Monaghan ELLIOTT User manual

TM-61
ELLIOTT DIAMOND BURNISHING TOOL
INSTALLATION AND OPERATING INSTRUCTIONS
Operang Instrucons:
Part preparaon : 80-100 µ-inch Ra (2.0-2.5 µ-m Ra)
Part hardness : 40 Rc or under. Consult factory for harder
materials
Feed Rate : 0.003-0.004 Inch/Rev or IPR, (0.076-0.100 mm/Rev)
Speed : 200-500 SFM, 750 SFM max, (60-150 M/min, 230 M/min
max). These speeds are in reference to diameter of part.
Common starng values: 0.004 IPR & 500 SFM, (0.10 mm/rev &
150 M/min)
NOTE: Please run a safe speed for your lathe and set up! It is
okay to use less speed than the minimum shown. Consult us for
any quesons about operang parameters.
Coolant Required: Use water soluble 6% min concentraon
(8-10% is ideal) or straight cung oil. NEVER run tool without
coolant or oil applied to the part!!
Mounng:
The tools have various shank sizes in both inch and metric.
Extend tool from the machine’s tool pocket enough to allow
for proper machine clearances when deected completely,
approximately 0.200” (5.1 mm) radially. Ensure that the
centerline of the diamond is on the centerline of the part.
Spring Load:
The Ellio S2300-00 diamond burnishing tool has a max working
spring deecon of 0.200” (5.1 mm).
Tool Seng (ID and OD Surfaces):
Before the tool can be operated, it must be determined how
much spring deecon is required and the proper feed rate.
Soer materials such as non-ferrous metals and so steels
should not require a lot of deecon (tool pressure) to burnish
properly whereas harder steels and cast irons may require much
more deecon (tool pressure).
Inial Set Up:
Spring deecon should be determined rst. With the spindle
turning and coolant applied bring the diamond p in contact
with the workpiece. Deect accordingly: for soer materials,
use .025” (0.64mm) per side deecon. For harder materials,
use 0.075” per side deecon (tool pressure).
Tool Seng:
Immediately upon deecon, feed the tool across the surface at
inial starng values. Check nish to determine if acceptable.
If the nish is not smooth enough there are two adjustments:
1) Increase the spring deecon between tool & part. When
increasing the deecon, use 0.025” (0.64 mm) increments each
me. NOTE: At max tool deecon of 0.200” (5.1 mm), there
will be almost 112 pounds (51 kg) of force against the part. Use
cauon when applying this much pressure to keep from bending
the part or pushing it from the holding device.
OR (cont’d)
Machine chuck
or collet
Workpiece
Tool path
Shank

800.732.4565 937.253.7706 Fax: [phone]
[email protected] www.monaghantooling.com
2) Decrease feedrate by 0.001” IPR (0.025 mm/rev) increments.
If the surface starts geng too rough or starts aking, back o
deecon (tool pressure).
NOTE: Aer making adjustments to deecon (tool pressure)
or feedrate, do not burnish over the same area more than two
mes or the material may ake due to too much tool pressure.
Alternate method for tool pressure seng (such as O-ring
grooves, keyways, snap ring grooves or to feed on and o part):
Before this method can be used, the proper deecon (tool
pressure) must rst be determined by the Inial Set Up method
on an area without the interrupons.
From the factory, the cap screw has been screwed in just far
enough to touch the stem to the spring, eliminang any slack
in the assembly with approximately 5 lbs (2.37 kg) worth of
preload.
Using a 5/32” (0.156”) hex key wrench, turn the cap screw ½
clockwise to advance the screw approximately 0.025” (0.635
mm). Connue to ghten the screw in unl you reach the
amount of deecon you determined in Inial Set Up. Now, use
only approximately 0.002-0.003” (0.051-0.076 mm) worth of
deecon to burnish the part and you will have the same tool
pressure as in the Inial Set Up process.
Face burnishing parts:
Use same the methods outlined above, except turn tool 90
degrees to the face making sure the diamond is on center with
the part.
To replace the diamond stem, remove the cap screw and the
used diamond stem. Insert the new diamond stem and re-adjust
the cap screw to remove any play in the stem. If you used the
preload method, then you will need to adjust the cap screw to
the previous value.
For addional technical support:
11/2017
**PLEASE BE ADVISED THAT THE STEMS (S375D1) ARE NO LONGER ABLE TO BE MODIFIED IN ANY WAY**