Gerima SMA 30-p 62 User manual

1 V01_157_01.01.2014.ENG
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SMA30‐P62
Starngwiththemachineidenficaonnumber
11‐157‐00013


GERIMASMA30‐P62
OperangManual

2 V01_157_01.01.2014.ENG
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Machine‐No.
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Machineidenficaonnumber
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DearCustomer,

Congratulaons,youhavepurchasedahigh‐
qualitybevelmillingmachinethatwillhelpyou
toachieveoutstandingresultsinyourhandbev‐
ellingapplicaons.
Toensurethatthemachineisusedsafelyand
effecvely,pleasereadthisoperangmanual
carefullyinordertobecomeproperlyacquaint‐
edwiththetool.Pleaseinstructyourco‐workers
andemployeessothattheyalsobecomeac‐
quaintedwiththemachine.Learningtousethe
machineproperlywillsaveyoumeandmoney,
willsaveyouremployeesmeandeffort,and
willimprovethequalityofyourproducts.
Yourmachinewassubjectedtothoroughinspec‐
onandtesngbeforebeingpackedand
shipped.
Shouldyouneedtocontactusforassistance,
pleasealwayshavethemachineidenficaon
numberavailable.

Themachineidenficaonnumberisprinted
onthemachine’srangplate.


Themachineidenficaonnumberisalsoen‐
gravedonthegearhousing.
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1.Operangissues
Ifyouhavequesonsregardingtheuseoropera‐
onofthemachine,orifyouneedoursupportor
adviceregardingspecializedapplicaons,ourteam
ofspecialistretailersandapplicaontechnicians
wouldbepleasedtooffertheirassistance.
2.Servicingandrepairissues
Ifyouneedtomakeaguaranteeclaim,ifthema‐
chineneedstoberepairedorifyouneedtoorder
spareparts,pleasecontactourspecialistretailers
forhelp.
3.Sales
Ourspecialistretailersarealsothepeopletocon‐
tactifyouwishtopurchaseaddionalGERIMA
machines,accessoriesorconsumableitems.
Tohelpusprovidequickandefficientassistance,
pleasealwayshaveyourmachineidenficaon
numbertohand.

Wehopeyouenjoyworkingwithyourprecision‐
madeGERIMAmachine.
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TheGERIMATeam

3 V01_157_01.01.2014.ENG
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Adjusngthebevelheight  4
Changingthemillinghead  4
Changingtheguidebearing  5
Replacingtheindexableinserts 5

Generalsafetyinformaon  6
Specificsafetyinstrucons  7

Funconalcomponents  8
Intendeduse    8
Technicaldata    9
Power‐onme    11
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Adjusngthebevelheight  12
Indexablecunginsertsformilling 
bevels13
Indexablecunginsertsforradius
milling16
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Workingwiththemachine   21
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Maintenanceplan   23
Servicing24
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Changingthemillingheadandthe
DL/DSguidebearings25
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Radiusmillingcuer   27
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Overviewofindexablecunginserts29
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Gearunit30
Pneumacmotor    32
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Guarantee39
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ECDeclaraonofConformity40
Contents
1.Quickreferenceguide
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2.Safetyinformaon   
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3.Descriponofmachine 
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4.Machineadjustments
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5.Machineoperaon
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6.Maintenance
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7.Replacingthemillingheadand
guidebearing
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8.GERIMAspareparts

9.Consumables
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10.Spareandwearingparts
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11.Guarantee
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12.ECDeclaraonofConformity 

4 V01_157_01.01.2014.ENG
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Adjustment
Seperateairconnecon
Workingdirecon:
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MovemachineONLYinthedireconofthe
Arrow!
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Adjusngbevelheight:
Thebevelheightissetbyadjusngtheheight
ofthemachine’sguideplate.Theheight
sengcanbereadfromthefixedmain
scaleandtheverniercollar.
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On/Off
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1.Releaseclampingscrew
2.Rotatetheguideplateunltherequired
bevelheighthasbeensetasshownbythe
fixedmainscaleincombinaonwith
theverniercollar.
3.Re‐ghtenlockingscrew.
1
3
2
1
2
3
1
Changingthemillinghead:
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1
2
3
5
6
74
Quickreferenceguide
1.Quickreferenceguide

5 V01_157_01.01.2014.ENG
  
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Seperateairconnecon
Adjustment
14
24-5 Nm
5
36
Quickreferenceguide
Changingtheindexableinserts:

6 V01_157_01.01.2014.ENG
  
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Safetyinformaon
2.Safetyinformaon
Generalsafetyinformaon:
Beforeusingthemachine,theoperangmanual
andsafetyinformaonmusthavebeenreadand
understoodintheirenrety.Theinstrucons
containedthereinmustbefollowed.

