Traub INDEX G400.2 Manual

INDEX G400.2
INDEX G500
Tool holder Technical Information
INDEX G400.2, INDEX G500
Tool holder - Technical Information
DIW057EN - 09.04.21

Note on applicability
Illustrations in this publication may deviate from the product supplied. Errors and omissions due to technical
progress expected.
A word on copyright
This document is protected by copyright and was originally compiled in German.
The duplication and distribution of this document or parts thereof is prohibited without prior consent of
the copyright owner, and any violators will be prosecuted. All rights, including the right to translate, are
reserved.
©Copyright by INDEX-Werke GmbH & Co. KG
Englisch

3
INDEX G400.2, INDEX G500
DIW057EN - 09.04.21
Tool holder - Technical Information
CONTENTS
1
2
3
Technical information ..................................................................................................................................................... 5
Tool holder selection .......................................................................................................................................................... 5
Warranty .............................................................................................................................................................................. 5
Information on wear parts................................................................................................................................................. 5
Inspection of live tool holders........................................................................................................................................... 5
Tool holders with cooling lubricant supply....................................................................................................................... 6
Cooling lubricant filtering ................................................................................................................................................... 6
Cleaning live tool holders................................................................................................................................................... 6
Speed ratio specifications on tool holders ...................................................................................................................... 6
Direction of rotation specification ..................................................................................................................................... 7
Tightening torque................................................................................................................................................................ 8
Coolant supply .................................................................................................................................................................... 8
Replacement seals for tool shank .................................................................................................................................... 8
Sealing air port.................................................................................................................................................................... 8
Tool holders with fixation .................................................................................................................................................. 9
High-pressure unit .............................................................................................................................................................. 9
Load limits of live tools...................................................................................................................................................... 9
Live tool holders ................................................................................................................................................................. 10
Weight distribution on turret head.................................................................................................................................... 11
Collision................................................................................................................................................................................ 11
Tool change on live tool holders....................................................................................................................................... 11
Notes on how to use the diagram when using tool holders ....................................................................................... 12
Usage information........................................................................................................................................................... 13
Modular system of INDEX G400.2, INDEX G500 ......................................................................................................... 13
Work area of INDEX G400.2 ............................................................................................................................................ 14
Tool carrier top and bottom XYZ, VDI40 with 12 stations (SW380)
Main/counter spindle, spindle clearance D120mm, turning length 1600mm ........................................................ 14
Work area of INDEX G400.2, INDEX G500 ................................................................................................................... 16
Tool carrier top XYZ, VDI40 with 12 stations (SW380)
Tool carrier bottom XZ, VDI40 with 18 stations (SW480)
Main/counter spindle, spindle clearance D120mm, turning length 1600mm ........................................................ 16
Tool carrier top XYZ, VDI40 with 12 stations (SW380)
Tool carrier bottom XZ, VDI40 with 18 stations (SW480)
Main/counter spindle, spindle clearance D120mm, turning length 2300mm ........................................................ 18
Swivel range........................................................................................................................................................................ 20
Tool carrier XYZ bottom left, VDI40 with 12 stations.............................................................................................. 20
Tool carrier XYZ bottom right, VDI40 with 12 stations............................................................................................ 21
Tool carrier XZ bottom left, VDI40 with 18 stations ................................................................................................ 22
Tool carrier XZ bottom right, VDI40 with 18 stations .............................................................................................. 23
Performance diagram ......................................................................................................................................................... 24
Live tools with tooling system VDI40 ........................................................................................................................ 24
Tool carrier XYZ bottom, VDI40 with 12 stations ............................................................................................... 24
Tool carrier XZ bottom, VDI40 with 18 stations.................................................................................................. 25

4INDEX G400.2, INDEX G500
DIW057EN - 09.04.21
Tool holder - Technical Information
1
2
3

