parte list and - wickman group...9-l2 l3-1 8 l9-72 73 plfr5/5b 0e / 07 /88 summary section section...

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PARTE LIST

and

HAI}ITETAHGE HfrTIUAL

For

Wlckman 2.5lEt G-Eplndlc

}illckmrn 3.{ l4a $$p6666

Bar Automatlc Lather

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I

I

Your affention please !

The references at the foot of most pages show that this manual wasprepared in 1988.

unfortunately it was never completed, probably due to thecompiler being made redundant as a result of the drastic reductionsin manpower which the company was forced to make during thatdifficult time.

The 'masters' were found in the company archives in February2005. The manual was found to be complete and ready forprinting apart from Section 5: Parts Lists and GeneralArrangements. only a few of the lists of parts had been done andmost of the artwork was missing.

we have now completed the job although we must apologise forthe fact that the end result is not as professional as we would haveliked. It has been necessary to mix 'old style' pages with new onesbut nevertheless this is the most comprehensive manual we haveever issued for the 2.518" and 3.114" machines and we hope thatyou will find it useful.

of course, should you require any assistance in identiffing partnurnbers etc the expertise of our engineeis is always at yourdisposal.

Wickman Coventry Limited

Fffi& trST

ilffiHAE|,|B

fer

W**a S.t/Fesphd[s

k lafr$e Ldiles

WICKMAN COVTN'TRY LIMITIiDAutomatic House, Discovery Way, Leo{iic Business Park, Binley, Coventry CV3 2'l'D

Telephone +44 (0) 2476547900 Spares +44 ({)) 24 76547q10Facsimile +.14 (0) 241654 79?A E-mail: [email protected],uk

and

PARTS LIST

AT{D

}IATNTENAI{CE MANUAL

FOR

wrcruAN 2.518n-6 SPTNDLE

AIID

I{TCKUAN 3.LI 4"-6 SPINDLE

BAR AUTOUATIC LATHES

I'rame 5, 6-SpindleBar, Parts

PLFRs/680e/07/88

A1l enquiries tu^i

Wickman Coventry LimitedAutom4tic Ho_use

Discov.ery IMavLeofric Bu:siness FarkBinlayCovenfiryCV3 2TD

Tel:02476,54V9A0,Fa* 024 7'654 7920

Wiokman Covonfyt-imitod oporate a polic,y of eontimial improvement andwe thoroforeres€w€ the right to ohange tho sp,eoifioations and illustrations with notica

TABLE OF CONTENTS

DESCRIPTION

TABLE OF CONTENTS

PREFACE

HEAITH AND SAFETY

MACHTNE srzE / tuoorr, RANGE

II{ACTIINE SERIAL / TUSPNCTION NUMBER

DETAILED CONTENTS LIST - Refer below for Summary List

PAGE

1

2

2-3

4

4

5-6

7-8

9-L2

L3-1 8

L9-72

73

PLFR5/5B0e / 07 /88

SUMMARY

Section

Section

Section

Section

Section

CONTENTS LISTING

One: Installation

Two: Lubrication Charts and SpecificationsThree: Preventative Maintenance Schedule

Four: Machine Construction & Maintenance Procedures

Five: Parts Lists and General Arrangements

Frame 5, 6-SpindleBar, Parts

t

PREFACE

This llanual provides the basic information and instructions that arenecessary for the maintenance/servicing of the Wickman 2.5/8"-6 and3.L/4"-6 Spindle Bar Automatic Lathes *ittr Relay Logic ControlEguipment.

The contents will familiarize the reader with the machine constructionspecifications, installation procedure, safety at work and all therelevant aspects of the machine.

The manual should be read thoroughly. It will enable the Engineer togain the knowledge required. for the correct and efficient s6rvicing ofthe machine.

An Operatorrs Handbook is also available for the 2.5/8"-6 and the3.L/4"-5 machines.

EEJAITII AND SAFETY

Health and Safety at Work Act, L974 U.K. users onIy.

In accordance with the requirements of the Health and Safety at WorkAct 1974, this manual embodies the necessary information to ensurethat the machine tool can be maintained properly and with safety. Itshould be clearly understood that the engineer must be properrytrained, have the required skills and be authorised to maintain themachine.

