外文資料--Precitech Grinder Systems Supplemental Manual

Precith Grinder System SuplemtalMual Instaltion &Operation Maul M17931/B January 25, 2011 AMETK Precith, Inc. 44 Blackbrook Road Keene, New Hampshire 03431 Tel: (603) 357-2511, Fax: (603) 358-6174 All rights reserved, including those to reproduce this manual or parts thereof in any form without the prior consent of AMETEK Precitech, Inc.M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual TABLE OF CONTENTS SECTION 1 Safety.1 General Cautions and Warnings.2Safety Suggestions.4 System Interlocks.8Warning Labels. SECTION 2 LVDT Tool Setter A15415-05.9Description.10 Calibration of the LVDT Tool Setter to the Work Spindle Centerline.13Tool Set Procedure for XZ Grinding using the LVDT tool setter.14 Calibration of the LVDT Tool Setter to the Rotary B Axis Centerline with Virtual Centering Software.15 Tool Set Procedure for XZB Grinding using the LVDT Tool Setter With Virtual Center Software.17 Calibration of the LVDT Tool Setter to the B axis centerline without Virtual Centering.19 Tool Set Procedure for XZB Grinding using the LVDT Tool Setter Without Virtual Center Software.20 SECTION 3 PI 50,000 RPM Motorized Air Bearing Spindle.22Setup of Horizontal Spindle Mounted on Rotary B axis A17750 (Top) or A16810-04 (Bottom).24 Setup of 45 Degree Fixed Spindle Mount (A16810-04) (right) -OR 45 Degrees to Vertical Adjustable Spindle Mount (A17750) used with 45 Degree Spindle Orientation (left).27 Setup of Vertical Spindle Mount A16810-03.30Setup of 45 Degrees to Vertical Adjustable Spindle Mount (A17750) used with Vertical Spindle orientation.32 Spindle Tooling for the PI 50,000 RPM Spindle.34Electrical Power to Grinder Cart (if Supplied).35 SECTION 4 SP-75 15,000 RPM Motorized Air Bearing Spindle.36Setup of Vertical Mount (A16810-03).37 Spindle Tooling for the SP75 Spindle.39SECTION 5 Loadpoint 80,000 RPM Turbine Air Bearing Spindle.41 Setup of the Loadpoint Spindle A17670.43Setup of the Loadpoint Spindle A18825 (shown - Nanoform 700) and A16857 (Nanoform 250).44 Spindle Tooling for the Loadpoint 80,000 RPM Spindle.SECTION 6 DIFFSYS Programming Notes.45 Vertical Grinder Setup.4645 Degree Grinder Setup.49 SECTION 7 General Grinder Operational Notes.54Grinder Spindle Commands.55 Tool Radius Compensation.General Grinding Parameters.57 M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual Typical Feeds, Speeds, and Depth of Cut.57 Mounting the Grinding Wheel.58Setting Wheel Height. Truing and Dressing.Balance The Spindle.58 Find Wheel Size and X Offset using the LVDT tool setter.59Find Wheel Size and X Offset without the LVDT tool setter. Touching Off or Finding the Surface.Depression or Hole at Center.59 Correcting X Offset using Stylus Instrument.60Correcting X Offset using Interferometer.61 Correcting Wheel Height using Microscope.62SECTION 8 Grinding Wheel Dressers and Truers.63 Pointer #1.64Pointer #265 Nib Dresser.Work Spindle Mounted Dresser.66 Flexible Dresser A17777.6745 Degree Downhill Spindle Dresser.68 Horizontal Spindle Dresser.SECTION 9 Other Accessories.69 Coolant System Options:.70Tool Holders and Ultracomp Mounts.71 SECTION 10 Cleaning and Maintenance.75Maintenance.76 Cleaning.SECTION 11 Service Documentation.78 M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 1 SECTION 1 Safety M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 2 General Cautions and Warnings Read The Instruction Manuals -The INSTALLATION AND MAINTENANCE MANUAL and the OPERATION MANUAL mustbrad n thorughly nderstod bythose rspoibl for the instaltion,piomaiencofhi Ultra Precision Machining System.Py prclar te t WARNING aCAUTION arghs tprvtiju tsnlrdgt mine. Operator Training -Operatos mut betrained ithe pro ad sfe us of thisUltra Precision Machining System. Be Safety Conscious -bserv alocl safety codes an regulations. D not perat orsevicthiMachining System unrfcdTerms Used WARNING -In this manul, the word WARNING isued toincate procedurswic,fotf,mayesult injrytprsl.SPECIF ARNIG GENRAL WRNIG (REF TO MANUL) CAUTION -In this manul, the word CAUTION isued toincate procedurswic,fot f,mayesult indamgh mhin. IMPORTANT -In this anul, th ord IMPORTANT isued toM17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 3 indcate nitm, the undrstandig ofwhic snecsary toachiev ful orpraio.NOTE -In this nul, the ord NOTE isued toincate ims ofan explatoryaretaspt,butarenotvalh x.Electrical Hazard Types Below are th ypes oflectrial hzrds aefind bythe safty guidelns for srvicngulrcin mngytm. Thsazrmbcteddu mitna dsrvi tsk. ci wokin othis ym stbeflrwithe lcrialhzrd types.Type 1 - Equipnt isfuly de-ngie. Type 2 - imet iergiz, but liv ciruits are covred oinsulatdopcludeacienashok.Type 3 - Eqipnt isi d li iits fls than 30Vrms, 240 VA, 20 jlsrxps acdencot. Type 4 - quipment isegized an live iruits ofgrate han 30rs, 240, or20julsrxpdcidlcota；or adifqcy (f) isent. GENERAL ELECTRICAL HAZARD Type 5 - Equipment isergized an djustment rquies physical entry ohqupmt,oreqipcofgraton woalw t s ofcl- bs. M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 4 SPECIF ELCTRIAL HZRD Safety Suggestions WARNING -Wear Safety Glasses - Operators and maintenance personnel must wear safety glasses whenvrthePRECITECH spindle isrunig. Itis god practie toarsfty glas ound the machatl tmesWARNING - Wear A Dust Mask -T iond-turing procs ay produce swarfo chips ta flotinthear.A precvaskutbenvtheransed mou tt ihli ringsi sbtas my btxic. ARNING - Dress properly -Do nt perat he