Theseoperanginstruconsarebasedonthe
relevantpartsoftheEuropeanMachinery
Direcve(98/37/EC)andtheCENTC255
regulaons“Hand‐held,non‐electricpowertools
–Safety”.

Theseinstruconscovertheoperaonandhan‐
dlingofthemachine,includingtools,accessories
andmachinemaintenance.
Failuretocomplywiththeseestablishedsafety
recommendaonscancauseserioushazards.
Themachineoperatormusthaveproperlyun‐
derstoodthefollowingsafetyadviceandmust
haveaccesstotheseinstruconsatallmes.
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Topreventimproperhandlingofthemachine
andtopreventaccidents,theoperatormust
complywiththesafetyprecauonssetoutbe‐
low.
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Installaon
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Complywiththespecificaonsregarding
compressedairquality,whicharecontainedin
theoperanginstruconssuppliedwiththe
machine.
Onlyusetherecommendedlubricants.

 Checkpneumactubingandairpressure.
Whenthemachineisrunning,theairpres‐
sureatthetoolinletshouldnotexceed
7bar(=700kPa=100psi),oralowermaxi‐
mumoperangairpressureifspecified.

 Avoidhazardsassociatedwithvibrang
pneumactubing.Checkthecondionof
thetubing,tubeconnectorsandtube
clampsregularly.

 Makesurethattheexhaustairventisposi‐
onedsothatdustorairdrawnfromthe
workpieceisnotdirectedtowardtheopera‐
tororanyotherperson.Asafetyscreen
should,ifpossible,beposionedbetween
theoperatorandtheworkpiece.
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
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Pneumacally‐drivenpowertoolsaregenerally
notinsulatedinawaythatwouldallowthemto
comeintocontactwithanelectricalpowersource.

 Ifanexplosionhazardexists,usesomeoth‐
ermachiningtechniquethatdoesnotgener‐
atesparksinordertoavoidpersonalinjury
ordamagetopropertyfromfire.
 Alwaysdisconnecttheairsupplytubefrom
themachinebeforeservicingorcarryingout
maintenanceonthemachine.
 Beforeeachuse,alwaysinspectthepneu‐
mactubingforsignsofwearordamage.



7 V01_157_01.01.2014.ENG
  

Safetyinformaon
Specificsafetyinstrucons:


Warning
Riskofinjurytohands!

 Donotplaceyourhandnearthemilling
head.
 Alwaysholdthemachinewithtwohands.




Cauon

Improperusecandamageequipmentand
property!

 Riskofmachinebeingdamagedorde‐
stroyed.
 Neverliorcarrythemachinebyitspow‐
ercable.
 Makesurethecableisdirectedbehind
andawayfromthemachine.Donotlay
thecableoversharpedges.
 Servicingandtesngmustonlybecarried
outbyappropriatelyqualifiedtechnicians.

 AlwaysusegenuineGERIMAspare
partsandaccessories.






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Riskofinjuryfromhotmetalchips
 Hotchipsareejectedfromthemachineat
highspeed.






Warning

Improperusecancauseseriousinjury!

 Makesureyoualwayshaveafirmfoong
whenworkingwiththemachine.
 Nevertouchthemillingheadwhenthema‐
chineisrunning.
 Neverusethemachineaboveheadheight.
 Themachineshouldonlybeusedforcon‐
venonalup‐cutmilling.




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

  Important

Themanufacturerreservestherighttomake
technicalchanges.