5
INDEX G400.2, INDEX G500
DIW057EN - 09.04.21
Tool holder - Technical Information
TECHNICAL INFORMATION
Technical information
Tool holder selection
For more information, please visit our iXshop
at ixshop.index-traub.com
We will be happy to send you an individual offer.
Just call us at [phone] or
send us an email to [e-mail].
Warranty
When using tool holders that are not adjusted, tested and marked as
such by INDEX TRAUB, the warranty for the tool drive is void.
Information on wear parts
Tool holders are wear parts requiring correct handling.
In order to ensure a long service life, compressed air or coolant must not enter the
gap seals of the holders.
Inspection of live tool holders
Tool holders must be inspected at regular intervals (at least twice a
year) for smooth running and play.
The drive pinion and drive clutch of the live tool holders must be sub-
jected to a visual inspection for damage or wear.
If one of the above-mentioned defects is detected during the inspection of the tool
holders, they must be returned immediately for preventive maintenance or repair to
the following address:
INDEX-Werke GmbH & Co. KG
Plochinger Straße 92
D-73730 Esslingen
Fon [phone]
[e-mail]

6INDEX G400.2, INDEX G500
DIW057EN - 09.04.21
Tool holder - Technical Information
TECHNICAL INFORMATION
Tool holders with cooling lubricant supply
Tool holders marked with this symbol must be operated with cooling lubricant (no
dry running permitted).
Tool holders marked with this symbol can be converted from external cooling lubri-
cant supply to internal cooling lubricant supply.
Observe dry running capability of IC attachment!
Cooling lubricant filtering
When using live tool holders with internal cooling lubricant supply, it is necessary to
use a cooling lubricant filter system with a retained particle size ≤50 µm.
Cleaning live tool holders
Live tool holders must never be immersed in cleaning fluid since mixing the clean-
ing fluid with the bearing grease will reduce the service life of the tool holders.
Speed ratio specifications on tool holders
The value to be programmed is specified in the documentation and on the live tool
holders (= the input in the NC program).
nprog = ntool x i
ntool = speed at the cutting tool edge
nprog = speed to be programmed
i = speed ratio in the tool holder
This means the speed increase or speed reduction is not specified as a fraction but
as a number.
This gives speed increase ratios as numbers less than 1.
Example: i = 0.333 (corresponds to i = 1:3)
i = 0.676 (corresponds to i = 1:1.48)
Speed reduction ratios are numbers greater than 1.
Example: i = 2 (corresponds to i = 2:1)
i = 1.333 (corresponds to i = 4:3)

7
INDEX G400.2, INDEX G500
DIW057EN - 09.04.21
Tool holder - Technical Information
TECHNICAL INFORMATION
Direction of rotation specification
Definition of the viewing direction.
Viewing direction for determining the direction of rotation is always from behind (that
is, from the drive direction) toward the shaft.
On the machine side, the direction of rotation has been set by parameters such that
M03 always denotes clockwise rotation and M04 counter-clockwise rotation at the
interface of the drive pinion of the tool holder.
The direction of rotation given on the holder therefore refers to a “change in direc-
tion within the holder”. M03 and M04 are machine functions to be programmed.
The and arrows indicate the direction of rotation of the cutting edges.
This means:
No reversal of direction of rotation
When the holder drive shaft has the same direction of rotation as the tool cutting
edge, the clockwise direction of run must be specified by M03 (clockwise rotation).
Accordingly, counter-clockwise rotation must be specified by M04.
Reversal of direction of rotation
When the holder drive shaft has the opposite direction of rotation as the tool cut-
ting edge, the clockwise direction of rotation must be specified by M04.
Accordingly, counter-clockwise rotation must be specified by M03.
Example
No reversal of direction of rotation
M04
M03
M03 M04
M04 M03

8INDEX G400.2, INDEX G500
DIW057EN - 09.04.21
Tool holder - Technical Information
TECHNICAL INFORMATION
Tightening torque
The tightening torques of the clamping pieces to the tool holder mounting depends
on the shank diameter of the tool holder.
Shank size Tightening torque
ø20mm 8 Nm
ø25mm 20 Nm
ø30mm 25 Nm
ø40mm 40 Nm
Coolant supply
For tools with W-serration and double clamping serration. the 2nd hole for coolant
supply must be closed by the end plug and the seal.
The gaskets on the tool shank and the coolant bushing must be regularly checked
for damages.
Replacement seals for tool shank
The gaskets on the tool shank and the cooling lubricant bushing must be regularly
checked for damages.
O-ring Material number Installation location
ø 18.77 x 1.78 10763730 Shank ø 20mm
ø 23.52 x 1.78 10823023 Shank ø 25mm
ø 28.3 x 1.78 10777976 Shank ø 30mm
ø 37.77 x 2.62 10066870 Shank ø 40mm
ø 9.75 x 1.78 10046965 Cooling lubricant adapter
ø 12.42 x 1.78 10824672 Cooling lubricant adapter
Sealing air port
It must be ensured on all machines with sealing air ports that the sealing air ports in
the tool carrier and in the tool holders are sealed/closed with M5x6 mm set screws.