PRECITECH Machining System while arigjewly,losfitngclothing,ecktis, shirtlevs, orunprotcdl hir. WARNING - Stay Alert -Do nt perat he PRECITECH Machining System whileundr theifluecfmdicon,drugs,oralchol. - Safety Guards Must Be In Place -Operts mut besur tha lguardsre inplace while t PRECITECH Machining System i runi toptcgstbodynjur. M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 5 WARNING - Adjustable Guard -The adjustble guard shiels the oprat from lubespraynd fie chipstantrly fromtotangidldingth chigro. r i,hwvr, rt es fi-tue t stufteol,ubrcatin chipextrcio,whilethpdle sroain.A hs ims the poray sld h adjustb guar if ctoctngar,t his guuteri emnclurig e ai ocsfrmxi fy. WARNING - Maintain the Machine Properly -Do nt perat his machining system when its ined ofrepairservic.Pomaintec il lpavodmachiwntm, l frductin d jury oprsn. Warning - Do Not Disable Machine Safety Interlocks - Many safety features have been built into the Machining System and should not be disabled. Special applications and service may require temporary interlock override, please consult with Precitech. Warning - Electrial/Eectronic Troubleshoting - Must be performed by personnel trained to troubleshoot electrical circuits. An electrical hazard exists when personnel exceed the limitations of their training. Warning - Electrical Repair - Main Disconnect must be turned OFF before attempting any repairs of electrical components. Follow your Lock Out-Tag-Out procedure so that another person cannot accidentally start the machine. This device can also be used as an Emergency OFF switch in the event of an unforeseen electrical hazard. WARNING - Hydraulic/Pneumatic Repair -Do nt aempt oreair oservic pneumatic orhydraulic ompnetswhilePRECITECH M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 6 Machining System is conetd othe pnumatic orhydraulic power sources orif ethrytm rainsudres.WARNING - Material Safety Data Sheet (MSDS) -PRECITECH provides a MSD andhzard wrnig labels onctainersfoeach ofitsuctconsierto beousthitmeg t Oupnal Sfy d HlAmistri (OSHA) zrd Cuit tdr,29CFR190.2. Rad nderstanthMSD and hzarwig lbels befor usingyhzrou il. LOCK OUT-TAG UT Defined -The placment ofal hzardous enrgy under th exclusive contrl fanutorizd pye(s)pefmithsvicomant, fwig urstbli byth ploer a rqrd byOSHA 29 CFR 1910.147, Isolation of Energy Sources-Machinery Safety Directive 89/392EEC the Control of Hazardous Energy. LOCK OUT-TAG UT Capabilities - The machine comes equipped with the means to secure the energy systems of the machine in a manner consistent with all LOCK OUT-TAG UT requirements. The Main Electrical Disconnect Switch allows a lock to be inserted in the handle when the switch is in the OFF position. This ensures that the Electrical System of the Machine is in a condition where it can be safely serviced. This device can also be used as an Emergency OFF switch in the event of an unforeseen electrical hazard. M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 7 This Machine is equipped with an accessory receptacle. This receptacle is fed from a separate power source in addition to the Machine Main Feed. Although the E STOP Switch is depressed and the Main Disconnect Switch is OFF and locked, there may be voltage potential at this receptacle. In order to fully (secure) LOCK OUT-TAG UT this receptacle, the plug for the source conductor must be pulled and covered with a lockable shell (boot) made expressly for this purpose. The Pnumatic Suply Lockut Valve isclary lbeld. This valve allows a lock to be inserted in the handle when the valve is in the OFF position. Always folw your cmpanies LOCK OUT-TAG-OUT procedur sotha ntheps otcidentaly str the mahin.M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 8 System Interlocks Precitech Machining Systems are designed with mechanical, electrical, and pneumatic components whose use is dedicated to protecting the operator and the machine. All Cabinet Doors and Service Access Panels have tool-operated latches or fasteners to prevent casual entry. The Electrical Cabinet is mechanically interlocked to prevent exposure to lethal voltage. The electrical cabinet door cannot be opened unless the Main Disconnect is turned OFF. Warning Labels This label is located on the sliding guard door that protects the operator during a machining cycle. When this guard must be slid aside to allow operator access to the cutting area, it is imperative that safety glasses be worn. M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 9 SECTION 2 LVDT Tool Setter A15415-05 M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 10 Description The LVDT tool setter A15415-05 uses a Precitech designed air bearing slide inside a 0.75 inch diameter housing. On one end is mounted a LVDT core. The other end carries a replaceable ruby ball tip. The air bearing slide provides zero friction and therefore low tip forces are possible. The tip force comes from gentle pneumatic pressure behind the air bearing and is adjustable. The unit kinematically mounts on the top of the spindle with high repeatability and positions the LVDT with the sensing direction parallel to the travel of the Z slide. The LVDT tool setter is used to measure the offset positions between a tool or grinding wheel and the work spindle or B axis centerline positions. It can also be used to measure the radius of the tool or wheel. Tools are probed in three positions and the resulting data is used by the controller to accurately