WAGNER DSD12 User manual

Operating Manual
Triple-Cutter Turning Head DSD12

2 Brief instructions DSD12
Inhalt
1. Preface 3
2. Safety Instructions 5
3. Working with a DSD12 6
4. Spare Parts 8

Brief instructions DSD12 3
Preface
1. Preface
You bought a high-quality commodity, which facilitates effective and economic ope-
ration. Our Thread Rolling Heads are known for their high quality and long-life cycle.
We hope that you are fully satisfied with our products.
This manual is made to help you taking the first steps with your new WAGNER®pro-
duct, explain the operation and point out possible hazards.
After Sales Service
If you need further advice, training or ulterior help or if you are not satisfied with your
WAGNER®product, please contact us!
Our sales team is at your disposal.
The contents of this manual should be read, understood and followed in every aspect
by everybody involved. This is especially true for the safety instructions and notes on
hazards found throughout this manual (see chapter 2 Safety Instructions).
Following these instructions will help avoid accidents, mistakes and malfunctioning.
This documentation includes all information necessary for using and maintaining
your WAGNER®Thread Rolling Head. The documents are up-to-date at the time the
product was manufactured.
Use only these documents when working with the Thread Rolling Head.
Wagner Tooling Systems Baublies GmbH reserves the right to make technical chan-
ges to improve the product, if and when appropriate.
If the instructions in this manual are not followed, and this negligence results in mis-
takes, damages, loss of production, etc., Wagner Tooling Systems Baublies GmbH
will not be responsible for any subsequent damages.
Due to copyrights, we must point out that this manual is for internal use only. Provi-
ding this manual to third parties is prohibited.
During operation, maintenance and repair the respective national and international
»regulations for the prevention of industrial accidents« apply in addition to the pre-
viously listed instructions. The operating instructions, particularly the chapter »Safety
instructions«, have to be read in any case. Following the safety instructions and legal
regulations helps to prevent doing damage to persons, machines and our product.
Warranty
In case of buying and using original WAGNER®spare parts and accessories, we gu-
arantee proper operation of the Thread Rolling Head.
We exclude any warranty for damage of persons, machines and our products, in
case of:
• improper mounting and operating
• using no original spare parts
• removing components and assemblies
• arbitrarily modifying our products
• using broken rolling heads.
When using accessories which are not made by WAGNER®or explicitly approved by
us, we exclude any warranty.
Generally, we are not liable for damages of all kind caused by removing safety
equipment on the machine. We imply that our products are only set up on technically
proper operating machines.

4 Brief instructions DSD12
Preface
CAUTION:
Do not use this product for any other purpose than its designated use! Follow
the »safety instructions and notes on hazards«! This product should only be
used by trained specialists; otherwise its use may constitute a risk to life and
limb of the user and cause damage to material property. For such cases, the
manufacturer declines all responsibility.
Do not use force when mounting, demounting and operating. You could otherwise
damage the rolling head or the machine.
Initial operation
Please carry out an operational check before initial operation of the Thread Rolling
Head.

Brief instructions DSD12 5
Safety Instructions
2. Safety Instructions
Persons in charge of operating, maintaining and repairing always have to read and
understand the manual and the safety instructions. People who are under the influ-
ence of alcohol and/ or drugs may cause accidents!
When mounting, please bear in mind the weight of the thread rolling attachment
and, if necessary, lift by means of a lifting equipment.
Take care that the cutting sides between the attachment and the machine are clean.
Dirt may affect the precision of the workpiece.
Generally, shut down the machine at the main switch when mounting the attachment.
Make sure that the spindle cannot start unexpectedly when exchanging the rolls.
Remove all tools and inspection equipments from the working chamber of the ma-
chine before setting into operation. There is a risk of injury by centrifuging tools and
equipment!
Close the safety gate or protection cover before operating! Hurtling chips and broken
heads or work pieces may cause damage to people and machines.
Make sure that the Thread Rolling Head cannot disengage during operation.
When closing the Thread Rolling Head do not touch the head, do not touch rotating
tools: risk of injury!
Please check and handle the thread rolls extremely carefully. The rolls have square
edges. If necessary, wear safety gloves!
Please make sure the Thread Rolling Head is protected and fastened appropriately
when transporting.

