EMUGE Softsynchro 1/ PGR User manual

®
Operating instruction for the collet holders type
Softsynchro
®
1/ PGR
Softsynchro
®
3/ PGR
Date of edition: 01.04.2012
Stage of alteration: 1
Please keep this for future use!

Operating instruction for collet holder
type Softsynchro
®
/ PGR
®
powRgripis a registered trademark of REGO FIX AG.

Operating instruction for collet holder
Type Softsynchro
®
/ PGR
Edition: 01.04.2012 1
®
Contents:
1Application range and technical data ...................................................... 3
1.1 Application range, determined use......................................................................... 3
1.2 Specifications......................................................................................................... 4
1.3 Safety instructions.................................................................................................. 4
1.4 Dimensions and technical data .............................................................................. 5
2Putting the collet holders into operation................................................. 6
2.1 Unpacking.............................................................................................................. 6
2.2 First putting into operation...................................................................................... 6
2.3 Re-putting into operation........................................................................................ 6
2.4 Assembly of the coolant-lubricant pipe for collet holders with shank type HSK
(hollow taper shank DIN 69893A).......................................................................... 7
2.5 Collets.................................................................................................................... 8
2.5.1 Application ............................................................................................................. 8
2.6 Assembly instruction for the collets and tool........................................................... 8
2.6.1 Cleaning directions ................................................................................................ 9
2.6.2 Length adjustment ................................................................................................10
2.7 Remove tool and collet..........................................................................................10
3Maintenance ............................................................................................. 11
3.1 Maintenance schedule ..........................................................................................11
3.2 External cleaning ..................................................................................................11
4Storage when not in use ......................................................................... 11

Operating instruction for collet holder
type Softsynchro
®
/ PGR
2
Edition: 01.04.2012
®
Warnings, symbols
In these operating instruction the following symbols are used:
Marks special instructions, rules and prohibitions, which are important in order to
avoid any damage.
Please observe these instructions!
Marks application instructions and other useful information.
Sectional view: Collet holder Softsynchro
®
/PGR

Operating instruction for collet holder
Type Softsynchro
®
/ PGR
Edition: 01.04.2012 3
®
1 Application range and technical data
1.1 Application range, determined use
The collet holders type Softsynchro
®
/PGR are used on CNC machining centres with
synchronous control.
The integrated minimal length compensation on tension and compression compensates
arising minimal pitch differences between synchronous spindle and tool which would lead to
high thread flank friction forces. An eventual increase of the axial force during the thread
producing cycle is reduced to a minimum. The resulting advantages are:
- No miscutting of the threads
- Optimised tool life
The clamping system PGR is a mechanical tool clamping system with extremely high
clamping force and excellent concentricity. The system consists of the tool holder, the high-
precision collet and a compact clamping unit. The taper collet is pressed up to the plane
contact surface into the tool holder with a force up to 90 kN. The arising press fit creates a
radial force working on the tool shank via the slotted collet. The tool is clamped safe and
centrical.
Normally the collet holders are equipped with one of the following shanks:
Cylinder shank acc. to DIN 1835 B+E
Hollow taper shank acc. to DIN 69893-HSK-A
The cutting range of each type of tool is indicated in table 1, page 5.
The tool is locked via the collets type PGR-GB (for tools with shank tolerance h9 and
integrated square). The collets must be chosen depending on their type and the tool used,
for more information please refer to chapter 2.5.1, page 8.
The collet holders type Softsynchro
®
/PGR are suitable for coolant pressures up to 50 bar.
The non-determined use exempts the manufacturer from any liability.

Operating instruction for collet holder
type Softsynchro
®
/ PGR
4
Edition: 01.04.2012
®
1.2 Specifications
Further features of the collet holders type Softsynchro
®
/ PGR are:
- For collet holders with cylindrical shank:
The standardized cylinder shank acc. to DIN 1835 B+E allows a simple adaptation with
the required adaptation shank. For adaptation shanks please refer to the EMUGE main
catalogue.
- Quick clamping: tool change within 10 seconds
- Clamping true to the µ: high concentricity guarantees reliable and repeatable tool life
values and high surface quality
- Length adjustment of the tool through integrated adjusting screw in the collet
- Suitable for VHM and HSS tools
1.3 Safety instructions
For all works, i.e. putting into operation, production and maintenance, please observe the
details given in the operating instructions.
All relevant safety regulations as well as local instructions are to be observed when working
with the collet holders.
Below please find some basic rules:
- Please wear gloves during tool change to avoid injury.
- Basically change the tool yourself to avoid the sudden start of the spindle
caused by misuse.
- Hold the tool when loosening the tool clamping to avoid it falling down and
damaging the tool and the workpiece.
- Please keep the tool adaptation clean.
- There are maximum values for cutting speeds and feeds for every kind of
machining. Please observe such data.
- Please observe the maximum tool dimensions.
- Furthermore, the instructions of the tool manufacturers are valid!

