LMT FETTE T18F User manual

www.lmt-fette.com
Operating Manual
Tangential Rolling System
T18F - T27F
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Copyright
While every effort has been made to ensure that the information provided in this Operating Manual
is correct, changes cannot be fully excluded. Any necessary corrections will be documented in
the following version. The manufacturer nevertheless retains ownership of the copyright of this
Operating Manual. Therefore, this Operating Manual may not be reproduced, by whatever means,
in whole or in part, copied, distributed or used for competition purposes without the prior written
consent of the manufacturer.
© 2011
Manufacturer
The tangential rolling system specified on the title page is manufactured by:
LMT Fette Werkzeugtechnik GmbH & Co. KG
Grabauer Str. 24
21493 Schwarzenbek
Germany
Phone [phone] - 0
Fax [phone]
www.lmt-fette.com
Rolling-Hotline [phone]
E-Mail-Hotline [email protected]
Contact LMT Fette Werkzeugtechnik GmbH & Co. KG (see Chapter 13 Service
Information, page50)
■if you have any questions or problems.
■for ordering spare and wearing parts.
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Table of contents
1 Introduction .............................................................................. 1
2 Safety ...................................................................................... 3
3 Design and function ................................................................... 7
3.1 The method ............................................................................... 7
3.2 Application area/working range ...................................................... 7
3.3 Materials ................................................................................... 8
3.4 Thread length ............................................................................. 8
3.5 Position of the thread run-out ........................................................ 9
4 The rolling equipment ................................................................ 11
4.1 The rolling head – selecting the size ................................................ 11
4.2 The rolling head holder ................................................................. 13
4.3 The thread rolls .......................................................................... 14
4.3.1 Tool life ..................................................................................... 14
4.3.2 Versions ................................................................................... 15
4.3.3 Labeling .................................................................................... 17
4.4 The setting gauge ....................................................................... 17
5 Assembly and installation ........................................................... 19
5.1 Preparing the rolling head ............................................................. 19
5.1.1 Checking the gear settings ............................................................ 19
5.1.2 Inserting the thread rolls ............................................................... 20
5.1.3 Adjusting the axial rolling clearance ................................................ 21
5.1.4 Functional testing ........................................................................ 22
5.1.5 Adjusting the distance between the axes ......................................... 22
5.2 Installation on the machine tool ...................................................... 23
5.2.1 Preparing the workpiece ............................................................... 23
5.2.2 Inserting the rolling head into the holder .......................................... 24
5.2.3 Adjusting the pendulum clearance .................................................. 25
5.2.4 Coolants and lubricants ................................................................ 27
6 Putting into operation and setup .................................................. 28
6.1 Rolling speed and RPM ................................................................ 28
6.2 Working feed – number of workpiece rotations .................................. 28
6.3 Traverse paths ........................................................................... 30
6.4 Tangential force, drive power and torque ......................................... 32
6.5 Rolling time ............................................................................... 33
7 Special applications ................................................................... 34
7.1 Rolling tapered threads ................................................................ 34
7.2 Knurling and burnishing ................................................................ 35
7.3 Thread rolling on pipes ................................................................. 37
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8 The first rolling process .............................................................. 38
8.1 Correcting the distance between the axes ........................................ 39
8.2 Correcting the axis inclination ........................................................ 39
9 Troubleshooting ........................................................................ 41
10 Cleaning, maintenance and servicing ........................................... 44
10.1 Changing the thread rolls .............................................................. 44
10.2 Maintenance intervals .................................................................. 44
10.3 Wear parts ................................................................................. 45
11 Putting out of operation, disassembly and disposal ........................ 46
12 Technical data .......................................................................... 47
12.1 Tool dimensions ......................................................................... 47
12.2 Spare parts lists .......................................................................... 48
13 Service information .................................................................... 50
14 Quick guide .............................................................................. 52
15 Calculation sheet ....................................................................... 53
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www.lmt-fette.com
1 Introduction
Congratulations on choosing a LMT Fette tangential rolling system. This tool offers
decisive advantages in terms of economic viability and efficiency and sets new stand-
ards in chipless thread forming.
Setting up and working with the tangential rolling system is very easy. Only a short
training period is needed to ensure cost-effective production.
