WAGNER ZR22-E User manual

Operating Manual
Cutting-in head ZR22-E
Product No. 72916800

2 Operating Manual ZR22-E
Table of Contents
1. Preface 3
2. Security advice 5
3. Main components 6
3.1. The base body 6
3.2. The guide ring 6
3.3. The eccentric ring 6
3.4. Knives /stinger bits 6
3.5. Chaser holder 6
4. The cutting head insert‘s design and control system 7
5. Grinding the knives 8
6. Preparing the cutting head for machining 9
6.1. Adjusting the knives 9
6.2. Fitting the chaser holders 9
6.3. Setting up the diameter 10
7. The machining 11
7.1. Setting values knives size 02 (6.5 x 14.5 x 32) 11
7.2. Special cutting insert holders 12
8. Spare parts 13
8.1. List of spare parts 13
8.2. Spare parts 14
8.3. Functional dimensions 15
8.4. Installation drawing 16

Operating Manual ZR22-E 3
Preface
1. Preface
Dear customer,
you purchased a high-quality technical tool which guarantees you an efficient work
performance.
The cutting heads of our company are widely known for their high quality and long-
life cycle. We do hope that you are perfectly satisfied with our products, too.
Customer care even after purchase:
This operating manual helps you to make the first steps with the new WAGNER®pro-
duct. It helps to understand its
Function and alludes to possible hazards.
However, should you be in need of further consulting service, training or some other
advice do not hesitate to contact us.
Even if you are not happy with one of our WAGNER®products!
Our marketing staff is more than glad to help you at anytime.
This operating manual should be read, understood and paid attention to by every
person in charge.
In particularly this applies for safety- and hazard warnings which are specially indi-
cated. (See chapter 2. Security Advice)
Following these advices helps to avoid accidents and faults.
This manual provides all information on operation and maintenance of your WAG-
NER®Thread cutting head. The information laid down in this manual is state of the
art according to the production date of the product.
Please use only this manual when working with the thread cutting head. The Wagner
Tooling Systems Baublies GmbH reserves the right to technical amendments regar-
ding the improvement of this product. However, the Wagner Tooling Systems Bau-
blies GmbH cannot held liable for any faults, damages, failures and production loss
resulting thereof caused by disregarding of some aspects mentioned in this manual.
Due to copyright reasons we would like to point out that this operating manual is for
internal use only. Please refrain from distributing it to third parties.
In addition to the instructions mentioned before, national and international „safety in-
structions and rules for accident prevention“ apply when operating and maintaining
the cutting head. The operating manual, in particular, the „safety instructions“ have
to be read carefully. Through observing the safety instructions and legal regulations
damage to persons, mechanical breakdown and damage to the cutting head should
be avoided.
Warranty
We warrant perfect function of the thread cutting heads when purchasing and using
original WAGNER®spare parts and equipment.
We cannot hold liable for any damage to persons, mechanical breakdown and da-
mage to the thread cutting head in the event of:
• Improper installation and operation
• Usage of non original spare parts
• Removal of component parts and screws
• Unauthorised modifications of our products
• Usage of damaged cutting heads.
Please note:
Read this operating
manual carefully be-
fore initial operation
and take note of the
hazard warnings!

4 Operating Manual ZR22-E
Preface
We cannot hold liable for any use of components which are not manufactured or not
approved by WAGNER®.
We cannot hold liable for damages occurring through removing of safety devices of
the machine. We imply the placing into operation of our products on efficient tech-
nical machines.
Normal use:
Don’t use force when mounting, dismounting and operating the cutting head. Other-
wise you will cause damages to the cutting head or the machine.
Initial operation
Check the function of the thread cutting head before initial operation.
Limitation of liability:
Please note: Use this pro-
duct only for the purpose it is
manufactured for!
Please take notice of the sa-
fety instructions and hazard
warnings! The thread cutting
head should only be used
by trained technical staff.
Otherwise health hazard or
danger of life and damage
to property cannot be ruled
out. In that case we cannot
hold liable for any of these
damages.