compute tool radius and offset positions. Air Bearing LVDT Specifications Side stiffness .05 mm/gmf 60 psi Ruby tip diameter 0.125 inch (3.175 mm), others available Tip thread size #4-48 Air flow rate 0.5 scfm Tip force 3-7 grams, adjustable Mount and Connect If your machine includes a cover over the work spindle, open this to expose the kinematic balls on the spindle. Clean the ball seats and the mating rods on the bottom of the tool setter with a cloth to remove any contaminants. Mount the LVDT tool setter on the kinematic balls provided on the work spindle. Plug in the electrical wire to the channel A input of the Integrated Gage Amplifier (IGA) board (Channel B is reserved for Ultracomp) and hook up the air line to the Probe Air connection port. Verify the Probe Air pressure is set at 60 psi. The air bearing LVDT can now be uncovered and should be tested for free motion (not sticking). Align the LVDT Using an indicator, align the body of the LVDT so that it runs parallel to the Z axis motion of the machine to less than 5 microns per 5 mm travel both on top of the LVDT housing and on the side of the housing. M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 11 Calibrate Output Linearity and Offset The electrical LVDT output signal can be viewed on the UPX screen under the Integrated Gage Amplifier window (Channel A). The probe should be touched to ensure the signal is being amplified correctly, then set up to touch against any rigid object on the tooling plate such as a tool holder. Jog the Z slide to null the LVDT, press the RESET OFFSET button to cancel any offset, and again move Z to nul the ga. When t machine Zaxis moved 10icrons ad isplaces the LVDT by this amount, the LVDT output should also read 10 microns. Adjust this calibration using the CAL pots on the gage amplifier board until the slide motion is measured correctly within 2% (0.2 microns). Adjust the Offset pot until both the positive and negative travel directions and Forward / Reversed display reflect equal amplitudes. You may wish to label the IGA channel A input connector with a tag reading Cal for LVDT Toolsetter with the inspector initials and date of the calibration. Set LVDT Height Adjust the height of the LVDT body until the probe is at the same height as the work spindle. This can be accomplished in multiple ways such as using a transfer reading from a 0.75 inch diameter part mounted and aligned to rotate true with the work spindle. There is also a fixture (15428) that accepts a contact point (168-0052) where the height of the two contact points (one in each) can be transferred to set the height. The height adjustment is accomplished by turning the brass locking rings on the vertical threaded body of the tool setter. Brass RingFixture 15428 M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 12 Calibrate Contact Point Radius Use the LVDT tool setter to measure the radius size of a calibrated pin, dowel, or other artifact placed vertically on the tooling plate. If the reported size (Calc Radius) is not correct this error is subtracted from (or added to) the ProbeRadius so that the size of the artifact is measured correctly. Write this number down on a piece of paper for future reference. M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 13 Calibration of the LVDT Tool Setter to the Work Spindle Centerline Turn or grind a setup stud so that the part is produced with less than a micron of X offset. Alternatively, set a tool using the Optical tool setter. This tool or wheel with known accurate X position is then the master for calibrating the X offset of the LVDT tool setter to the work spindle. Use the LVDT tool setter routine (with the same tool active from the tool table) to measure the tool or wheel position. The resulting values are shown in the X Center ABS on the LVDT tool setter window (shown above). Enter a corrected value to the X Probe Offset value and repeat the LVDT measurement until the resulting Center ABS number matches the known accurate X position for the tool. Write these numbers down on a piece of paper for future reference. M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 14 Tool Set Procedure for XZ Grinding using the LVDT tool setter Typical for use with vertical axis spindles and when the rotary B axis will not be used. First enter MDI mode and cancel all machine offsets by entering G59 without parameters and then entering G92 without parameters. In Setup mode, open the TOOL TABLE and select the tool number to be used for this wheel or tool. Enter nominal radius and sweep values for this tool number, then press the LVDT TOOL SETTER button. Select the type of the tool set from the choices by pressing the appropriate X/Z button. Clean the kinematic mount on the spindle and the bottom of the tool setter, then mount the tool setter to the spindle. Put tape on the grinding wheel so it does not rotate during the measurements. Jog the machine axes to put the wheel near the LVDT tip and then null the tip using the IGA screen. Crown the wheel in the X direction until the peak is found, then back off by 2 mm in the Z direction. When rady, seth fed rate ovride to10%, then prs the STAR POBE TOOL # button and the green START pushbutton. The routine will probe the wheel in three locations and display the results in the window. Press CLOSE and SAVE to save the results. M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 15 Calibration of the LVDT Tool Setter to the