That said: before using the tool for the first time please make sure to read carefully
and thoroughly through this Operating Manual, paying special attention to the safety
instructions! This will quickly familiarize you with all the features of this tool and help to
prevent damage occurring to the tool and machine.
Expertise help is also available from LMT Fette at any time (see Chapter 13 Service
information).
Notes on this Operating Manual
This Operating Manual (OM) contains all the information which you need to know
about transport, storage, assembly, installation, putting into operation and use. This
Operating Manual does not permit the operation of the processing machine into which
the tangential rolling system is or is to be integrated. Information relating to the said
processing machine is contained in the respective Operating Manual. This Operating
Manual is designed to help you avoid improper handling. Personal safety can only be
ensured if you strictly follow the instructions provided in the Operating Manual. There-
fore, this Operating Manual should be kept in close proximity to the tangential thread
rolling head.
Target group
This Operating Manual is intended for use by appropriately trained and qualified per-
sonnel who are entrusted with the responsibilities of mounting, putting into operation
and using the tangential rolling system.
The following conventions are valid for this Operating Manual:
■Abbreviations are used in the text. Each chapter provides an explanation of the
abbreviations used when they appear for the first time. The respective abbreviation
is contained in brackets after the term.
Example: Operating Manual (OM)
■The pages are numbered consecutively in each chapter. Tables and figures are
numbered consecutively.
■Cross references in the text are linked to additional or more in-depth information.
■Some chapters specify part numbers. Part numbers with the addition “SP” contain
a reference to the spare parts list (Figure 24 on page 48).
Chapter 2 Safety, page 1, contains generally valid safety instructions relating to haz-
ards which may occur during the operation of the tangential rolling system. Specific
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safety instructions also appear immediately in front of instructions where there is a risk
of danger to persons or the tangential rolling system.
This Operating Manual is subject to change management. Should changes serving
technical progress be made to the tangential rolling system, you will be required to
include any additional or updated pages at the relevant position.
Explanation of symbols and notes
This Operating Manual uses different symbols to convey safety instructions and
information.
The safety instructions include information on the hazard source, possible or likely
consequences as well as measures to avoid the hazard.
DANGER
This warning category indicates an imminent hazardous situation which, if
not avoided, will result in serious injury or death.
CAUTION
This warning category indicates a potentially hazardous situation which,
if not avoided, could result in serious injury.
CAUTION
This warning category indicates a potentially hazardous situation which,
if not avoided, could result in minor injury.
ATTENTION
This warning category indicates a potentially hazardous situation which,
if not avoided, could result in material damage.
NOTICE
This symbol appears next to hints containing special information on key
functions or special application tips designed to optimize the use of all
functions.
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2 Safety
General safety instructions
The tangential rolling system was constructed in compliance with all binding rules and
regulations and safety standards. It complies with the current state of technology and
EC conformity requirements.
■The tangential rolling system must be put into operation in accordance with the
Operating Manual.
■The general safety instructions for processing machines (machine room) apply.
■Operating personnel must be trained using this Operating Manual. Successful com-
pletion of training must be confirmed in writing. This applies in particular to operat-
ing personnel without knowledge of the respective national language or national
writing system.
■For the replacement of spare parts only original LMT Fette spare parts must be
used for safety reasons.
Residual dangers
Even if the tangential rolling system is used as intended, it is not possible to exclude
all dangers.
Such dangers not only arise from the tangential rolling system itself, but generally
through negligence or operating errors.
Make sure to observe
■the general legal and operational safety regulations pertaining to the use of a
tangential rolling system.
■the universally recognized technical rules to ensure safe and professional working
practices.
■all the safety instructions in this Operating Manual.
■the safety markings on the tangential rolling system.
■the accident prevention regulations.
■the environmental protection regulations.
Obligations of the operator
■The operator is responsible for ensuring that the tangential thread rolling head is used
as intended, that the safety regulations are adhered to and that this Operating Manual
is always accessible to personnel for consultation at all times.
■The operator must ensure that all persons commissioned by him to perform com-
missioning work, operation and maintenance tasks have read and understood this
Operating Manual.
■The operator is required to provide all the necessary protective equipment for the
personnel.
