ALBERTI TURBODRILL User manual

INSTRUCTION

BOOK

TURBODRILL /

TURBOFLEX

TURBODRILL / TURBOFLEX

ANGLE HEADS

TABLE OF CONTENTS

SafetyRecommendations............................................................

Tool Run-in..................................................................................

Determining the Retaining Block Thickness................................

Mounting the Retaining Block.....................................................

Retaining Block Mounting Errors.................................................

Radial Positioning of Angle Heads Around the Z Axis................

Re-setting the Graduation Ring (if applicable)............................

Air / Oil Regulator Installation.....................................................

Air / Oil Regulator Operation......................................................

Air / Oil Regulator Picture Diagram............................................

Troubleshooting.........................................................................

IC-300 / KC-300 Cutting Tool & Collet Instructions...................

RA-100 / RA-200 Cutting Tool & Collet Instructions....................

Turbodrill (30 Taper) / NSK Tooling Chart..................................

Turboex / NSK Tooling Chart....................................................

Collet Chart.................................................................................

Warranty......................................................................................

Parts and Service........................................................................

Page

All information in this manual is subject to change without notice.

Please contact Koma for more information.

SAFETY RECOMMENDATIONS

- Do not touch or hold anything near the head when it is running or

rotating in any manner.

- When the angle head is mounted in the machine spindle or tool

magazine, be sure it is not hot.

- When the head is to be used, ensure the input taper is correctly mated

to the machine spindle, the arrester arm and block are engaged

properly, and that the cutting tool is clamped tightly before activating the

air circuit to start the spindle rotating.

- Make sure the cutting tool is designed to run in the same direction as the

NSK air motor (R = Right and L = Left).

- Use caution during set-up of the head as personal injury may occur if

dropped or mishandled.

AUTOMATIC TOOL CHANGER

- Check the Automatic Tool Changer (ATC) speed and manually check

loading and unloading of the head into the machine spindle prior to

running in automatic cycle.

- Routinely check the stopper block to be sure it is clean and free of chips.

NSK CARTRIDGE INFORMATION

- The threaded input of the cartridge is not qualied to the output. To

ensure accurate positioning, install the NSK cartridge into the head,

insert the ground mandrel in the collet and indicate to conrm / adjust

the position.

- The NSK cartridges are not designed to withstand high axial and

radial thrust.

- A weekly visual inspection and cleaning of the head is recommended.

- Be sure to check the oil level on the oil lubricator periodically.

- Always use cutting tools with precision ground shanks to ensure proper

tightening and minimal tool runout.

- For extended reach machining, a CN-01 extension spacer may be used.

Koma Precision Inc. • 20 Thompson Road, East Windsor, CT 06088

1-800-249-KOMA Fax: 860-623-4132

www.komaprecision.com • [email protected]

TOOL RUN-IN

For new heads or units that have not been used for over (1) month, the

motor speed should be increased gradually. Increase the air pressure

slowly using the pressure adjustment knob (refer to drawing on page 8),

over a period of 15-20 minutes, until the unit is at maximum operating

speed.

DETERMINING THE RETAINING BLOCK THICKNESS

Use the following procedure to correctly to locate the retaining block , with

a 3mm space between end of pin and bottom of 18mm ID in the block.

1. Mount the angle head in the machine tool spindle and measure

dimension X. (Fig 1a)

2. Remove the angle head from the machine tool spindle and slip the

retaining block on the arrester pin.

3. Measure dimension W. (Fig 1b)

4a. If dimension Wis less than dimension X, prepare a shim with

thickness as below:

S= (X - W + 3mm)+0.5mm

4b. If dimension Wis greater than dimension X, machine the thickness

of the retaining block as below:

W= (X + 3mm)+0.5mm

Koma Precision Inc. • 20 Thompson Road, East Windsor, CT 06088

1-800-249-KOMA Fax: 860-623-4132

www.komaprecision.com • [email protected]

Koma Precision Inc. • 20 Thompson Road, East Windsor, CT 06088

1-800-249-KOMA Fax: 860-623-4132

www.komaprecision.com • [email protected]

DETERMINING THE RETAINING BLOCK THICKNESS

Arrester pin

Retaining

block

Shim

(if required)

Arrester pin

Retaining block

gap between

bottom of

arrestor pin and

retaining block

Alberti head shown in

machine tool spindle,

ready to run.

3mm (.118”)

Shim (if required)

360

Fig. 1a

Fig. 2

Fig. 1b

Standard Stopper Block

4Koma Precision Inc. • 20 Thompson Road, East Windsor, CT 06088

1-800-249-KOMA Fax: 860-623-4132

www.komaprecision.com • [email protected]

MOUNTING RETAINING BLOCK •ORIENTATION OF ARBOR

To locate the retaining block at the correct distance from the spindle center

line and to assure the correct orientation of the arbor with reference to the

arrester pin, use the following procedure:

1. Secure the retaining block by slightly tightening the mounting screws.

2. Loosen set screws 06 one turn and fit the head into the machine spindle

(make sure that the arrester pin slips in easily).

3. Fully tighten the mounting screws of the retaining block.

4. Remove and carefully clean set screws 06.

5. Check whether the collet chuck is properly oriented for tool change.

6. Put a few drops of Loctite 242e or equivalent on the threads of set

screws 06 then tighten set screws 06 on orientation ring 10.

7. Unload and load the head several times with the automatic tool changer

to check for correct operation.