Operating instruction for collet holder
Type Softsynchro
®
/ PGR
Edition: 01.04.2012 5
®
1.4 Dimensions and technical data
C
T
L
3
Ø
D
3
Ø
D
1
Ø
D
Adjusting screw
Collet
Picture 1: Technical data of the collet holder type Softsynchro
®
/PGR
Table 1: Technical data of the collet holder type Softsynchro
®
/PGR
Type Cutting
range
Clamping
range
∅D
1
[mm]
Collet size
∅D
[mm]
∅D
3
[mm]
L
3
[mm]
C
1
[mm]
T
2
[mm]
max.
Coolant
pressure
[bar]
Softsynchro
®
1/ PGR M4 - M12
(Nr. 8 –
7
/
16
)
4,5–10 PGR15GB
34 24 57 0,5 0,5 50
Softsynchro
®
3/ PGR
M8 - M20
(
5
/
16
– ¾) 8–16 PGR25GB
45 40 67 0,5 0,5 50
Further outer dimensions depend on the required shank.
The dimensions may be taken from the EMUGE main catalogue or may be given by your
EMUGE-representative.
1
Length compensation on compression
2
Length compensation on tension

Operating instruction for collet holder
type Softsynchro
®
/ PGR
6
Edition: 01.04.2012
®
2 Putting the collet holders into operation
2.1 Unpacking
- Take the collet holder from the packing
- Clean the collet holder with a duster to remove any conservation oil
Clean the collet holder as described in the cleaning directions, see chapter 2.6.1,
page 9.
⇒The collet holder is now ready for operation
Exception:
Type with hollow taper shank (HSK). Please refer to chapter 2.4, page 7, for how to put
this collet holder into operation.
2.2 First putting into operation
For collet holders with HSK-shank (hollow taper shank) the coolant-lubricant pipe
must be mounted prior to putting into operation, see chapter 2.4, page 7.
The collet holders are inserted into the machine manually or - if provided - by the tool
exchanger.
The exchange of the collet holder must not be executed while the machine
spindle rotates!
- Only use tool shanks and tightening bolts suitable for the specific machine.
- Make sure the tool is correctly clamped.
⇒Risk of accident by spinning of the tool!
- Please see also the indications in the operating instruction of your machine
tool!
2.3 Re-putting into operation
If the collet holder is reputed into operation as described in chapter 4, page 11, please go
through the following steps:
- Clean the collet holder with a duster to remove any conservation oil
Do not use any aggressive solvents.
Do not use fibrous materials i.e. steel wool.
- Clean the powRgrip

interface of the tap holder as described in the cleaning directions
- Insert the collet holder into the machine as described in chapter 2.2.

Operating instruction for collet holder
Type Softsynchro
®
/ PGR
Edition: 01.04.2012 7
®
2.4 Assembly of the coolant-lubricant pipe for collet holders with shank type HSK
(hollow taper shank DIN 69893A)
a) Components
b) Prepare coolant-lubricant pipe
1. Slide on the two O-rings.
2. Slide on thread nut.
c) Mount coolant-lubricant pipe in the shank
Required tool:
Assembly wrench, choose appropriate assembly wrench for the shank size
(For the assembly wrench please refer to the EMUGE main catalogue, category
accessories)
Groove
Pin
1. Put assembly wrench on the
coolant-lubricant pipe
Watch the position of the
pins against the grooves!
2. Screw coolant-lubricant pipe
in the shank
Coolant-lubricant
pipe
O-ring small
cross-section
O-ring big
cross-section
Thread nut
O-ring small cross-section
O-ring big cross-section