Operating Manual ZR22-E 5
Security advice
2. Security advice
• Persons operating, maintaining or servicing the cutting head should always
read and understand the operating manual in particular the safety inst-
ructions. Persons under the influence of alcohol and /or drugs may cause
accidents!
• Take into account the weight of the thread cutting head upon installation. If
necessary lift it with a lifting gear.
• Please take note that the cutting sites between tool and machine are kept
clean. Should they be fouled the accuracy of the workpiece is affected.
• When installing the tools switch off the machine at the line switch. When
changing the chaser holders and chasers take note that the tool shaft isn’t
starting unexpectedly.
• Remove all tools and testing equipment from the workspace of the machine
before activating it. Risk of injury arises through tools and testing equip-
ment which are flung about!
• Close guard door or protection case before machining. Flying chipping and
damaged tools or workpieces can cause damage to persons or mechanical
breakdown.
• Make sure that the thread cutting head isn’t loosening when machining.
• Don’t touch the cutting head upon closing. Don’t touch rotating tools: Risk of
injury!
• Be very careful when dealing with the chasers. The edges of the chasers are
very sharp. Wear safety gloves if necessary!
• Please ensure that the thread cutting head is properly secured and attached
whilst transporting.

6 Operating Manual ZR22-E
Main components
3. Main components
(see Installation Drawing No. 00360258)
3.1. The base body
The base body [10] holds and guides the chaser holder [190].
Four cylinder screws [100] are used to flange-mount the base body onto the machine
spindle or else it can be clamped in the chuck using a mounting shank.
3.2. The guide ring
The adjustable guide ring [80] is mounted on the base body [10]. The external
force needed to control the cutting head is transferred to the guide ring through the
grooved ball bearing [81].
3.3. The eccentric ring
The eccentric ring [20] is attached to the guide ring [80] and they generate the axial
movement. The stinger bit’s feed motion is generated via the eccentric ring’s chamfer.
The machining diameter can also be re-adjusted by turning the eccentric ring.
3.4. Knives /stinger bits
The stinger bit [200] is the actual toolpiece. It is designed to match the relevant
groove shape and is available in various qualities and with different coatings.
3.5. Chaser holder
The knives [200] are clamped in the chaser holders [190]. The guide ring’s axial mo-
vement is converted into the stinger bit’s radial adjustment movement by the sliding
block chamfers on the holders.

Operating Manual ZR22-E 7
The cutting head insert‘s design and control system
4. The cutting head insert‘s design and control system
Four cylinder screws are used to attach it directly onto the spindle in tail spindle or
slide units or else a mounting shank can be used in the chuck.
The cutting head’s installation dimensions can be found in the Installation Drawing
No. 00360216.
Drawing No. 00366546 shows you the control principle and the control paths.
Axial movement generated by the guide and eccentric rings opens and closes the
cutting head. The chamfers on the eccentric ring and the sliding blocks, which are
mounted on the chaser holders, convert the guide and eccentric ring’s axial move-
ment into the stinger bit’s radial movement.
A control box (not included in the package) is needed to transfer the clamping force
to the guide ring via a ball bearing. This can be either a ring or a fork design.
A dual-effect pneumatically or hydraulically operated cylinder can generate the ad-
justment movement, but you need to be able to control the speed and guarantee
even feed rates. The feed rate speed must be set up to match the raw material that
is being machined.
The required clamping force will depend on the durability of the material, the shape
and the size of the stinger bit and the toolpiece’s rotational speed. The following set-
tings can be used as a guideline:
Spindle rpm
(min-1)
Clamping force
(N)
1000 400
2000 880
3000 1800
Installation drawing
00360216:
page 15
Control principle & control
paths:
page 16

8 Operating Manual ZR22-E
Grinding the knives
5. Grinding the knives
The stinger bit’s cutting angle γmust match the material that has to be machined. The
standard settings can be found in the following table:
Material Cutting angle
Free-cutting stainless steels 20 - 25°
Structural steels 20 - 25°
High-alloyed steels (stainless) 22 - 30°
Grey cast iron 10 - 20°
Short-chipping brass (MS 58) 0 - 5°
Long-chipping brass (MS 60 - 63) 15 - 20°
Bronze
Copper 20 - 30°
Aluminium alloys 20 - 30°
Synthetic material (soft) 15 - 25°
Synthetic material (hard) 5 - 15°
Any universal toolpiece grinding machine can be used to whet or re-grind the stinger
bit. The bit can be reground until the remainder is too short.
So-called shims are supplied with the chaser holders in order to ensure that very short
stinger bits can be clamped in place securely.