9
INDEX G400.2, INDEX G500
DIW057EN - 09.04.21
Tool holder - Technical Information
TECHNICAL INFORMATION
Tool holders with fixation
Except for very few cases, all tool holders have been pre-adjusted with
high precision and sealed with the INDEX V bar / TRAUB adjusting bar/
W-serration.
This setting must not be changed.
The INDEX V bar / TRAUB adjusting bar / W-serration ensures positional accuracy
of the tool when re-inserted.
The tool holders are fixed around the shank axis by pins (DIN 69880).
DIN holders can be used.
Double serration of the tool holders allows several uses.
High-pressure unit
The cooling lubricant up to 80 bar (e.g., for deep-hole drilling) is supplied
through the standard cooling lubricant line.
Load limits of live tools
The drive power and torques are indicated in the performance charts. These values
represent the upper limit of the calculated theoretical performance values (average
values). In case of interrupted cuts, e.g., for milling, the load peaks occurring when
the cutting edge enters the material may be much higher than the theoretical torque
according to the performance chart.
The cutter should be selected so that a cutting edge is constantly being
used for cutting during the machining process.

10 INDEX G400.2, INDEX G500
DIW057EN - 09.04.21
Tool holder - Technical Information
TECHNICAL INFORMATION
Live tool holders
Only the tool located in the working position is live.
The live tool holders are inserted into the mounting bores in the tool carriers just like
non-live tool holders.
Each turret station can accept one live tool.
The motor drives the tool that is exclusively in working position. In addition, the index
drive is actuated by switching using the same motor.
The sealing washer (1) must be removed first.
Tool carrier XYZ VDI40 with 12 stations
1 Sealing washer 12014790
2 Blanking plug 10911003
3 Mounting pin 10682808
Tool carrier XZ VDI40 with 18 stations
1 Sealing washer 12014790
2 Blanking plug 10573819
3 Mounting pin 10682808
Before using the machine, make sure that all mounting bores without
a tool have been closed with a sealing washer and that the gasket on
all tool holders is not damaged.
Any mounting bores not used must be closed with blanking plugs during
machining processes.
Z
X
Z
X
478120_b
1
2
1
3

11
INDEX G400.2, INDEX G500
DIW057EN - 09.04.21
Tool holder - Technical Information
TECHNICAL INFORMATION
Weight distribution on turret head
Tool holders may have considerably different weights depending on their
function and equipment. Therefore, be sure to balance the tool holders
evenly around the turret head when tooling.
Collision
After a collision has occurred, check whether the tool carrier has been
displaced. If this is the case, the tool carrier must be realigned to ensure
that the drive and tool holder gears accurately engage with each other.
Tool change on live tool holders
To avoid damaging or changing the adjustment of the drive train in the turret, tools
must not be changed on the live tool holders inserted in the turret.
Tools in live tool holders must be changed outside the machine.

12 INDEX G400.2, INDEX G500
DIW057EN - 09.04.21
Tool holder - Technical Information
TECHNICAL INFORMATION
Notes on how to use the diagram when using tool holders
The diagram relates to the output speed nof the tool unit. The tool speed can be
read directly from the diagram only if the internal speed ratio iin the tool holder is
1:1.
For tool holders with an internal speed ratio i ≠ 1, the output speed nof the tool unit
to be programmed must be calculated from the required tool speed and the speed
ratio i. Afterwards, the actual powers or torques can be read off or determined.
Example (at 100% duty cycle):
live tool unit, tool speed nTool = 1000 rpm
Internal speed ratio i
of the tool holder i = 4
Programmed speed nprog
for the drive of the unit nprog = nTool *i = 1000 rpm * 4 = 4000 rpm
Torque MTool
at the output of the tool holder
Read-out Mdat speed nprog = 4000 rpm = 1.6 Nm
Md= MTool: i
Formula changed: MTool = Md*i = 1.6 Nm *4 = 6.4 Nm
Power P
at the output of the tool holder
≈ Power P
at the output of the setup
Read-out at 4000 rpm –> P = 0.67 kW
calculated: P = 2 *π *nprog *Md
P = 2 *π x 4000 *1.6 Nm = 0.67 kW
60 *1000
0,00
0,50
1,00
1,50
2,00
2,50
01000 2000 3000 4000 5000 6000
0
100
200
300
400
500
600
700
800
900
1000
Torque Md at output of unit (Nm)
Power P (kW)
Speed n1
at output of unit (rpm)
Md
P
0,82,0
0,41,0
0,6
0,674
1,5
1,6
0,20,5
1,02,5
0,00,0
0 1000 2000 3000 4000 5000 6000
The transmission ratio and the technical data of each tool holder are available in our
iXshop at ixshop.index-traub.com