If it should arise that the person authorised to maintain the machineis undergoing training, he must be under the close supervision ofanother skilled and authorised person.

Adequate information is provided to enable the machine to be servicedand maintained Ln a satisfactory condition by engineers and,electricians who have the necessary skiIls and authority. W€ recommendthat a rPermit to Workr system as detailed in the code of practice8S5304; 1988 entitled "safety of Machinery", should be operated.

Frame 5, 6-Spind1eBar, Parts

2 PLFR5/6809/07/88

'i|

HEALTH AND SAFETY (Continued)

It is important that the various statutory regulations which areapplicabre, eg, 'The Protection of Eyes Regulationsr are compliedwith.

Operating Discipline(I) A clean, neat and well ordered machine and working area is thefirst essential of safety at work.

(II) All guards, cover plates, cabinet doors and the tooling areaguards must be in place or closed before any production runconmences.

(III) Never leave articles lying on any working surface where thereis a danger that they may be disrodged bt: any moving part ofthe machine, vibration, etc.

(ry) Never wear rings, watches, neck-ties or loose-sleeved clothingwhen working on the machine.

(v)

(vr 1

(VII )

(vrrr )


Never operate the machine in excess of its rated capacity.

Know where the EMERGENCY STOP BUTTON is.Never reach across a moving or rotating part of the machine

Never enter the tooling area or any other working part of themachine when the machine is running on production.

(rx) When tool setting, changing tools or making adjustments, neverenter the tooling area until the machine has been shut dor,vn.

When carrying out maintenance work, never enter any part ofthe machine, either mechanj-cal or electrical, until the machinehas been shut down and the isolator on the electrical controlpanel is in its "off" position, disconnecting the power supply.

(x)

(xr ) When working with lubrication oils and cutting oils of thesoluble and straight cutting oil types, cleanliness isessent,ial. Precautions must be taken to avoid all unnecessarycontact with oi1 by ensuring that the machine's protectivedevices against coolant and oil spray are correctly closed andthat protective clothing is worn. Never wear oil soaked clothesor place oily rags or tooling in the pockets of wearing apparel.Always was oil from the body as soon as possible aftercontamination.

The Safe Operation Of Work Holding Devices

Collet equipment and collet operating mechanisms must always be keptin first class condition, in order to ensure that the bar is securelygripped to withstand all the applied cutting forces. Tooling areaguards must always be closed when the machine is in the "run"condition.

3 PLFR5/6B09/07/88

I'IACHINE SIZE / UOOEL RANGE

WICKMAN 2.5/ 8"-6 SPINDLE BAR AUTOMATIC LATHE *WICKMAN 2.5/ 8'I-6 SPINDLE BAR AUTOMATTC LATHE WITH SPINDLE STOPPTNG *WICKMAN 2.5/8"-6 SPINDLE BAR AUTOMATIC LATHE WITH DOUBLE BAR FEED *

WICKMAN 3.L/4N-6 SPINDLE BAR AUTOMATIC LATHE *

WICKMAN L.3/ 4'I-8 SPINDLE BAR AUTOMATTC LATHEWICKMAN L.3/4"-8 SPINDLE BAR AUTOMATIC LATHE WITH SPINDLE STOPPING

WICKMAN 50mm-8 SPINDLE BAR AUTOMATIC LATHEWICKMAN 5OMm-8 SPINDLE BAR AUTOMATIC LATHE WTTH SPINDLE STOPPING

WTCKMAN 7.L/4"-6 SPINDLE HYDRAULIC CHUCKTNG AUTOMATIC LATHEWICKMAN 7.L/4"-6 SPINDLE HYDRAULIC CHUCKING AUTOMATIC LATHE WITH

DOUBLE INDEXTNG

WICKMAN 6"-8 SPINDLE HYDRAULIC CHUCKING AUTOMATIC LATHEWICKMAN 6I'-8 SPINDLE HYDRAULIC CHUCKTNG AUTOIIATIC LATHE WITH

DOUBLE INDEXING

This Manual applies only to the lvlachines marked * , above.