Rotary B Axis Centerline with Virtual Centering Software Mount a tooling ball (sphere) in the collet of the grinding spindle, or a pin vertically near the B axis centerline. Tape the spindle to prevent rotation during the calibration. Position the B axis at approximately 45 degrees away from the operator, and position the X & Z axes until the sphere or pin is near the LVDT probe tip. Verify the LVDT is calibrated by setting it to null against the sphere, then jog the machine a known amount such as 0.02 mm in Z and witness the display reading on the IGA screen for the LVDT displacement. It should match the machine motion within 2% or be recalibrated if necessary. Go the TOL ABE and selct Tol number 10. Touch te ylow BAXISCENRISTUPfky.chtFINDB(X,Z)I using VD st Etr spre adis nth RTIFIfield,an swepangle of 30 degrees (half of total swep) inthe ATFC SWPfild. Touch EGI AIS CL SEUP,jog axes ifn, rstgrenSTRpushbton.The sphere will be probed and the results reported in X1, Z1, B1, and Calc Radius 1. Touch ROTE BXIS 90DEGRS POIVE ad te Baxis wil rta to a new location. Jog the axes to bring the sphere and probe tip near each other and repat e procedur. Touch BIN AXIS CL TUP, jog the xs ifneeded, and press the green START pushbutton. The sphere will be probed and the results reported in X2, Z2, B2, and Calc Radius 2. If the results are to be discared n the squenc tobe rstared, prs the buton REST CORDS. Press CLOSE, then YES to Save Results, then Save again. The results are isply it Tol #10 wid inth ON XAIS ad N ZAXI fields of the B Axis LVDT CENTERLINE area. Record these numbers for future reference. M1793/B -Precitech Grinder Systems Supplemental Installation & Operation Manual 16 Virtual Center is active any time a tool number is active that contains values in Virtual Centr Amplitude an Virtual Centr Ofset filds. The user must be aware that when a tool number that contains entries in these fields is called, axes motion will occur. The Virtual center offsets become active immediately following activation of a tool number. Virtual Center is disabled by setting AMPLITUDE to zero, or by selecting an alternate tool. If a Virtual Center assigned tool is active and the offsets are cleared (i.e. set to zero) the user must also be aware that axes motion will occur as the offsets are removed. M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 17 Tool Set Procedure for XZB Grinding using the LVDT Tool Setter With Virtual Center Software Use when the rotary B axis will be used in tool normal grinding. In MDI mode, cancel any machine offsets by entering G92 without parameters and G59 also without parameters. In Setup mode, Open the TOOL TABLE, and select the desired tool number. The Tool Table window is shown below. Enter the nominal radius and sweep for the grinding wheel. Zero out any existing virtual center data. Tape the grinding wheel so it does not rotate during the measurement. Select , then select the image showing the LVDT tool setter and a grinding spindle. Clean the spindle kinematic balls and the bottom of the tool setter using a cloth to remove any contaminants, then mount the tool setter on the work spindle. Jog the axes to position the LVDT tip near the wheel then display the output on the IGA screen and null the LVDT against the wheel. Crown the wheel to determine the high point in X, then back away 2 mm. Set the Feed rate override to 100%, then when ready press the START PROBE # button and the green START button. The routine will then probe the wheel in three locations and display the results of the tool set. M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 18 Select TOOL EDGE when exiting to set the edge of the wheel to be the virtual center of rotation of B. Use this mode if multiple tool set locations are to be repeated around the radius of the tool. Select TOOL CENTER when exiting to set the center of the radius to be the virtual center of rotation of B. Use this mode to alw the Baxis tobe shifted inrotain topresnt fresh tol(frsome applications) or for use when testing the software on a dowel pin. Also note that when the Virtual Center tool set routine is active, the offsets are made active when the user exits the tool set page. This will cause motion of the machine so the axes should be jogged into a clearance position before exiting the tool window. Ensure to SAVE the results when closing the window. Validation of Virtual Center Toolset Calibration To check the quality of the tool set and operation of Virtual Centering, setup a round test part, artifact or pin eccentric from the B axis centerline by 5-10 mm. Go to the TOOL Table, and enter the part radius in the RADIUS field, and enter 40 degrees in the SWEEP field for Tool #2. Close the Tool Table and activate tool #2 using the MDI command T2. Go back to the Tool Table and perform the Virtual LVDT Tool Set routine on the test part. Save the resulting data to Tool #2. Close the screen, selecting CENTER data. Jog the axes until the LVDT toolset probe is nulled on the surface of the test part, using the IGA screen to view the displacement of the LVDT. Find the crown of the test part by jogging back and forth in the X direction. With T2 active, rotating the B axis should cause a shift of the X and Z slides, such that the center of the test part does not move in respect to the probe tip. The display reading of the LVDT probe should have very minimal movement. M17931/B - Precith Grinder System Suplental