8 V01_157_01.01.2014.ENG
  


















6Spindlelock
7Millinghead
8guidebearing(DL)
9Heightclampingscrew
10 Paddleswitch(starterlever)
Intendeduse:
TheGERIMASMA30‐Pisahand‐held,pneuma‐
callydrivendeviceintended:
 formachiningworkpiecesmadeofsteel,
fine‐grainedsteel,aluminium,aluminium
alloys,brassandplascs;
 forcommercialuseinindustrialsengs
andintheskilledtrades;
 forpreparingK,V,XandY‐shapedwelding
grooves;
 forcreangvisibleedgesinplantandme‐
chanicalengineeringwork;
 foredgeroundingtopreparematerialsfor
painngorcoangorasimpactprotec‐
on.
1
2
3
4
5
7
10
9
8
6
Funconalcomponents
3.Descriponofmachine









1Airconnecon
2Air‐Motor
3Mainscale
4Guideplate
5 Grip

Toavoidinjuryanddamagetohealth,please
observethefollowing:

Themachinemayonlybeusedforworkand
materialsdescribedinthesecon‘Intended
use’.

Donotusethemachinetoworkon
materialscontainingasbestos!

9 V01_157_01.01.2014.ENG
  

SMA30‐P62

6bar


28l/s


1300W


8.5001/min


2,5kg




1‐10mm

1‐4mm


1,5mm


12‐20,0mm



30‐40mm



2‐4mm



Themanufacturerreservestherighttomake
technicalchanges.
Technicaldata
Technicaldata:
Airpressure


Requiredairflowrate


Ratedpowerconsumpon


Motorspeedwhenidling


Weight(approx.)

Bevelwidth(material‐dependent)

Aluminium

Steel


Minimumthicknessofworkpiece


Smallestcontourradius(bevel‐dependent)



Smallestborediameter(bevel‐dependent)


Edgeradius



Donotoverload!(seepage11)

10 V01_157_01.01.2014.ENG
  

Noiseemissions
Vibraons
Noiseemissionvaluesinaccordancewith
theDINEN60745‐1standard

Vibraons:

Note:
Themeasuredvalueslistedabovedependonthe
materialsandoperangproceduresusedandmay
thereforebeexceededunderotheroperang
condions.
Usingthemachinetocreatebevelswithawidth
greaterthanthatpermiedwillresultinadispro‐
poronallylargereduconinthemachine’son‐
meandtheservicelifeoftheindexablecung
inserts.Thevibraonandnoiseemissionvalues
willincreaseaccordingly.
Noiseemission
Emissionsoundpressurelevel(inidlemode,speed
Peakemissionsoundpressurelevelatworkplace
(duringmillingoperaons)
Soundpowerlevel
Totalvibraonvalue
Workprocess:
‐45°millinghead
‐2mmbevelwidth(C)in12mmsteelsheet(S355)
RadiusR2Radiusin12mmsteelsheetS355
Totalvibraonvalue
Workprocess:
‐45°millinghead‐
‐3mmbevelwidth(C)in12mmsteelsheet(S355)
RadiusR3Radiusin12mmsteelsheetS355






Thepower‐onperiodslistedonpage11have
takenthevibraonvaluesintoaccount.
Topreventoverloadingthemachineandtoavoid
operatorfagueitisveryimportanttoobserve
themaximumpower‐onperiodsespeciallywhen
machiningwidebevelsorhigh‐strengthmaterials.
ValueUncertainty
LpAindB(A)833
LpGpeak1013
LWAindB(A)943
Measuredvibraonemissionvalueah=
2,50m/s²
UncertaintyK=1.5m/s²
DeterminedasperEN60745:

Measuredvibraonemissionvalueah=
3,0m/s²
UncertaintyK=1.5m/s²
DeterminedasperEN60745:


11 V01_157_01.01.2014.ENG
  

On–Time


Thecompressedairthatpowersapneumac
drivealsoservestocoolthemotoraswell.Pneu‐
mactoolscanthereforebeoperatedforlonger
periodsthanelectricallypoweredtools.
However,ifthemachineissubjectedtoparcu‐
larlyextremeloads(e.g.whenmachiningwide
bevelsorveryhardortoughmaterials)and/orif
themachineisrunforverylongperiods,theair
coolingmaysllbeinsufficienttopreventover‐
heangofthemillingdriveunit.Iftheoperator
connuestousethemachine,themillingdrive
unitmayoverheatandbedamagedasaresult.



Donotoverloadthemachine!

