fine oil stone Older...

Страница 221: ...J630D 7 Accessories 26 7 02 215 Mount the magnetic chuck on the grinding table with the base facing down and regrind the active magnetic pole face...

Страница 222: ......

Страница 223: ...ungi bacteria toxicants and or other impurities may cause permanent damage to human health Your machine and workpieces may also suffer considerable damage if poor quality or contaminated coolant is us...

Страница 224: ...ant sup ply see section 3 2 Machine control unit on page 51 position 13 The necessary pumps and solenoid valves are started or opened automatically during a program cycle 7 2 2 Functional description...

Страница 225: ...nections 2 connections with 3 4 couplings 1 connection with 3 8 coupling Transparent coolant additives are only allowed to be mixed with ordinary tap water Do not use decalcified water or water which...

Страница 226: ......

Страница 227: ...e water not the other way round Avoid using coolants which contain the following Chloro organic substances Nitrite Secondary amines Free formaldehyde Requirements for the water used to prepare emulsio...

Страница 228: ...n Interval Measurement Limit value Result Daily Concentration See manufacturer s specifications Concentration too low risk of corrosion Concentration too high machine becomes mis ted and sticky Weekly...

Страница 229: ...upply all the materials necessary to enable staff to comply with the plan 7 3 2 Skin protection plan Apply special skin protection cream to your hands and forearms before starting work Hautschutz in E...

Страница 230: ...Change all clothing that is wet with coolant immediately and have it cleaned If necessary wear a form of splash protection or a rubberized apron Do not touch your mouth eyes or nose with your hands af...

Страница 231: ...drawn into the coarse filter chamber via the suction flange It is then filtered in three separate stages The liquid which is separated out collects in the drip pan and is then pumped back to the coola...

Страница 232: ...page 51 position 17 Starting and stopping the extractor automatically during a program cycle The extractor is switched ON and OFF automatically during a program cycle Never open the unit when it is sw...

Страница 233: ...ioning after prolonged downtimes and after the cooling circuit has been opened and subse quently re closed If the system operates with a frequency of 50 Hz you must add 0 5 anti corrosive agent If the...

Страница 234: ...position Allow a minimum clearan ce of 12 inch between the suction screen on the end and all other objects or walls Connect the discharge line for the cooling circuit Fill the coolant tank up to the u...

Страница 235: ...valve on the inlet line of the pump lever 1 horizontal Immerse the return hose in the tank Carry out a trial run until the coolant emerges without any bubbles Re fill the pump if necessary Fasten the...

Страница 236: ......

Страница 237: ...the grinding wheel flange on the grinding spindle Unscrew the locking bolt as far as the limit stop clockwise direction Fit the spindle nut anti clockwise direction Apply counter pressure with the loc...

Страница 238: ...langed grinding wheel at the outside diameter and the flanks at ap proximately half speed until it runs absolutely true If you have a grinding machine with a dynamic balancer you can now fine balance...

Страница 239: ...se the heaviest point of the grinding wheel was at the top If the balancing stand inclines towards the right clockwise the heaviest point of the grinding wheel was at the bottom Mark the heaviest poin...

Страница 240: ...e weights symmetrically according to the inclination of the balancing stand Unlock the weighing frame Watch the inclination of the balancing stand Repeat this procedure until the stand is properly bal...

Страница 241: ...wheel flange carefully onto the spindle The long lug must be inserted in the deep groove Position the ejectors on the screwed clamping mechanism To do so you must unscrew the clamping bolt hexagon soc...

Страница 242: ...se as far as the limit stop Now hold the grinding wheel firmly and unclamp the locating flange from the spindle by jerking it anti clockwise Unscrew the clamping bolt 1 5 turns clockwise The ejectors...

Страница 243: ...control unit of the balancer Keep the keys pressed down until your grinding wheel is within the prese lected tolerance range again Flange the grinding wheels in accordance with the instructions set o...

Страница 244: ......

Страница 245: ...ways switch off the main switch on the machine before disconnec ting the plug of the dividing head Please study and heed the original operating manual provided by the manufacturer This manual contains...

Страница 246: ......

Страница 247: ...cordingly Make sure that your workpieces are properly clamped and secured When you change the speed range no programs are allowed to be active and the grinding spindle drive must be switched off To ch...

Страница 248: ......

Страница 249: ...ct a valid dressing technology in Dressing Program What to do Either select a valid dressing technology or deselect dressing mode 65002 No grinding technology programmed Situation After Machining Grin...

Страница 250: ...ta are no longer vailid as a result What to do Check the tool data for the active wheel and re enter it if necessary run the Actual Values Grinding function again 65006 Machining stopped reset Actual...

Страница 251: ...tputs the message What to do Change the wheel and update the wheel data in the tool management mask You can cancel the internal lock again with Activate Data 65010 Change diamond limit not reached Sit...

Страница 252: ...ng position can only be found with the reference diamond What to do Either mount the reference diamond or enter the diamond number in the tool management mask 65014 Cannot dress grinding wheel Situati...