Authorized personnel, operating personnel training
All operating personnel must have the required training for their tasks and meet the
requirements for using the tangential rolling system. The valid regulations concerning
the occupational safety and protection of minors must be observed.
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The operating personnel must be trained in the correct use of the tangential rolling
system before using the tangential thread rolling head for the first time, after accidents
and also at regular intervals.
What to do in an emergency
Accident
■Perform first aid measures if necessary.
■Notify a doctor.
Fire
■Notify the fire department.
Environmental hazard
■Notify the fire department and the appropriate authorities.
■Provide information on special hazardous substances.
NOTICE
Also observe the in-house alarm and emergency plans.
Packaging
CAUTION
Risk of foot injury!
Personnel must take care when handling the packaging as there is a risk
of the tangential thread rolling head falling down and causing injury. Wear
safety shoes to prevent foot injuries.
CAUTION
Risk of hand injury!
Personnel must take care when handling the packaging as there is a risk
of injury from rough surfaces or sharp edges on transport cases, cartons,
pallets and packaging aids.
Wear safety gloves to prevent hand injuries.
During packaging secure the tangential thread rolling head against uncontrolled
movements.
The tangential rolling system is packed in cartons. The tangential thread rolling head
is packed in cartons or plastic containers. Any protruding parts must be padded to
prevent damage.
NOTICE
Improper disposal of the used packaging materials can pose a threat
to the environment. All materials must be disposed of separately and in
accordance with national and local regulations.
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Transport
CAUTION
Risk of hand injury!
Personnel must take care when handling the packaging as there is a risk
of injury from rough surfaces or sharp edges on transport cases, cartons,
pallets and packaging aids. Wear safety gloves to prevent hand injuries.
CAUTION
Risk of foot injury!
During transport there is a risk of transport cases, cartons and pallets falling
down and causing injury.
Wear safety shoes to prevent foot injuries.
During transport secure the unit against uncontrolled movements.
Check that the delivery is complete and that no parts have been damaged in transit.
Refer to the delivery note for information on the scope of delivery. Conduct an on-site
inspection of the tangential rolling system upon acceptance for external damage. Any
damage must be reported to the manufacturer immediately.
Storage
CAUTION
Risk of hand injury!
During storage there is a risk of injury from rough surfaces or sharp edges
on transport cases, cartons, pallets and packaging aids. Wear safety gloves
to prevent hand injuries.
CAUTION
Risk of tripping and falling over!
During storage there is a risk of injury from tripping or falling over transport
cases, cartons or pallets positioned in gangways. Wear safety shoes to
prevent foot injuries and make sure to keep all paths free from obstruction
at all times.
Store the tangential rolling system in a dry, dust-free environment away from direct
sunlight.
If prolonged storage is planned, agree on strictly defined contractual storage con-
ditions with the manufacturer.
If the tangential thread rolling head is stored under extreme temperature conditions,
there is a risk of injury to personnel from hot or cold surfaces.
Do not remove or damage the packaging of the tangential rolling system during
storage.
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If, for operational reasons, the tangential rolling system is stored in areas in which it
is exposed to the effects of weather or aggressive substances, it must be checked for
proper condition by a qualified person prior to initial operation.
Storage temperature min. –10 °C (14 °F)
max. +30 °C (86 °F)
Relative humidity 60 % ± 5 %
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3 Design and function
3.1 The method
During the thread rolling process, the workpiece is produced by cold forming. This
ensures that the flow of the fibers within the thread profile is not interrupted. Notch
effects are thus avoided. The surfaces in the thread flanks are press-finished. Threads
produced by thread rolling are characterized by high fatigue strength, wear resistance
and corrosion resistance.
LMT Fette tangential thread rolling attachments have been primarily designed for roll-
ing either in front of or behind a shoulder. The thread length is limited by the maximum
roll width. This makes the rolling head particularly suitable for short threads.
Operation takes place according to the plunge method. The rolling head is moved at
a constant feed laterally onto the workpiece. The workpiece rotates. The thread rolls
which are synchronized via a gear unit are rotated by the workpiece. The thread is
rolled within a few workpiece rotations and the rolling head is drawn back again from
the workpiece.