Themachinecanbecomeoverloadedif,forex‐
ample,itconnuestobeusedeventhoughthe
bevelbeingcutistoolargeforthematerialbe‐
ingmilled,orifthecunginsertshavebecome
bluntandthereforeunabletopenetratethema‐
terial.
Thepower‐onmeisalwaysexpressedasa
percentageofonehour.
Example:
Ifthepower‐onmeisspecifiedas50%,thenyou
canusethemachinetomillbevelsforamaximum
of30minutesinanhourandmustthenleavethe
machinetocoolfor30minutes.Ifthemachineis
subjectedtoheavyloads,thepower‐onme
mightbe20%,whichmeansitcanbeusedfor
12minutesinanyhourandmustbeletocoolfor
48minutes.







Suchcondionscanleadtoexcessivemachinevi‐
braonsorevenmachinefailure.Topreventthis
sortofdamagewhenmillinglargebevelsand/or
hardmaterials,nevertrytomachinethebevelina
singlepass,alwaysusemulplepasses,anddo
notforgettochangethecunginsertsbefore
theybecomebluntorworn.
Materialstrength
Aluminium,copper,brassorplascs
Steelupto400N/mm²
Steelupto600N/mm²
Steelupto900N/mm²
Power‐onme
80%
60%
50%
40%
————————————————————————————————————

12 V01_157_01.01.2014.ENG
  



alengthofadjacentleg=bevelheight(a)
blengthofoppositeleg=bevelheight(b)
Cbevelwidth
αbevelangle
βoppositeangle
Avolumeofmaterialremoved
hbeveldepth
Sbase
tmaterialthickness

Thebevelheight(a)issetbyadjusngtheposion
oftheguideplate.Theheightsengcanberead
fromthefixedmainscale andthevernier
collar
Releaseclampingscrew
Rotatetheguide‐plateunitunltherequired
bevelheighthasbeensetasshownbythefixed
mainscaleincombinaonwiththevernier
scaleonthecollar.
Re‐ghtenclampingscrew

Oncethebevelheighthasbeenset,abevel
shouldbemilledonatestsampletocheck
whetherfurtherheightadjustmentsarerequired.
Thesemaybenecessarybecausetheprecisionof
thescaleisapproximately±1mm,dependingon
thetypeofmillingheadfied.
3
4
9
3
9
4
3
9
Adjusngthebevelheight
4.Machineadjustments



Thevaluesspecifiedaretypicalbutwithoutim‐
pliedguarantee.
Insomematerials,flame,plasmaandlaser
cungtechniquescanleadtohardeningofthe
edgesoftheworkpiecebeingmachined.Thiscan
resultinsignificantdeviaonsfromthespecified
referencevalues.
Materialandtensile
strength
Bevelheight(a)Bevelwidth
α=30°α=45°c
mmmmmm
Aluminium 1-8,7 1-7,1 1,2-10
Steelupto
400N/mm²
1-3,5 1-2,8 1,2-4,0
Steelupto
600N/mm²
1-2,6 1-2,1 1,2-3,0
Steelupto
900N/mm²
1-1,7 1-1,4 1,2-2,0


13 V01_157_01.01.2014.ENG
  

Indexablecunginsertsformillingbevels
Eight‐foldindexablecunginserts:

Theeight‐foldindexablecunginsertsarethe
actualtoolsthatperformthebevellingandde‐
burringoperaons.Theycanbeusedtomachine
plasc,steel,stainlesssteelsandnon‐ferrous
metalssuchascopperaluminiumandbrass.
Theyaresuitableforcungbevelswithangles
of30°or45°.






OuruniversalB02coangisausefulgeneral‐
purposecoangthatcancopewithalltheabove
materials.

Wealsoofferinsertswithspecialcoangsforma‐
chiningothermorespecializedmaterials.Please
contactusfordetails


Indexablecungin‐
Type
PlascM
Aluminium,copperor
brass
M
Steelupto400N/mm²M
Steelupto600N/mm²M
Steelupto900N/mm²M
 
Materialstrength
Typeofcoang

B 00

B 00
B 02
B 02
B 05


14 V01_157_01.01.2014.ENG
  
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CAUTION!
Itisextremelyimportanttoensurethatthelowercor‐
nerofthecunginsertisalwayscoveredbytheguide
bearingDLorDS.