Istaltion &Operation Maul 19 Calibration of the LVDT Tool Setter to the B axis centerline without Virtual Centering. Install the LVDT tool setter to the work spindle. Place the 3 mm pin and fixture (or equivalent similar fixture) on the B axis table and indicate the pin to run accurately in rotation with the B rotation within 0.000040 inch at the working height of the tools. Epoxy the fixture to keep it from moving during the remaining calibration. The LVDT tool setter can be monitored on the IGA screen on the UPX controller. Move the machine axes until the probe is touching the pin. Crown the pin by moving X until a peak is reached. Then null the gage in Z. Verify the LVDT is calibrated by jogging the machine a known amount such as 0.02 mm in Z and witness the display reading on the IGA screen for the LVDT displacement. It should match the machine motion within 2% or be recalibrated if necessary. The center of B is this X position and a Z position offset from the current position by the radius of the pin. Record these values in the B Axis LVDT CENTERLINE field for Tool #10. M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 20 Tool Set Procedure for XZB Grinding using the LVDT Tool Setter Without Virtual Center Software sharp edged wheels Install the grinding wheel into the collet of the high speed spindle. The B axis should be set to be 0.0 when the two spindles are parallel. Rotate the B axis until it is at the angle where it is intended to be used. Install the LVDT tool setter to the work spindle. Move the X axis until the probe aligns with the side of the wheel and move Z to position the tool setter at the B axis centerline. Ensure the wheel does not interfere with the probe during this motion. Move the high speed spindle sideways on top of B using the XZ sliding adjustment if needed to establish clearance. Move the high speed spindle sideways until the probe is then nulled. Check the run out of the wheel surface and dress if necessary before continuing. Move Z to clearance, Rotate the B axis to zero, and align the X axis to align with the end of the wheel. Move Z to position the LVDT null over the B axis and shift the high speed spindle axially until the probe is nulled. ball shaped wheels Install the grinding wheel into the collet of the high speed spindle. Rotate the B axis until it is at 90 degrees. Install the LVDT tool setter M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 21 to the work spindle. Move the X axis until the probe aligns with the edge of the wheel and move Z until the probe is nulled. Check the run out of the wheel surface and dress if necessary before continuing. Record this value of Z. Back Z away, rotate B to -90 degrees, realign X, and probe the other side of the wheel. The Z null position on the other side should be the same as the first side. Any error represents the amount the high speed spindle is shifted away from the B axis centerline. Move the Z by half the error, and shift the high speed spindle the same half of the error (move to clearance first to avoid a crash). Repeat probing both sides of the wheel until they repeat within the tolerance desired (at least smaller than the error motion of the wheel surface). At this point move the rotary B axis to zero, move the X to align with B, and probe the wheel vertex. Shift the high speed spindle axially if needed until the probe is at the same Z position as the two side probings. This will provide stock for dressing 180 degrees of wheel grinding area. Repeat the probing at all three points to ensure the parts have not shifted during the alignment and bolt all joints down tight. Spare Parts for the LVDT tool setter: Ruby stylus tip 0.125 inch diameter 168-0019 Ruby stylus tip 0.062 inch diameter 1680018Ruby stylus tip 0.031 inch diameter 168-0017 Replacement probe cover 03264 + 1010022 O ring + 700-0397 set screw Replacement 10 foot extension cable A11133 M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 22 SECTION 3 PI 50, RPM otrized Air Beaing Spidle M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 23 Air Bearing Specifications Wher t word Ultimateisued blow, this te point wher t airbering will not float any more and the spindle is likely to seize under these conditions. It is recommended to maintain forces less than half of the Ultimate ratings. Data as provided by the Spindle Supplier: Inlet Air Pressure 6.9 Bar Air Flow Rate10 lpmUltimate Axial Load Capacity 340 N Ultimate Radial Load Capacity at the Spindle Nose 195 N Axial Stiffness 65 N/um Radial Stiffness at the Spindle Nose 20 N/umAxial Error Motion 25 nm at 50,000 RPM Radial Error MotionMaximum Speed 50,000 RPM Spindle Weight6.8 kg Estimated Values: Lqucont fowrate istimated t1 lpm50 psi resur Ht l vrsRPM40watst3,0 RPMChierquiets: 120 Wts for ul ed rng oration M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 24 Setup of Horizontal Spindle Mounted on Rotary B axis A17750 (Top) or A16810-04 (Bottom) Mounting Grinder Clear the B axis (or round tooling riser) table top and clean and stone the mounting surface. Also clean and stone the mounting surfaces for the grinder parts. Mount the grinder on the tabletop. Due to the weight of the grinder, it is recommended to use a crane to lift the grinder into place. Tapped holes are Radial Adjust Height Adjust Radial Adjust Height Adjust Cross Adjust M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 25 provided in the grinder for the use of lifting rings. Ensure