Страница 253: ...the probing control data is missing What to do Enter the data 65018 No probing control signal Situation Probing while setting actual values Probing during plunge grinding Conse quences Machining Actu...

Страница 254: ...th grinding in accordance with the postprocessor specification 65039 Invalid dressing geometry no in tool management mask Situation Machining Dressing Conse quences The machining operation is cancelle...

Страница 255: ...infeed or feed rates What to do Check the entry in the tool management mask for the dressers and change it if necessary 65052 G54 G55 not selected Situation Actual Values Grinding Conse quences The ma...

Страница 256: ...eck the angle you entered in Face Geometry and change it if neces sary 65060 Angle entered for face geometry negative or zero Situation Machining Face Dressing Conse quences The machining operation is...

Страница 257: ...65063 Reciprocating X axis active Situation When actual values are set in the X axis Conse quences The X axis is not set Meaning The X axis can only be set while it is stationary What to do Traverse...

Страница 258: ......

Страница 259: ...tuation Wheel management Response Press Reset to cancel Press NC START to delete the wheel data 67007 Change wheel residual sum Y SE419 Situation Machining Dressing This advance warning tells you that...

Страница 260: ...Diamond Response Dressing Start 67020 Important E axis traversing to 60 deg Situation Adjust Diamond Response Dressing Start 67021 Important E axis traversing to 60 deg Situation Adjust Diamond Respo...

Страница 261: ...w active Situation 2nd system query cf 5123 the new radius takes effect as soon as you confirm it Response Grinding Start Reset 67025 Machining of 1st side complete please turn part over Situation Whe...

Страница 262: ......

Страница 263: ...or circuit breakers Switch the master switch on 510101 Fault in fuse motor circuit breaker Situation Any Conse quences A feed lock is active in all the NC axes and a halt dwell is active for the NC bl...

Страница 264: ...s been received from the spindle drive What to do Switch the machine OFF an then ON again Check the module connections Replace the module if defective 510116 Activate magnetic chuck Situation Automati...

Страница 265: ...in the lubricant piping repair Air in the lubricant piping bleed 510120 Oil pressure too low to lubricate Z axis Situation During lubrication Conse quences A feed lock is active in all NC axes and a...

Страница 266: ...Error and status messages 8 3 2 NC start locked 510300 510315 510300 Oil level too low Situation Any Conse quences The NC program cannot be started Meaning The oil level in the tank is too low What to...

Страница 267: ...witch on the machine and traverse to the reference point 600101 Maximum temperature exceeded in X axis Situation Any Conse quences It is no longer possible to traverse in the X axis Meaning Overtemper...

Страница 268: ...clear in this axis see Operating Manual Check the hardware limit switch Check the software limit switch Switch on the machine and traverse to the reference point 600208 Alter setting of key switch Sit...

Страница 269: ...ion When traversing clear of the hardware limit position Conse quences It is no longer possible to traverse in the Z axis Meaning The key operated switch 6 S2 in the control cubicle is set to ON but t...

Страница 270: ...es 26 7 02 264 600402 Spindle module error FC18 Situation After spindle ON or OFF Conse quences An error is indicated Meaning An error occurred when the spindle was activated or deactivated manu ally...

Страница 271: ...es An error is indicated Meaning Data is being written to the NC What to do NC reset Switch the machine OFF and then ON again 700003 Data read error FB2 Situation After a data transfer is initiated Co...

Страница 272: ...eady signal has been received from the stepping motor dri ver What to do Replace the board if defective 700032 Guard door closed Situation When the NC Program is started Conse quences The NC program c...

Страница 273: ...have traversed clear in the Y axis and started an NC pro gram you must decide whether or not you want to continue machining at the breakpoint If so start the NC program again If not press the Reset ke...

Страница 274: ...onfirm the wheel diameter after you entered it What to do Confirm the wheel diameter 700042 Operate W axis manually press Cancel key Situation After an automatic infeed motion in the V axis with the M...

Страница 275: ...he axes What to do Switch on the air pressure 700047 Used oil level machine bed full Situation Always Conse quences Display only Meaning What to do Drain used oil from the machine bed 700049 PA130T dr...

Страница 276: ......

Страница 277: ...at to do Traverse clear of the software limit switch with the plus minus key 10720 Channel axis at software limit switch Situation After a program is started Conse quences The program stops Meaning Yo...

Страница 278: ......

Страница 279: ...lectricians A knowledge of the general safety regulations and rules of conduct is also essential these are not referred to specifically in the follo wing If it is necessary to dismantle or deactivate...

Страница 280: ...to points 1 and 2 Check lubricating point 12 visual inspection and if necessary top up with oil Check the maintenance unit for optional equip ment visual inspection and if necessary top up with oil A...

Страница 281: ...book and record the results of all tests in it every 12 months Replace the coolant hoses Perform a functional test for all safety devices Jung Customer Service If any defects faults or damage are det...

Страница 282: ...sticky weekly pH value 8 5 9 4 Value too low risk of corrosion and microbial contamination Value too high skin irritation Nitrate content Less than 50 mg l Increased risk of cancer Nitrite content Les...