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Thecunginsertsformillingedgesmustbefas‐
tenedtothemounngseatonthemillingheadby
meansoftheoriginallockingscrews(max.ghten‐
ingtorque:4.0–5.0Nm).
Aseachinserthasfourcungedges,itcaneach
beindexedatotaloffourmesbeforerequiring
replacement.

Astheinsertsareeachapproximately11mmlong,
eachinsertcanbeindexedfourmeswhile
fastenedviathelowerlocangholeandafurther
fourmeswhilefastenedviathemiddlelo‐
cangholeprovidedthatthewidthofthebevel
beingcutislessthanorequalto5.0mm.There‐
fore,ifthewidthofthebevelsbeingmilledisnot
greaterthan5mm,eachinsertcanbeusedatotal
ofeightmesbeforerequiringreplacement.

Tofacilitatethemillingofghtcontoursandsmall
bores,asmallguidebearing(DS)isalsoavailable
asanaccessorytoeachmillinghead.WhentheDS
guidebearingisfied,thecunginsertscanbe
usedatotaloffourmes.

1
2
Indexablecunginsertsformillingbevels
Adjusngtheeight‐foldindexable
cunginserts:
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
Locanghole1
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Locanghole2

15 V01_157_01.01.2014.ENG
  
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Largeguidebearing
DL
Largeguidebearing
DL
Smallguidebearing
DS
3
1
2
Indexablecunginsertsformillingbevels
Posioningofinsertsonthemillinghead:
ThetypeMindexableinsertshavefourcung
edgeseach11mmlong.Ournewtechniqueof
‘rotang,flippingandshiing’theinsertsmakes
itpossibletoindexeachinserteightmesifma‐
chiningbevelswithwidthsofuptoabout5mm.
Ifmachiningbevelwidthsgreaterthan5mm,
thecunginsertscanbeindexedfourmesin
total.
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LargeguidebearingDLfiedtomillingheadand
cunginsertsfastenedvialocanghole1.This
configuraoncanbeusedtomillbevelswith
widthsofupto5.0mm.
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LargeguidebearingDLfiedtomillingheadand
cunginsertsfastenedvialocanghole2.This
configuraoncanbeusedtomillbevelswith
widthsofupto5.0mm(eight‐foldindexingof
insertpossible)orformillingbevelswithwidths
ofupto10.0mm.
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ThesmallguidebearingDSisusedformillingcon‐
toursanddrilledholeswithdiameters≥30mm
andforbevelwidthsintherange1–10.0mm
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16 V01_157_01.01.2014.ENG
  
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Eight‐foldindexableradius‐millinginserts:
Thenewindexableinsertsusedforradiusmilling
operaonscanalsobeindexedatotalofeight
mesbeforerequiringreplacement.Theycanbe
usedformachiningplasc,steel,stainlesssteel,
aswellasnon‐ferrousmetalssuchasaluminium,
copperandbrass.
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Typeofcoang
2 3
B00B00
B00 B00
B02B02
B02B02
B05B05
MaterialstrengthTyp
RM
Plasc
Aluminiumandaluminiumalloysup
To250N/mm²

Steelupto400N/mm²
Steelupto600N/mm²
Steelupto900N/mm²
Indexablecunginsertsforradiusmilling

17 V01_157_01.01.2014.ENG
  

Largeguidebearing
DL
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Largeguidebearing
DL
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Indexablecunginsertsforradiusmilling
Radius:2.0mmand3.0mm
Theindexableradius‐millinginsertsRM2and
RM3aredesignedwitheightcungedges.Our
newtechniqueof‘rotang,flippingandshiing’
theinsertsmakesitpossibletoindexthese
cunginsertsatotalofeightmes.
Alwaysusetheoriginallockingscrewstofasten
theradius‐millinginsertstothemounngseat
onthemillinghead(max.ghteningtorque:4.0–
5.0Nm).
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
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Radius‐millinginsertsfastenedvialocang
hole1canberotatedandflippedatotaloffour
mes.
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Whenperformingradiusmillingwork,itisessen‐
althatthecorrectguidebearingisaachedto
themillinghead.
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Aershiingtheradius‐millinginsertsfromlo‐
canghole1tolocanghole2,theinsertscan
thenberotatedandflippedafurtherfourmes.
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18 V01_157_01.01.2014.ENG
  