Tangential thread rolling heads can be used on all machine tools which are provided
with automatic feed motion. The tangential thread rolling head is held in a rolling head
holder. This is adapted to the respective tool holder of the machine. Before using a
tangential thread rolling head, check whether the rolling head is suitable for use on the
automatic lathe and clarify whether the shoulder diameter could collide with the rolling
head.
The rolling head for right-hand threads is also used for left-hand threads. This then
requires the use of special left-hand thread rolls. The thread length, including the
thread run-out, cannot be larger than the width of the roller.
In particular the following profiles can be produced:
■Threads behind a shoulder
■Extremely short threads
■Threads with a very short run-out (approx. 1 x pitch)
■Tapered threads
■Knurling profiles as per DIN 82
■Burnishing
■Forms
3.2 Application area/working range
LMT Fette tangential thread rolling heads cover a working range of up to 64 mm. The
way in which this range is divided is shown in the following table:
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Working range of parallel threads
Rolling
head type
Workpiece major diameter
Max. pitch Max. roll widthMin. Max.
[mm] [Zoll] [mm] [Zoll] [mm]
[Thread/
inch] [mm] [Inch]
T18F 25/64 30 1 3/16 2 12 21.5 0.8465
T27F 25/64 42 1 5/8 2.5 10 31 1.2205
Working range of tapered threads
Rolling
head type Standard Min. Max.
Allowed shoulder
diam. and working
T18F DIN 158
DIN 2999
DIN 3858
ANSI B 1.20.1
M6 x 1 keg.
R 1 /16 –28
R 1 /8–28
1
/16 –27 NPT (NPTF)
M30 x 1.5 keg.
R ¾–14
R ¾–14
½–14 NPT (NPTF)
For profiles as per
DIN 158, DIN 2999 &
DIN 3858, the shoul-
der diameter and
working strokes with
parallel threads of
the same dimensions
are identical; for
profiles as per ANSI
B1.20.1 see Internet
T27F DIN 158
DIN 2999
DIN 3858
ANSI B 1.20.1
M6 x 1 keg.
R 1 /16 –28
R 1 /8–28
1
/16 –27 NPT (NPTF)
M42 x 2 keg.
R 1¼–11
R 1¼–11
1–11.5 NPT
(NPTF)
3.3 Materials
The tangential rolling method can be used for all metallic materials with a breaking
elongation A ≥ 7 %. The tensile strength Rmshould not exceed approx. 1000 N/mm2
(145.000 Pa). If the material properties are close to the said limiting values, the rollabil-
ity is dependent on the required volume of forming. If the volume of forming is very
small, these values can be exceeded. In general, the materials should have a minimum
breaking elongation of approx. 7 % and not exceed a tensile strength of 1700 N/mm2
(246.000 Pa). Accordingly, structural and case-hardening steels, stainless steels, heat-
treated steels up to approx. 1600 N/mm2(232.000 Pa) are suitable. Soft brass, copper,
light metals, ferritic castings such as GGG 40 or GTS 35 etc.
Brittle materials with a low breaking elongation such as gray cast iron, hard brass
alloys and hardened materials are not suitable.
Warning
Only materials with a breaking elongation > 7 % are suitable for processing.
Brittle materials may cause splinters. Risk of injury!
3.4 Thread length
On each roll side there is a chamfer of the width of the thread pitch P. The largest
theoretical thread length L thus corresponds to the maximum roll width B2(see Chap-
ter 12.1) minus 2 x thread pitch P (also make sure to note the requirements specified
in Chapter 3.5!).
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If smaller thread lengths are required, recessed rolls can be used, if necessary. It is
also necessary here that the roll width A is at least the screwable thread length on the
workpiece plus 2x thread pitch P. The standard dimensions specified in the table are
preferably to be used. When placing orders for rolls include details of the minimum
and maximum possible roll width.
Table 1: Standard roll width version
Rolling head Roll widths A [mm]
T18F 6 8 10 12 14 16 18 21.5
T27F 810 12 14 16 18 20 22 24 26 28 31
The forces which occur during the thread rolling process vary depending on the tensile
strength of the workpiece, the major diameter d of the thread and the thread pitch P.
Therefore, not all thread sizes can be rolled with the maximum roll width. The maxi-
mum rollable thread length L can be estimated using the formulas from the following
table. The following is to be used:
L = rollable thread length [mm]
P = thread pitch [mm]
d = major diameter of the thread [mm]
All values are indicative and may vary in individual cases.