Страница 283: ...machine bed Open the clamping bolt of the valve you want to adjust with a hollow hexagon wrench Turn the table reversal valve anti clockwise to make the reversal path shor ter and harder Turn it clock...

Страница 284: ...ghten the clamping bolt again after adjusting the valve Be careful not to turn the valve too far clockwise because this could make the approach path so long and soft that the table no longer tra vels...

Страница 285: ...e machine which results from failure to comply with this requirement Study and heed the general rules and requirements for working with oil Avoid direct contact between your skin and the oil by wearin...

Страница 286: ...J630D 280 26 7 02 9 Maintenance servicing disposal 9 3 5 Lubrication instruction plate...

Страница 287: ...ubrication system The oil level of the automatic central lubrication system is monitored by means of a float switch If oil needs to be topped up either the warning lamp on the machine control unit lig...

Страница 288: ...ull enclosure for this purpose You should in any case drain off the used oil items 8 and 9 in the lubrication plan at the latest once every month or after 160 operating hours 9 3 8 Maintenance unit fo...

Страница 289: ...A 31K optional Apply 2 to 4 strokes of lubricant to points 1 and 2 after 500 hours operation or after 3 months in single shift duty Use the following grease Kl ber ISO Flex NBU 15 Kl ber A grease gun...

Страница 290: ......

Страница 291: ...J630D 9 Maintenance servicing disposal 26 7 02 285 9 4 Hydraulic plan...

Страница 292: ...Throttlevalve 9N 600 B 11 Parker Hanifin 14 1 4 2 wayvalveNG6 DG4V 3 2A M U H7 60 0810090469 Vickers Bosch 13 1 4 2 wayvalveNG6 0810090469 Bosch 12 1 Conenon returnvalve RHD10L1bar Ermeto 11 1 Pressur...

Страница 293: ...pe 1 Remove the cover of the hydraulic fluid cooler 2 3 screws Additional steps which must always be carried out Remove the side cover 3 6 screws The hydraulic fluid cooler must not under any circumst...

Страница 294: ...il the window 6 indicates half full approx 45 l Close the hydraulic fluid tank again and re assemble the dismantled units in re verse order The hydraulic oil can be extracted again through the same op...

Страница 295: ...J630D 9 Maintenance servicing disposal 26 7 02 289 9 5 Pneumatic plan...

Страница 296: ......

Страница 297: ...ed an impact load If the runout of the grinding spindle is greater than 0 003 mm you must release the tension Screw two lock nuts onto the spindle left hand thread Loosen the round nut 1 left hand thr...

Страница 298: ...oved beforehand Removing the grinding spindle Remove the bracket from the coolant pipe Remove the cover of the grinding wheel Remove the wedge for the grinding spindle Loosen the locking pins 1 Carefu...

Страница 299: ...J630D 9 Maintenance servicing disposal 26 7 02 293 Install the spindle in reverse order Do not tighten the locking pins too far...

Страница 300: ......

Страница 301: ...the door of the control cubicle and set the key operated switch 6 S2 to the horizontal position i e turn it to the left roughly in the middle Press the illuminated NC reset key Traverse the axis clea...

Страница 302: ......

Страница 303: ...age by pressing NC reset In this case however the first error message is displayed again The servo motors can no longer be activated with the machine in this condition Correcting the error Select sett...

Страница 304: ......

Страница 305: ...ffered data has been lost and you will have to restart the control unit after you have replaced the battery 9 9 1 Replacing the battery for the MMC 103 display The back up battery for the MMC 103 disp...

Страница 306: ...placing the battery for the NCU Battery backed SRAMs and clock chips are installed on the NCU The back up voltage is monitored by the NCU Battery designation Jung order no Siemens order no Lithium bat...

Страница 307: ...press the catch 3 on the underside of the module upwards and grasp the module firmly Install the new module Switch on the control unit The battery alarm should have disappeared Siemens order number fo...

Страница 308: ...remove the battery Insert the new battery and plug the connector into the socket in exactly the same position as the connector of the old battery Install the battery fan module again Switch on the con...

Страница 309: ...of your District Authority 9 10 1 Disposal of the machine Draining Dispose of old coolants Drain off the oil collect it segregate it into types and dispose of it Remove and dispose of the coolants in...

Страница 310: ......

Страница 311: ...to us by fax or by post K Jung GmbH Enter your address here optional Abt Dokumentation Postfach 640 73006 G ppingen Germany Telefax 49 0 7161 612213 Please enter any errors points requiring clarifica...

Страница 312: ......

Страница 313: ...perating person nel are sufficiently familiar with the relevant safety regulations and instructions for operating the machine The checks should be repeated every six months The Safety and Coolants sec...

Страница 314: ......

Страница 315: ...Coolant supplier Product designation Concentration specified pH value specified Nitrite max 20 mg m3 nitrate max 50 mg m3 no of nuclei yeast fungus less than 104 no of nuclei bacteria less than 106 D...

Страница 316: ......

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