13
INDEX G400.2, INDEX G500
DIW057EN - 09.04.21
Tool holder - Technical Information
USAGE INFORMATION
1
2
3
Usage information
Modular system of INDEX G400.2, INDEX G500
1 Main spindle
2 Counter spindle
3 Lower tool carrier VDI40 - XZY
(INDEX G400.2)
4 Lower tool carrier VDI40 - XZ
(INDEX G400.2/G500)
5 Upper tool carrier VDI40 - XZY
(INDEX G400.2/G500)
6 Tailstock
7 Upper steady rest on separate slide (optional)
8 Lower turret steady rests (optional)
9 Shaft type workpiece handling unit (optional)
10 Flange type workpiece handling unit (optional)
ZZ
XX
YYZZ
XX
YY
ZZ
XX
YY
ZZ
ZZ
ZZ
ZZ
XX
XX
7 5 2
31
4
6 9 10
4
8
ZZ
XX
ZZ
XX
ZZ

14 INDEX G400.2, INDEX G500
DIW057EN - 09.04.21
Tool holder - Technical Information
USAGE INFORMATION
1
2
3
Work area of INDEX G400.2
Tool carrier top and bottom XYZ, VDI40 with 12 stations (SW380)
Main/counter spindle, spindle clearance D120mm, turning length 1600mm
0
0
1920
160 (M1)
1760 (M1)
160 (M5)
1760 (M5)
2060
-140
SW 380
SW 380
105
340
60
160
1740
380
85
SW380
369,5
266
0
0
70
70
100 100
667, 5
62
167, 5
213
20°
213
167, 5
73
290
1600 300300
20°
1580
160
180
210
542
524
246
134
134
62
73
min.300
M1 M5
N1
N2/N3
N1
N1
N2
N2
N3
N3
N3
N2/N3
N2/N3
N1
Arbeitsraum G400 - A11 GSP RevXYZ 12067280
617,5 wird 667,5

15
INDEX G400.2, INDEX G500
DIW057EN - 09.04.21
Tool holder - Technical Information
USAGE INFORMATION
1
2
3
Work area of INDEX G400.2
Tool carrier top and bottom XYZ, VDI40 with 12 stations (SW380)
Main/counter spindle, spindle clearance D120mm, turning length 1600mm
0
0
1920
160 (M1)
1760 (M1)
160 (M5)
1760 (M5)
2060
-140
SW 380
SW 380
105
340
60
160
1740
380
85
SW380
369,5
266
0
0
70
70
100 100
617, 5
62
167, 5
213
20°
213
167, 5
73
290
1600 300300
20°
1580
160
180
210
542
524
246
134
134
62
73
min.300
M1 M5
N1
N2/N3
N1
N1
N2
N2
N3
N3
N3
N2/N3
N2/N3
N1
Arbeitsraum G400 - A11 GSP RevXYZ 12067280

16 INDEX G400.2, INDEX G500
DIW057EN - 09.04.21
Tool holder - Technical Information
USAGE INFORMATION
1
2
3
Work area of INDEX G400.2, INDEX G500
Tool carrier top XYZ, VDI40 with 12 stations (SW380)
Tool carrier bottom XZ, VDI40 with 18 stations (SW480)
Main/counter spindle, spindle clearance D120mm, turning length 1600mm
0
0
1920
340
60
160
1740
380
85
SW380
369,5
266
0
100 100
667, 5
1580
160
180
210
542
524
246
M1 M5
N1
N2/N3
N1
N1
N1
160 (M1)
1760 (M1)
160 (M5)
1760 (M5)
min. 300
2060
-140
SW 480
SW 480
105
0
315
1600
300
20°
20°
300
166,5
134
267
112
123
135
166,5
112
123
135
200
120
134
267
N2
N2
N3
N3
N3
N2/N3
Arbeitsraum G400/G500 - A11 GSP RevXZ 12093064
617,5 wird 667,5