the connectors are clear of any contaminants, and purge the air line of any contaminants. With the machine in E stop, connect the power cables, signal cables, air line to the air bearing, spindle coolant hoses, and spray mist hoses or flood coolant hose and nozzle. Collect any dust caps or hose plugs and bag these with a label indicating the contents. Align the Parts Mount a pin in the collet of the grinding spindle. If the B axis is present, rotate the B axis until the side of the grinding spindle mount is parallel to the Z axis using an indicator and zero the B axis angle in this location (G92B0). Indicate the side of the pin and examine if the pin moves parallel when the grinding spindle is moved along the radial positioning slide. If the pin is not moving parallel then loosen the spindle mounting bolts and tap the spindle into alignment with the radial slide travel. If this tep isnot cmpletd he wl il shift nX ofset whn its adjuste along this slide. Realign the spindle to the Z axis using B rotation and rezero the B axis in this location. Setting of Grinding Spindle Height Mount the pointer A13782 in the work spindle and align it to run true with the spindle axis of rotation. The pin size in A13782 should be the same size as the pin in the grinding spindle collet. Indicate the height of the pin in the work spindle, and then move the indicator to read the height of the pin in the grinding spindle collet. If necessary, adjust the grinding spindle height by loosening the clamping bolts and adjusting the spindle up and down until the grinding spindle is at the correct height. Retighten the clamping bolts and remove the pin and fixture A13782. Aligning with B axis Centerline The A17750 assembly does not have provisions for cross axis motion so this requires the use of Virtual Centering software to put the edge of the wheel at the center of rotation of the B axis. The A16810 assembly does have a cross axis slide so this can be used to position the wheel edge over the B axis centerline. For process instructions see the section later in this manual on General Grinder M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 26 Operational Notes. Fine Setting of Wheel Height Once the ground part has been examined under a microscope, it may show the need to fine tune the wheel height to remove any center defect that was not ground correctly. For these fine adjustments, place an indicator in a position to measure the spindle height motion. For the A17750 assembly, the height is adjusted using the wedge plate under the grinder. Loosen the four clamping bolts and shift the height using the brass hex under the spindle. For the A16810 assembly, there is a drive screw on one side and flexure on the other side of the spindle. Loosen the clamp bolts and adjust the drive screw to change height, and then reclamp the bolts. M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 27 Setup of 45 Degree Fixed Spindle Mount (A16810-04) (right) -OR 45 Degrs toVertical Adjustable Spindle Mount (A17750) used with 45 Degree Spindle Orientation (left)Mounting Grinder: Clear the B axis (or round tooling riser) table top and clean and stone the mounting surface. Also clean and stone the mounting surfaces for the grinder parts. Mount the grinder on the abltop. Due tohe weight of the grinder, it is recommended to use a crane to lift the grinder into place. Tapped holes are provided in the grinder for the use of lifting rings. Ensure the connectors are clear of any contaminants, and purge the air line of any contaminants. Connect the power cables, signal cables, air line to the air bearing, spindle coolant hoses, and spray mist hoses or flood coolant hose and nozzle. Collect any dust caps or hose plugs and bag these with a label indicating the contents. Align the Parts: Mount a pin in the collet of the grinding spindle. If the B axis is present, rotate the B axis until the side of the grinding spindle mount is parallel to the Z axis using an indicator. Zero the B M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 28 axis angle in this location (G92B0). Indicate the side of the pin and examine if the pin moves parallel when the grinding spindle is moved up and down the 45 degree slide. If the pin is not moving parallel then loosen the spindle mounting bolts and tap the spindle into alignment with the 45 degree slide travel. If this step is not completed the wheel will shift in X offset when it is adjusted in height. Coarse Setting of Wheel Height: Mount the grinding wheel in the spindle. Mount the pointer A17775 in the work spindle and align it to run true with the spindle axis of rotation. Jog the slides to close the gap and examine the height of the wheel against the pointer. If necessary, adjust the spindle height by loosening the clamping bolts and adjusting the spindle up and down the 45 degree slope with the coarse adjustment screw until the wheel is at the correct height by eye with an eye loupe. Retighten the slide clamping bolts. Aligning with B axis Centerline: The A17750 assembly does not have provisions for cross axis motion so this requires the use of Virtual Centering software to put the edge of the wheel at the center of rotation of the B axis. The A16810 assembly does have a cross axis slide so this can be used to position the wheel edge over the B axis centerline. For process instructions see the section later in this manual on General Grinder Operational Notes. Fine Setting of