6 Brief instructions DSD12
Working with a DSD12
3. Working with a DSD12
Application area:
The DSD 12 turning head is used for cylindrically stripping workpieces. The diameter
of the journal that has to be turned can be between ø 1.5 mm and ø 12 mm.
The DSD 12 can be used both stationary with rotating workpieces (e.g. on a turret in
a lathe) and as a rotating unit with stationary workpieces.
Operation:
The DSD 12 turning head is equipped with 3 cutting inserts, which are distributed
evenly around the circumference, which enables the workpiece to be centred opti-
mally. The toolpiece is positioned during the machining so that it is centred on the
workpiece and the working feed moves it in the 'Z' direction so that it is over the
workpiece. It is retracted in the 'Z' direction with the spindle still rotating after the
programmed turning length has been reached. Fast traverse can be used for the
retraction movement.
Fitting the cutting inserts:
The cutting inserts are fitted compactly in the cutting insert holders [100] and a coun-
tersunk screw [110] is used to secure them in place. A T7 Torx screwdriver must be
used to tighten up the screw.
Setting up the diameter:
The coarse adjustment is realised by offsetting the cutting insert holders in the serra-
tions. You must always ensure that all three holders are positioned in the same way
in the serrations. The serration pitch is 1 mm, i.e. if the holders are offset by one
serration then the turning ø setting will be changed by 2 mm.
Fine adjustment is realised centrally for all three cutting insert holders by using two
threaded pins [30]. Never over-tighten the three clamping screws [120] (max. 2 Nm).
The threaded pin marked with a '–' should be unscrewed until the diameter that is
approx. 0.5 – 1 mm bigger than the required turning diameter can be set up by
screwing in the threaded pin marked with a '+'. The '+' threaded pin should now be
screwed out slightly. The threaded pin marked with a '–' should now be screwed in so
that the cam ring [20] can be turned until the required setting is set up. One turn of
the threaded pin effects a diameter change of 0.08 mm.
A hardened bolt, whose diameter corresponds to the desired turning diameter, can
be used for a fast and precice adjustment of the turning diameter
The second threaded pin can now be screwed back in. The second threaded pin must
only be screwed in place lightly (approx. 3 Nm); never over-tighten!
Now tighten up the clamping screws [120] (approx. 4 Nm).

Brief instructions DSD12 7
Working with a DSD12
Maintenance:
The turning head can be dismantled into separate parts for maintenance and
cleaning. Proceed as follows:
1. Unscrew and remove the cylinder head bolts [120] that secure the cutting insert
holders in place and then remove the cutting insert holders [100] and the slide
bars [40].
2. Unscrew the cylinder screws [90] and then detach the mounting shank from the
base body [10].
3. Fully unscrew and remove the two threaded pins [30] used for setting up the
diameter.
4. The cam ring [20] can now be pulled away from the base body [10].
5. Clean and lightly oil all of the parts, especially the smooth surfaces and the ser-
rations.
Reassembly:
1. Slide the cam ring [20] onto the base body [10]. The grooves must be pointed in
the direction base body’s flat face.
2. Screw the threaded pins [30] back in and position the cam ring [20] relative to
the base body [10] so that the threaded pins fit in the relevant milling grooves.
3. The base body [10] must be mounted on the holding flange and the 3 cylinder
head bolts [90] must be screwed back in to hold it in place.
4. Refit the slide bars [40] in the base body’s guide so that the slide bar’s pin sits in
the relevant recess in the cam ring [30]. You must always ensure that the num-
bering on the slide bar concurs with the numbering on the base body.
5. Refit the cutting insert holders [100] in the slide bar’s serrations [40] so that the
required turning diameter can be set up as closely as possible. A pin or a drill
shank can be used to determine the approximate turning diameter. Insert the cy-
linder head bolts [120 with the washers [130] and tighten the screws slightly
(approx. 2 Nm).
You must ensure that the serrations are clean, that the holder’s serrations sit cor-
rectly in the slide bar’s serrations and that all three holders are fitted in the same
positions, i.e. in the same positions in the serrations.
Now use the threaded pins [30] to set up the turning diameter (a pin or a drill shank
can be used as the gauge) and then tighten up the cylinder screws [120] to lock the
setting in place.

8 Brief instructions DSD12
Spare Parts
4. Spare Parts
List of spare parts / accessories DSD 12
Item Quantity Designation Article No.
10 1 base body 74663100
20 1 cam ring 74663200
30 2 ball-ended thrust screw 03016132
31 1 threaded pin 03016133
40 1 set slide bar 78058500
60 3 feather key 74663600
90 3 cylinder head bolts M 5 x 25 02015059
200 1 screwdriver 4 02677004
DSD carbide insert holder
100 1 set carbide insert holder 74663400
110 3 countersink screw M 2.5 x 9 02018002
120 6 cylinder head bolts M 4 x 16 02015005
130 6 washer 02080007
150 1 T7 Torx screwdriver 02676907
160 1 screwdriver 3 DIN 911 02677003

Brief instructions DSD12 9
Spare Parts
Exploded drawing

10 Brief instructions DSD12
Spare Parts
Drawing No. 74663000
glued with
Loctite