Table 2: Maximum rollable thread length L
Rolling head
Tensile strength of the material [N/mm2]
< 500 500 … 700 700 … 900 > 900
T18F L =
580.5
______
P · d L = 483
_____
P · d L = 446
_____
P · d L = 414
_____
P · d
T27F L =
1255.5
_______
P · d L =
1046
_____
P · d L = 965
_____
P · d L = 896
_____
P · d
3.5 Position of the thread run-out
The thread can be produced on the workpiece very close to a shoulder, or similar. In
such cases, corresponding safety distances must always be maintained (see Figure1).
The thread roll (1) must have the safety distance c to the shoulder of the workpiece(2).
The screwable thread begins at the distance a1from the shoulder.
The following applies: a1= b + c [mm]
Lead chamfer angle Thread lead b Distance a1
45° 0.6 · P 1.1 · P
60° P1.5 · P Standard
70° 1.55 · P 2.05 · P
In standard cases (lead chamfer angle = 60°) the thread lead b on the roll corresponds
to the thread pitch P. The safety distance corresponds to c = 0.5 · P.
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If the geometrical proportions
are unfavorable – especially if the
shoulder diameter DBis very large in
proportion to the thread – it will still
be necessary to add the width c1of
the bearing washer (3) to the safety
distance. This will result in the maxi-
mum distance of the thread from
the shoulder:
a1= b + c(+c1) = P + 0.5 · P(+c1) =
1.5 · P(+c1) [mm]
Figure 1: Distance of the thread roll from the shoulder
At the free end of the thread or the
workpiece tip, the leading edge of
the thread roll (1) must ideally be
located at the dimension
b + P = 2 · P before the start of the thread (see Figure 2-left). If this dimension is not
achieved it may result in a significant tool life reduction of the thread roll.
The same applies also to a thread undercut (see Figure 2-right). The dimension
b + P must be maintained. The correct safety distance c is automatically achieved if
the length g2of the thread undercut is as per DIN 76-A. The length is then approx.
g2≈ 3.5 · P.
1
2
1 x P
b
b + P
13
2
1 x P
b
≥ c
g2
DB
Figure 2: Thread roll at the free end and thread undercut
Rolling head type Width of bearing washer c1
T18F 0.6 mm l0.0236 inch
T27F 0.8 mm l0.0314 inch
b
1
2
3
a1
c
c1
DB
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4 The rolling equipment
Your complete rolling equipment
consists of four components:
■Rolling head
■Rolling head holder
■Rolls (1 set = 2 pieces)
■Setting gauge
As the rolling equipment can
be used flexibly for different
processing applications the indi-
vidual components are delivered
independently of each other.
Figure 3: Rolling equipment
4.1 The rolling head – selecting the size
The rolling head is the core of the tangential rolling equipment. The respective version
is available in two sizes: T18F and T27F.
It is recommended to use the largest suitable rolling head for the respective machine
tool to ensure that the largest possible working range is available. This also helps to
achieve larger thread lengths, the max. shoulder diameter DBon the workpiece as well
as the maximum cost-efficiency of the rolling head.
Using the following tables and figures check whether the selected rolling head could
result in collisions with the machine tool, spindle or workpiece.
DBK DBK DBK DBG DBR
B1
B2B5B4B6 B3
Figure 4: Width dimensions and shoulder diameter at the tangential rolling head
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The width dimensions B1… B6of the rolling head are specified in Chapter 12.1. Note
that the rolling head can also be rotated in the holder. That is, either the narrow arm
side B3or the wide arm side B4may be facing towards the workpiece clamping.
The maximum shoulder diameters DBK, DBG and DBR at the workpiece are dependent
on the respective thread size. The values are specified in table form online at
www.fette.de/rk/fettekat.
Abbreviations used in the following table (excerpt only):
DBK = Max. shoulder diameter under the narrow (“short”) arm side of the rolling head
DBR = Max. shoulder diameter under a recessed thread roll
DBG = Max. shoulder diameter under the wide (“drive”) arm side of the rolling head
Av= Theoretical working stroke of the rolling head (see Chapter 4.4 and 6.3)
Z = Number of starts on the roll (see Chapter 4.4)
Table 3: Shoulder diameter and operation data (excerpt from the Internet)
NOTICE
With tapered threads (metric and Whitworth profiles) the shoulder diameter
and working strokes with parallel threads of the same dimensions are
identical.