Operating Manual ZR22-E 9
Preparing the cutting head for machining
6. Preparing the cutting head for machining
6.1. Adjusting the knives
The stinger bits [200] must be set up in the holders [190] so that they are even and
are correctly positioned in relation to the workpiece in order to obtain a smooth sur-
face.
The adjustment settings will depend on the diameter of the workpiece and they can
be found in the Table under Section 7.1 Stinger bit size 02 (6.5 x 14.5 x 32).
Always use the adjustment device (Figure 1) to help you set up.
The stinger bit must have been fitted in the chaser holder beforehand and it should
only be lightly clamped in place so that it can still be moved using the adjustment
screw [230].
Adjust the gauge’s sensor bolt in the adjustment device so that it lies up against the
fitted setting-up gauge and then reset the gauge to read »0«.
Now remove the setting-up gauge and then fit the chaser holder with the stinger bit
already fitted in it (Figure 2).
The stinger bit should now lie up against the stop bolt and the height should be ad-
justed so that the gauge’s sensor bolt is up against the grooving tooth. Now use the
knurled screw to lock the chaser holder in place and then use the adjustment screw
to set the bit up to the defined setting. The two clamping screws [210] on the holder
can now be tightened up (always tighten up the screw that is closest to the cutter first
to prevent it from twisting in place).
6.2. Fitting the chaser holders
After the stinger bit has been set up; refit the chaser holder [190] in the cutting head.
In this case you must withdraw the eccentric ring [20] with the guide ring [80] so that
the chaser holder [190] can be swung into place in the central guide.
Figure 1: Setting device with setting gauge Figure 2: Setting device with chaser in chaser holder
hand on dial gauge measuring pin setting gauge
0-position
clamping screw clamping screw
hand on measuring clamping screw
dial gauge
holder
setting value pin
chaser
adjusting
screw
chaser
holder
stop pin
Stinger bits size 02
(6.5 x 14.5 x 32):
chapter 7.1, page 11

10 Operating Manual ZR22-E
Preparing the cutting head for machining
Proceed as follows to realise this:
1. Slide the eccentric ring together with the guide ring back into place – head open
position.
2. Now use release pin on the combination wrench [290] to the push the stop bolts
[170] through the holes that are above them.
3. Slide the eccentric ring and the guide ring back again until the pin can be pulled
out slightly.
4. The chaser holder [190] can now be inserted in the holes. Ensure that the sur-
faces are clean!
5. Check that the holder slides easily in the guides, i.e. the holder that has been
swung in must have been pushed outwards from the pressure sleeves, as correct
operation depends on this.
6. Now slide the eccentric ring forwards again. The holder should now be com
pressed. You must also ensure that the holder has been swung into the central
guide correctly. The stop bolt, which prevents the holder from swinging back out
inadvertently, will lock into place automatically. The chaser holder is changed
using this same procedure.
6.3. Setting up the diameter
Turn the eccentric ring to set up the stinger bit diameter. The adjustment is a linear
adjustment. The setting is made using a sample part or a bolt that corresponds to the
smallest stinger bit diameter and with the head closed.
The diameter is set up by slackening off the six hexagon nuts [132] on the guide ring,
inserting the combination wrench with the serrations in the special hole and then
turning the eccentric ring until the sample part can no longer be turned manually.
Retighten the six hexagon nuts [132] to lock the setting in place.
The setting might have to be readjusted after the first machined part has been exa-
mined.
The numerical values on the peripheral scale are not diameter-related.
Altering the diameter setting by a single graduation will change it by approx. 0.12
mm.
Figure 3:
Setting up the diameter
hexagonal
piece
release pin
taper key