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Standard
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Alternav
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Important!
Toensuretheproperformaonoftheradiuson
theworkpieceendface,themachinemustbe
fiedwithcorrectguidebearing.
Toensurethesmoothandprecisetransion
fromthemilledradiustotheuppersurfaceof
theworkpiece,theheightoftheguideplate
mustbesetprecisely.
≤5mm=8‐fold
>5mm=4‐fold
RM3=8‐fold
1‐10mm=4‐fold
DL=large
DS=small
IndexablecunginsertsformillingbevelsM
IndexablecunginsertsforradiusmillingRM3
MillingheadMH‐45/R3‐L‐B33.1
Tomill45°bevels,combinewithaDL‐45/R3‐B33‐1
guidebearingandfittypeMindexablecungin‐
serts.Tomill3mmradii,combinewiththesame
guidebearingbutfitRM3radius‐millinginserts.
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45°bevel,largeguidebearingDL
CombiningthelargeDL‐45/R3‐B33.1guidebearing
withtypeMindexablecunginserts,enablesthe
insertstobeindexedatotalofeightmesifthe
bevelwidthsbeingmachinedare≤5mm,orin‐
dexedfourmesifthebevelwidthsare>5mm.

or
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Radius:3.0mm
ThesameDLguide‐bearingisusedwiththeeight‐
foldindexableRM3radius‐millinginserts.
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
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45°bevel,smallguidebearingDS
IfthesmallDS‐45/R3‐B33.1guidebearingiscom‐
binedwithtypeMindexablecunginserts,the
insertscanbeindexedfourmesifthebevelbeing
machinedisbetween1and10mmwide.
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19 V01_157_01.01.2014.ENG
  

Toohigh


Toolow
correct
Indexablecunginsertsforradiusmilling
Adjusngtheradii:
Pleasenotethatonlytheposionoftheupper
edgeoftheradiuscanbeadjustedbyrotang
theguideplate.Thelateralposionoftheradius
ontheworkpieceendfaceisdeterminedbythe
guidebearingfiedandcannotbealtered


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
Guideplatesettoolow
(Radiusincomplete)








Guideplatesettoohigh
(Radiuscutsintomaterial)








Guideplatesetcorrectly
(Radiusfullyformedwithsmoothtransionto
workpiecesurfaces)

20 V01_157_01.01.2014.ENG
  

Indexablecunginsertsforradiusmilling
>90°







Guidebearingtoolarge(radiusincomplete)







Guidebearingtoosmall(radiuscutsintomaterial)









Anglegreaterthan90°(radiusincomplete)







Anglelessthan90°(radiuscutsintomaterial)
<90°
toosmall
toolarge
Notesonradiusmilling:
Choosingtherightguidebearingtoensurethe
correctlateralposionoftheradiusisjustas
importantassengthecorrectheightofthe
guideplate.
Ifthewrongguidebearingisused,themachined
radiuswillnotformasmoothtransionwiththe
endfaceoftheworkpiece.
Iftheguidebearingusedistoolarge,theap‐
pearanceoftheresulngradiusissimilar(but
rotatedby90°)tothatcreatedwhentheguide
plateissettoolow.
Iftheguidebearingusedistoosmall,theap‐
pearanceoftheresulngradiusissimilar(but
rotatedby90°)tothatcreatedwhentheguide
plateissettoohigh.
Thesamephenomenonarisesiftheendandup‐
perfacesoftheworkpiecearenotalignedat
rightanglestooneanother.

Iftheedgeoftheworkpiecetobemachinedwas
createdbycungalargerplatewithaplasma
cuer,theupperandendfacesoftheworkpiece
maybeoutofrectangularalignmentbyasmuch
as7°.Thistypeofmisalignmentwillresultina
radiusthatiseitherincompleteorthatcutstoo
farintothematerialdependingonwhetherthe
upperorlowersurfaceoftheworkpieceisbeing
machined.


Althoughourconicallyshapedguidebearings
aredesignedtobuupagainsttheworkpiece
immediatelybelowthecunginsertsandcan
thereforeminimizetheproblem,theycannot
eradicateitenrely.