Operating instruction for collet holder
type Softsynchro
®
/ PGR
8
Edition: 01.04.2012
®
2.5 Collets
2.5.1 Application
The adaptation of the tool is executed via collets type PGR and/or PGR-GB. These
powRgrip

collets have a taper shank with plane contact surface and a central bore for the
tool shank. With collets type PGR the tool is centred and clamped via the clamping diameter,
the shank tolerance must be h6. With collets type PGR-GB the torque arising during the
thread producing operation is additionally transferred via the square, integrated in the collet;
tools with shank tolerance h9 may be used.
The powRgrip

collets have an integrated adjusting screw. With a pre-adjustment tool the
length of the tool system can be pre-adjusted.
Owing to the better torque transmission and the possibility to use tools with shank
tolerance h9, we would recommend the use of collets type PGR-GB.
The collet sizes for the according collet holders may be taken from table 1, page 5. The
clamping diameter is indicated by the tool used.
2.6 Assembly instruction for the collets and tool
Do not press in the collet without a tool!
Pressing in collets without a tool will destroy the collet!
Before clamping, clean and degrease collet and cutting tool as described in the
cleaning directions!
Dirt and grease reduce clamping force, accuracy and tool life.

Operating instruction for collet holder
Type Softsynchro
®
/ PGR
Edition: 01.04.2012 9
®
2.6.1 Cleaning directions
Clean the powRgrip

interface of the collet holder, i.e. with a
taper cleaner (see catalogue, chapter accessories) or with a
clean towel.
Degrease powRgrip

collet, dip in a clean, fat-dissolving and
oil-free solvent, i.e. alcohol, cleaning solvent.
Dry collet. Only use compressed air if it is clean and oil-free (no
maintenance unit done before).
Set collet into tool holder.
Degrease tool shank, by dipping into clean, fat-dissolving and
oil-free solvent, i.e. alcohol, cleaning solvent.
Insert tool into the powRgrip

collet.
When using a PGR-GB collet with integrated square, the tool
must be turned into position in order to be inserted into the
square of the collet.
Press in tool, using clamping unit as described in the operating instruction of the powRgrip

unit or pre-adjust the length as described in chapter 2.6.2, page 10.

Operating instruction for collet holder
type Softsynchro
®
/ PGR
10
Edition: 01.04.2012
®
2.6.2 Length adjustment
Tool
Collet
Pre-adjustment
tool
Collet holder
Adjusting wheel
1
0
0
m
m
1. Pick up collet holder
2. Set pre-adjustment tool in the collet holder
3. Set collet into pre-adjustment tool
4. Set tool into collet
5. Adjust tool length by turning the adjusting wheel
Observe min./max. clamping length for
tool shanks, as described in the operating
instruction of the clamping unit
Reduce overall length by 100 mm for the
pre-adjustment tool
After length adjustment press in tool using the clamping unit as described in the operating
instruction of the powRgrip

unit.
2.7 Remove tool and collet
Loosen tool using the clamping unit, as described in the operating instruction of the
powRgrip

unit.
As soon as the unclamping operation is completed, the tool and the collet can be removed
from the tool holder.

Operating instruction for collet holder
Type Softsynchro
®
/ PGR
Edition: 01.04.2012 11
®
3 Maintenance
3.1 Maintenance schedule
What? When? Who?
External cleaning Periodically, depending on the degree
of dirt
Operator
3.2 External cleaning
Before clamping please make sure the collet holder is oil-free in the area of the
powRgrip

interface, same for collet and tool shank. Eventually clean these
components as described in the cleaning directions, chapter 2.6.1, page 9.
4 Storage when not in use
If the collet holder is taken out of service, please go through the following steps:
- Clean the collet holder with a duster.
Important:
Do not use any aggressive solvent.
Do not use fibrous materials i.e. steel wool.
- Spray the collet holder with preservation oil to avoid rusting.
Important:
Before storage, all evidence of coolant and machining residues must be
removed!

Operating instruction for collet holder
type Softsynchro
®
/ PGR
12
Edition: 01.04.2012
®
Notes:

Operating instruction for collet holder
Type Softsynchro
®
/ PGR
Edition: 01.04.2012 13
®
Notes:

Operating instruction for collet holder
type Softsynchro
®
/ PGR
®
EMUGE-Werk Richard Glimpel GmbH & Co. KG ·
Fabrik für Präzisionswerkzeuge
Nürnberger Straße 96-100 · 91207 Lauf · GERMANY · Tel. [phone] / 186-0 · Fax [phone] / 14313
[email protected] · www.emuge-franken.com
ZB10040.GB