Wheel Height: Once the ground part has been examined under a microscope, it may show the need to fine tune the wheel height to remove any center defect that was not ground correctly. For these fine adjustments, place an indicator in a position to measure the spindle height motion. For the A17750 assembly, the height is adjusted using the wedge plate under the grinder. Loosen the four clamping bolts and shift the height using the brass hex under the spindle. For the A16810 assembly, there is a drive screw on one side and flexure on the other side of the spindle. Loosen the clamp bolts and adjust the drive screw to change height, and then reclamp the bolts. See below: M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 29 M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 30 Setup of Vertical Spindle Mount A16810-03 Mounting Grinder: Clear the B axis (or round tooling riser) table top and clean and stone the mounting surface. Also clean and stone the mounting surfaces for the grinder parts. Mount the grinder on the tabletop. Due to the weight of the grinder, it is recommended to use a crane to lift the grinder into place. Tapped holes are provided in the grinder for the use of lifting rings. Ensure the connectors are clear of any contaminants, and purge the air line of any contaminants. Connect the power cables, signal cables, air line to the air bearing, spindle coolant hoses, and spray mist hoses or flood coolant hose and nozzle. Collect any dust caps or hose plugs and bag these with a label indicating the contents. Align the Parts: Mount a pin in the collet of the grinding spindle. If the B axis is present, rotate the B axis until the side of the grinding spindle mount is parallel to the Z axis using an indicator and zero the B axis angle in this location (G92B0). Indicate the side of the pin and examine if the pin moves parallel when the grinding spindle is moved up and down the vertical slide. If the pin is not moving parallel then loosen the spindle mounting bolts and tap the spindle into alignment with the vertical slide travel. If this step is not completed the wheel will shift in X offset when it is adjusted in height. Coarse Setting of Wheel Height: Mount the grinding wheel in the spindle. Mount the pointer A17775 in the work M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 31 spindle and examine the height of the wheel against the pointer. If necessary, adjust the spindle height by loosening the clamping bolts and adjusting the height with the adjustment screw until the wheel is at the correct height by eye with an eye loupe. Retighten the clamping bolts. For process instructions see the section later in this manual on General Grinder Operational Notes. Fine Setting of Wheel Height: Once the ground part has been examined under a microscope, it may show the need to fine tune the wheel height to remove any center defect that was not ground correctly. For these fine adjustments, place an indicator in a position to measure the spindle height motion. Loosen the clamp bolts and adjust the drive screw to change height, and then reclamp the bolts. M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 32 Setup of 45 Degrees to Vertical Adjustable Spindle Mount (A17750) used with Vertical Spindle orientation Mounting Grinder: Clear the B axis table top (or round tooling riser) and clean and stone the mounting surface. Also clean and stone the top and bottom mounting surfaces for the wedge plate height adjuster. Mount the wedge plate on the B axis tabletop. Clean and stone the bottom surface of the grinder mount, then install the grinder to the wedge plate. Due to the weight of the grinder, it is recommended to use a crane to lift the grinder into place. Tapped holes are provided in the vertical grinder for the use of lifting rings. Ensure the Ultracomp mount will fit and shift the spindle mount by one set of bolt holes if necessary. Ensure the connectors are clear of any contaminants, and purge the air line of any contaminants. Connect the power cables, signal cables, air line to the air bearing, spindle coolant hoses, and spray mist hoses or flood coolant hose and nozzle. Collect any dust caps or hose plugs and bag these with a label indicating the contents. Align the Parts: Mount a pin in the collet of the grinding spindle. If the B axis is present, rotate the B axis until the side of the grinding spindle mount is parallel to the Z axis using an indicator and zero the B axis angle in this location (G92B0). Indicate the side of the pin and examine if the pin moves parallel when the grinding spindle is moved up and down the vertical slide. If the pin is not moving parallel then loosen the spindle mounting bolts and tap the spindle into alignment with the vertical slide travel. If this step is not completed the wheel will shift in X offset when it is adjusted in height. M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 33 Coarse Setting of Wheel Height: Mount the desired grinding wheel in the spindle. Mount the pointer A17775 in the work spindle and align it to run true with the spindle axis of rotation. Jog the slides to close the gap and examine the height of the wheel against the pointer. If necessary, adjust the spindle height by loosening the four clamping bolts (larger size, in slots) and adjusting the height with the coarse adjustment screw until the wheel is at the correct height by eye with an eye loupe. Retighten the four clamping bolts. For