8. Dowel the retaining block to the machine tool to prevent any shifting.

ATTENTION: During the first automatic tool change, make sure that the

angle head does not interfere with other components of the system.

Koma Precision Inc. • 20 Thompson Road, East Windsor, CT 06088

1-800-249-KOMA Fax: 860-623-4132

www.komaprecision.com • [email protected]

RETAINING BLOCK MOUNTING ERRORS

If the distance from the machine tool spindle centerline and the centerline

of the retaining block bushing is not correct, the arrester pin on the angle

head will not seat properly in the retaining block bushing. This will result in

the conditions shown below, causing damage to the angle head bearings.

retaining block

mounted too far

from spindle centerline

retaining block

mounted too close

to spindle centerline

Retaining

block bushing

Arrester pin

Retaining

block

Retaining

block bushing

Arrester pin

Retaining

block

If the arrester pin is completely compressed against the bottom of the

retaining block, the shank of the angle head will not seat properly in the

machine tool spindle, causing damage to the angle head bearings. The

3mm/.118” gap between the bottom of the arrester pin and the retaining

block must be met in order for the angle head shank to seat properly in the

machine tool spindle (see page 3).

Wrong!

Correct! 3mm

(.118”)

Arrester pin

Retaining block

6Koma Precision Inc. • 20 Thompson Road, East Windsor, CT 06088

1-800-249-KOMA Fax: 860-623-4132

www.komaprecision.com • [email protected]

RADIAL POSITIONING OF TURBOFLEX ANGLE HEADS

Applies to: RA-200, RA-100, RA-271E,

RA-151E, & RAX-271E NSK Cartridges.

To position the angle head body radially

around the Z axis of the machine tool,

use the following procedure:

1. Mount the angle head on the machine.

2. Loosen screws 08.

3. Rotate angle head body 30 to the

required position.

3. Clamp a ground mandrel in the collet

of the NSK output and use a dial gauge

with a flat point to check for precise

position.

5. Tighten screws 08. Suggested

screw torque 8-10 Nm (5.9-7.4 ft.lbs.).

Do not use an extension for the

Allen wrench.

RE-SETTING THE GRADUATION RING (IF APPLICABLE)

Applies to: RA-200, RA-100, RA-271E,

RA-151E, & RAX-271E NSK Cartridges.

When the head is correctly oriented

and positioned, graduated ring 12 can

be reset. Loosen screw 13 and rotate

the ring until the zero coincides with the

reference notch in the indexing ange.

Re-tighten screw 13.

AIR / OIL REGULATOR (#AL40-N02-3Z) INSTALLATION

Refer to picture diagram on page 8 for these instruction.

- Mount this unit on the machine tool, in a convenient location with easy

access for servicing (maintaining the proper oil level and draining of

the water).

- Fill oil reservoir using ISO-VG15 (paraffin based) oil or equivalent.

- Connect the air input line to the input side of the unit. (Be sure shut-off

valve is “OFF”).

NOTE: It is recommended that a Quick Disconnect be used for the input

air line!

- Connect the air output line to the stopper block (1/8” NPT) or thru spindle

circuit. (Stopper block set-up is most common).

- Adjust the air pressure using the air pressure regulator adjustment knob.

Recommended pressure is 58 - 87 psi (0.4 - 0.6 MPa).

- Open the shut-off valve and adjust the oil drip rate using the oil lubricator

adjustment knob to 1-3 drops/min. (This is a rough setting and will need

to be fine-tuned once the head is connected).

AIR / OIL REGULATOR (#AL40-N02-3Z) OPERATION

Refer to picture diagram on page 8 for these instruction.

- Oil Volume: Check the oil reservoir at least once a week. Use caution to

avoid under and over filling of the reservoir as it can cause the oil delivery

rate to vary.

CAUTION: Be sure to disconnect the air input line and check for zero

pressure at the gage, prior to opening the oil filler cap!

- Water in the Air Filter: Drain the water from the moisture reservoir by

unscrewing the black cap at the bottom of the reservoir bowl. A drain

hose may be installed on the bottom of the reservoir by depressing the

red button on the end of the black cap and inserting the correct diameter

hose into it.

- Adjusting the Oil Drip Rate: Run the head at the desired air pressure/

RPM and adjust the oil drip rate to the recommended amount by turning

the lubricator adjustment knob. Turn the CCW to increase the drip rate

and CW to decrease the drip rate.

- Remove Oil & Moisture Regularly: Remove and replace the oil in the

reservoir once a month to ensure a pure lubricant for the motor. Moisture

may collect and mix with the oil in the reservoir causing premature

damage to the motor. The easiest method to remove the oil and clean the

bowl is to remove it from the reservoir. Depress the release buttom in the

downward direction and rotate the bowl for removal.

- Oil Grade: ISO VG-15 (paraffin based oil) is recommended.

8Koma Precision Inc. • 20 Thompson Road, East Windsor, CT 06088

1-800-249-KOMA Fax: 860-623-4132

www.komaprecision.com • [email protected]

AIR / OIL LUBRICATOR DIAGRAM

AL40-N02-3Z Air / Oil Lubricator w/ Shut-Off Valve

Pressure Regulator

Adjustment Knob

Pressure Gage

Air Input

(1/4” NPT)

Air Filter

Moisture

Reservoir

Water

Drain

Oil

Reservoir

Bowl Reservoir

Release Buttons

Air Output with

Shut-Off Valve

Oil Filler Cap

Oil Lubricator Sight Glass

& Adjustment Knob

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