Operating Manual ZR22-E 11
The machining
7. The machining
Conditions: The cutting head must be installed in the machine. The control box and
control cylinder must also be fitted. The stinger bits must be mounted in the holders
and the holders must be fitted in the cutting head. The machining diameter has al-
ready been set up.
The machining process can be started if all of these conditions have been fulfilled:
• Now move the workpiece into position by the cutting head. It is extremely
important to ensure that the workpiece and toolpiece axes are aligned.
• The open and rotating cutting head will now move into position above the
workpiece.
• The control cylinder will press against the control ring when the correct
position is reached and the cutting head’s guide ring will then advance (i.e.
towards the workpiece). The stinger bit will now close and machine the work-
piece.
• The control cylinder will be retracted and the bit will re-open when the »head
closed« position is reached.
• The cutting head will now return to the start position and wait for the next
machining process.
You must ensure that the external stops limit the control cylinder’s path. The cutting
head’s internal limits (stop bolts and cylinder screws) are permanently unsuitable for
absorbing the control force.
7.1. Setting values knives size 02 (6.5 x 14.5 x 32)
machining
diameter *
Gauge Ø 40
setting value
machining
diameter*
Gauge Ø 40
setting value
2,00 1,60 14,09 0,85
1,55 0,80
4,03 14,45
1,50 0,75
6,58 14,81
1,45 0,70
7,63 15,16
1,40 0,65
8,48 15,49
1,35 0,60
9,22 15,82
1,30 0,55
9,88 16,13
1,25 0,50
10,46 16,44
1,20 0,45
11,02 16,74
1,15 0,40
11,52 17,04
1,10 0,35
12,01 17,32
1,05 0,30
12,46 17,61
1,00 0,25
12,90 17,89
0,95 0,20
13,31 18,00
0,90 0,15
13,70 0,85
* machined diameter on the finished workpiece

12 Operating Manual ZR22-E
The machining
7.2. Special cutting insert holders
Special cutting insert holder (11.5 mm high) fitted in a
standard holderZR22/D–0.00CD8.4–18.0
(Article-No. 73937400)
machining diameter setting value
21,30
1,10
4
0,95
5
0,80
6
0,65
7
0,45
8
0,26
9
0,05
10
Note:
Using this cutting insert holder reduces the holding range by -10
mm to Core Diameter 0.4 – 8.0 mm.

Operating Manual ZR22-E 13
Spare parts
8. Spare parts
8.1. List of spare parts
WAGNER®-Thread cutting head ZR22-E cutting-in 25°| Product No. 72916800
Item Quantity Designation Order No.
10 1 Head body 73894700
20 1 Eccentric ring 72917000
30 4 Pressure bush 70255600
40 4 Pressure spring 03310039
50 4 Headless screw M3x6 02030004
60 1 Feather key 02160501
70 1 Countersunk screw M6x15 02020157
80 1 Guide ring 72916900
81 1 Deep grrove ball bearing 02401112
82 1 Spacer ring 74147000
83 1 Snap ring 02084040
90 1 Sliding key 70257000
100 4 Cylinder screw M5x16 03011411
120 3 Clamping piece 70255700
130 6 Countersunk screw M5x8 03013302
131 6 Disc 02080008
132 6 Hex nut M5 02061004
140 3 Raised countersunk screw M4x6 02025003
160 1 Pressure spring 03310019
170 1 Stop pin 70255500
180 1 Cheesehead screw M3x8 02017003
190 4 Chaser holder on request
200 4 Knive on request
210 8 Clamping screw 03011301
220 4 Clamping plate according to holder type
230 4 Adjusting screw 02045102
290 1 Taper key 72166300

14 Operating Manual ZR22-E
Spare parts
8.2. Spare parts
Drawing No. 00360258

Operating Manual ZR22-E 15
Spare parts
8.3. Functional dimensions
Drawing No. 00360216

16 Operating Manual ZR22-E
Spare parts
8.4. Installation drawing
Drawing No. 0366546

Imprint
This operating manual is a publication made by Wagner Tooling Systems Baublies GmbH.
Information in this catalog is current as of publication date and subject to change.
All rights reserved.
Date: 10|2018
WAGNER Tooling Systems Baublies GmbH
Gutenbergstraße 4/1
D-72124 Pliezhausen
phone: [phone]
fax: [phone]
email: [e-mail]
web: www.wagner-werkzeug.de