17
INDEX G400.2, INDEX G500
DIW057EN - 09.04.21
Tool holder - Technical Information
USAGE INFORMATION
1
2
3
Work area of INDEX G400.2, INDEX G500
Tool carrier top XYZ, VDI40 with 12 stations (SW380)
Tool carrier bottom XZ, VDI40 with 18 stations (SW480)
Main/counter spindle, spindle clearance D120mm, turning length 1600mm
0
0
1920
340
60
160
1740
380
85
SW380
369,5
266
0
100 100
617, 5
1580
160
180
210
542
524
246
M1 M5
N1
N2/N3
N1
N1
N1
160 (M1)
1760 (M1)
160 (M5)
1760 (M5)
min. 300
2060
-140
SW 480
SW 480
105
0
315
1600
300
20°
20°
300
166,5
134
267
112
123
135
166,5
112
123
135
200
120
134
267
N2
N2
N3
N3
N3
N2/N3
Arbeitsraum G400/G500 - A11 GSP RevXZ 12093064

18 INDEX G400.2, INDEX G500
DIW057EN - 09.04.21
Tool holder - Technical Information
USAGE INFORMATION
1
2
3
Work area of INDEX G400.2, INDEX G500
Tool carrier top XYZ, VDI40 with 12 stations (SW380)
Tool carrier bottom XZ, VDI40 with 18 stations (SW480)
Main/counter spindle, spindle clearance D120mm, turning length 2300mm
0
0
340
60
160
2440
380
85
SW380
369,5
266
0
100 100
667,5
160
210
542
524
246
M1
N1
N1
N1
N1
617,5 ist 667,5
0
min. 300
60
2560
105
SW 480
2280
315
100
180
2620
2100
100
20°
112
135
134134
166,5
166,5
123
360 (M1)
2260 (M1)
360 (M5)
2460 (M1)
160 (M5)
2260 (M5)
160 (M1)
2460 (M5)
2100
267
112
123
135
20º
200
120
267
Arbeitsraum G520 - A11 GSP RevXZ und Montage des oberen Revolvers !!!!!!!!!!
12093137
N3
N3
N2
N2 N3 N2/N3
M5
SW 480
N2/N3
N2 N3

19
INDEX G400.2, INDEX G500
DIW057EN - 09.04.21
Tool holder - Technical Information
USAGE INFORMATION
1
2
3
Work area of INDEX G400.2, INDEX G500
Tool carrier top XYZ, VDI40 with 12 stations (SW380)
Tool carrier bottom XZ, VDI40 with 18 stations (SW480)
Main/counter spindle, spindle clearance D120mm, turning length 2300mm
0
0
340
60
160
2440
380
85
SW380
369,5
266
0
100 100
617, 5
160
210
542
524
246
M1
N1
N1
N1
N1
0
min. 300
60
2560
105
SW 480
2280
315
100
180
2620
2100
100
20°
112
135
134134
166,5
166,5
123
360 (M1)
2260 (M1)
360 (M5)
2460 (M1)
160 (M5)
2260 (M5)
160 (M1)
2460 (M5)
2100
267
112
123
135
20º
200
120
267
Arbeitsraum G520 - A11 GSP RevXZ und Montage des oberen Revolvers !!!!!!!!!!
12093137
N3
N3
N2
N2 N3 N2/N3
M5
SW 480
N2/N3
N2 N3

20 INDEX G400.2, INDEX G500
DIW057EN - 09.04.21
Tool holder - Technical Information
USAGE INFORMATION
1
2
3
Swivel range
Tool carrier XYZ bottom left, VDI40 with 12 stations
A-A
G400 / G420
Durchschaltraum WT unten links Rev XYZ
12042630
A
A B
B
B-B
()
D
D
SW
max. R
D
max. R150
0
0
0
0
0
0
414,5
38
153
154
380
R415
R415
344
406
163
150
185
0
185
0
0
34,5
23
0
0
414,5
(38)
153
154
3SW80
344
406
163
R415
R450
50%