Each rolling head size can be used for the complete working range; only the rolls and
the setting gauge need to be adapted to the individual work applications.
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4.2 The rolling head holder
The rolling head holder serves as an adapter between the machine tool and the rolling
head. Since machine tools are available in many versions (e. g. multi-spindle, turning
centers etc.) from different manufacturers, this requires that the rolling head holder
also needs to be adapted to the highly individual machine conditions. The rolling head
holder mount has been adapted to the respective mounted tool holder of the machine,
e. g. T-slot, parallel shank, prisma or square mount.
Figure 5: Different rolling head holder versions
On our homepage www.fette.de/rk/fettekat you can find a list of possible applica-
tions with Fette tangential rolling heads on different machine tools. This database is
constantly updated. If your application is not included, please contact us.
A drawing of the working areas in the machine is definitely helpful.
Table 4: Holder for machine (excerpt from the Internet)
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4.3 The thread rolls
A set of thread rolls is required for each thread size. A set consists of 2 different thread
rolls. They are labeled with the numbers 1 and 2.
Depending on the rolling head size and the thread size the thread rolls are either
constructed with a single or multiple thread design. In principle, the largest number of
starts on the roll Z and thus also the largest possible roll diameter Drshould be aimed
for in order to consider the largest possible shoulder diameter at the workpiece.
The thread rolls for the thread tolerance 6g (for threads as per DIN), 7e (for trapezoid
threads) and 2A (for UN threads) are delivered by default. A lot of other thread toler-
ances are also possible.
4.3.1 Tool life
The tool life of the thread rolls is dependent on many factors. This includes, e. g.:
■Material properties (especially tensile strength and breaking elongation)
■Hardening behavior of the material during cold forming
■Profile rolling degree
■Type of chamfers during workpiece preparation
■Correct adjustment of the tool
■Rolling speed and working feed
■Sufficient supply of clean coolant
■Avoidance of chips on workpieces and thread rolls prior to the rolling process
Depending on the application it can make sense to use thread rolls with a special
design (e. g. from another roll material) instead of thread rolls with a standard design.
Contact LMT Fette for more information (see Chapter 13).
After the thread rolls have become worn they will need to be replaced with new ones;
see Chapter 5.1.2 for more information
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4.3.2 Versions
Thread rolls are available in different versions depending on the respective application
(see table 5 and table 6). Version “A” is standard.
Table 5: Roll versions for parallel threads
Roll version
Full roll width A B
30 12 12
Code number (example)
T27-10-31 T27-10-12A T27-10-12B
MAB
Only possible when the
thread size is identical
126 12 6
Code number (example)
T27-10-12M6 T27-10-12A-6B
If both thread lengths are
identical, then:
T27-10-12AB
In the case of tapered threads please specify the standard and the version (“standard”
or “short”). If the threads differ from the standard, please inform us of the location of
the measuring plane (a). In this case the maximum roll run-out is 1 x pitch.
LMT_Bedienungsanleitung_T18F_T27F_e.indd 15 02.08.11 17:40

Operating Manual
Tangential Rolling System T18F - T27F
16
www.lmt-fette.com
Table 6: Roll versions for tapered threads
Roll version
A B M
a
12
a
12 126
a
Code number (example)
T27-100-12A T27-100-12B T27-100-12M
AV BV MV
a
12 12
a
126
a
Code number (example)
T27-100-12AV T27-100-12BV T27-100-12MV
ABV AB AVBV
Only possible when the
thread size is identical
Only possible when the
thread size is identical
Only possible when the
thread size is identical
10
12
aa
10
12
aa
10
12
a
a
Code number (example)
T27-100-12A-10BV
If both thread lengths are
identical, then:
T27-100-12ABV
T27-100-12A-10B
If both thread lengths are
identical, then:
T27-100-12AB
T27-100-12AV-10BV
If both thread lengths are
identical, then:
T27-100-12AVBV
LMT_Bedienungsanleitung_T18F_T27F_e.indd 16 02.08.11 17:40