process instructions see the section later in this manual on General Grinder Operational Notes. Fine Setting of Wheel Height: Once the ground part has been examined under a microscope, it may show the need to fine tune the wheel height to remove any center defect that was not ground correctly. For these fine adjustments, place an indicator in a position to measure the spindle height motion. Loosen the clamp bolts and adjust the drive screw to change height, and then reclamp the bolts. M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 34 Spindle Tooling for the PI 50,000 RPM Spindle This spindle is available with two types of tooling, either a collet or a bolt on flycutting head. Collet A11777: The 50,000 RPM spindle collet is A11777. It uses an ER-11 style collet which is available in 0.5 mm increments from 0.5 mm diameter up to 7.0 mm diameter size. The collet is clamped manually using spanner wrenches. The collet adapter is provided with balancing holes. Grinding Wheel 06050 Insert the desired grinding wheel or milling tool into the collet and insert it until it bottoms out. This enables the wheel to be reinserted with repeatability. Ideally all of the wheels used will have the same overall length so that wheels can be changed without resetting the spindle height. Bring the part to be ground and fixture to the machine and examine the interaction of the wheel and part. It may be necessary to extend the wheel out from the collet to provide shank clearance with the part and fixture. M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 35 Flycutting Head The flycutting head A13510 is used to carry a shank based diamond cutting tool at high speed for flycutting operations. These are typically used in the creation of freeform surfaces by raster milling or spiral milling. The shank based tool is mounted using setscrews. Balancing holes are also provided in the adapter. Electrical Power to Grinder Cart (if Supplied) The grinder cat isfactory wired (tocustmer spcifation) fr208 VAC or230 VAC,50/6Hz,nglephas.Thpwcont shuldbemadtadicat rpt trl bya 30 iruibrekr (sw rspne, typ /). Mximu oings2.KVA.M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 36 SECTION 4 SP-75 15,000 RPM Motorized Air Bearing Spindle This grinder atchment uilzes ahig-stifnes, vrticaly mounted 15,0RPMibrigspd,wc may bfid whgrigwhel ordiamo flyut a tort inteoriztalpne. T atcntcabe use tgrind hareeils,h eiotured,or spil CNilfo xis ymtric urfacs.Thsdl hs livfor acpti lrrofpas.Speil nd apricaprtmay begrundwih damnd ging whel ditrsgifom 5 (2.0)to127m (5.0). Air Bearing Radial Load Capacity atspindle os (derat 50%) 27 kg (60 lbs) 100 psi Axial stiffness 105 N/um Radial Stiffness35 N/umAxial and Radial Motion accuracy 50 nm Water cooling passages ProvidedMaximum Speed 15,000 RPM Grindg wheldiametr ange from 5 (2.0) to127m (5.0)M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 37 Setup of Vertical Mount (A16810-03) Mounting Grinder: Clear the B axis table top (or round tooling riser) and clean and stone the mounting surface. Also clean and stone the mounting surfaces of the grinder mount, then install the grinder to the tabletop. Due to the weight of the grinder, it is recommended to use a crane to lift the grinder into place. Tapped holes are provided in the vertical grinder for the use of lifting rings. Ensure the connectors are clear of any contaminants, and purge the air line of any contaminants. Connect the power cables, signal cables, air line to the air bearing, spindle coolant hoses, and spraymist hoses or flood coolant hose and nozzle. Collect any dust caps or hose plugs and bag these with a label indicating the contents. Align the Parts: Mount a pin in the collet of the grinding spindle. If the B axis is present, rotate the B axis until the side of the grinding spindle mount is parallel to the Z axis using an indicator and zero the B axis angle in this location (G92B0). Record this ABS angle in case it is needed later. Indicate the side of the pin and examine if the pin moves parallel when the grinding spindle is moved up and down the vertical slide. If the pin is not moving parallel then loosen the spindle mounting bolts and tap the spindle into alignment with the vertical slide travel. If this step is not completed the wheel will shift in X offset when it is adjusted in height. Coarse Sting ofWhel Hight: Mount the desired grinding wheel in the spindle. Mount the pointer A17775 in the work spindle and align it to run true with the spindle axis of rotation. Jog the slides to close the gap and examine the height of the wheel against the pointer. If necessary, adjust the spindle height by loosening the clamping bolts and adjusting the height with the adjustment screw until the wheel is at the correct M17931/B - Precitech Grinder Systems Supplemental Installation & Operation Manual 38 height by eye with an eye loupe. Retighten the clamping bolts. For process instructions see the section later in this manual on General Grinder Operational Notes. Fine Setting of Wheel Height: Once the ground part has been examined under a microscope, it may show the need to fine tune the wheel height to remove any center defect that was not ground correctly. For these fine adjustments, place an indicator in a position to measure the spindle height motion. Loosen the clamp bolts and adjust the drive screw to change height, and then reclamp the bolts. M17931/B - Precitech Grinder Systems Supplemental Installati