MACEINE SERIAL / INSPECTTON NT'MBER

In the event that queries arise with regard to the maintenance of themachine, it is important to note the following details which wouldneed to be given to $Iickman Bennett in all correspondence, ie:Machine Inspection/Serial number, Machine size and Model.

The machine Inspection/Serial Number must always be quoted and isstamped on the machined-rim of the Tray of the machine, on the lefthand side, close to the Operators position. Additionally the number isalso engraved on the machine Manufacturing P1ate (WSP500) which isaffixed to the Main Drive Housing casting at the rear of the machine.

Reference to this number will facilitate any service thatmay be required.

The Serial Number ofthe machine isstamped here.

Frame 5, 6-Spind1eRar - Parts

4 PLFR5/6809/07188

DETAILED CONTENTS LTST

SECTION ONE - INSTALLATTON

1.1 Lifting the !,tachine

L.2 Siting and Foundatlons

SECTION TWO - LUBRICATION CHARTS AND SPECTFTCATTONS

2.L General Description

2.2 Summary of Lubricants

2.3 Lubrication Chart 2.5/ 8r-6 , 2.5/ B,'-GS and 3.L/ 4"-6

2.4 Lubrj.cation Chart 2.5 / 8" -6 Double Bar Feed

SECTTON THREE - PREVENTATIVE UATNTENANCE SCHEDULE

3.1 1000 Hour Procedures



3.4 L2000 Hour Procedures

SECTION FOUR - M.ACHINE CONSTRUCTTON & TI{AINTENA}ICE PROCEDURES

4.L Spindle Speed. Drive

4.2 Spindle Drum

4.3 Work Spindles

4.4 Front Bearing End Float, Collets and Collet Adjustment andFeed Tube Removal

4.5 Work Spindles for Spindle Stopping Machines

4.6 Dismantling Work Spindles on Spindle Stopping Machines

4.7 Collet Operation and Bar Feed on 2.5/ 8"-6 , 2.5/ 8"-6S and3.L/ 4"-6 ltachines

4.8 Collet Operation and Bar Feed on 2.5/ 8"-6 DBE lrtachine

4.9 Indexing and Drum tocking

4.10 Feed Drive

4.lL The Main Camshaft

I'rame 5 | 6-SpindleBar, Parts

PAGE

13

19

PLFR5/5809/07/88

7

9

5

The Upper Camshaft

Centre Tool Block & Longitudinal S1ides Operating Mechanisrn

Changing Feed Stroke

Changing Fast Motion Approach Stroke

Centre Block and tongitudinal Slj.des

Cross Slide Operating Mechanism

Bar Stop and Operation

Eeed Brake Interlock & Bar Exhaustion Bar Feed Trip

Coolant

Stock Carriage

Swarf Conveyor

SECTION FI\IE - PARTS LISTS ATID GENERAL ARRA}IGEUENTS

4.12

4 .13

4.L4

4.15

4.t6

4.L7

4.L8

4.L9

4.2A

4.2L

4.22


6

73

PLFR5/68oe /07 188

SECTION ONE - TNSTALLATION

L. 1 r,ift the llachine

When planning the siting of a machine consider the space reguired forchip removal, bar loading and servicing, i.e. centre-shaft iemoval.Dimensions of suitable l5.fting bars for use with a crane are shown onthe Foundation Drawing Fig.L.1.Slings must not lie against the machineduring hoisting. Examine the position of the sling wittr tension on therope before the full weight of the machine is lifted.where a crane is not availabre, the machine may be moved by,'wedge"truck or rollers and continuous machined surfaces are provided on theunderside of the machine tray to facilitate the operation. Rollersmust be

.longer than the machine tray width.

Careful handling of the new machine will ensure accurate alignment.L.2 Siting and Foundations

The machine should be installed on a level and stable foundation inorder to ensure accurate alignment is maintained. A concrete base isrecommended. It provides the most suitable foundation because of itsstability and because it is less prone to distortion when laid down inadverse soil conditions.

The actual depth of concrete base must be determined to suit theprevailing soil conditions, which must be capable of supporting themachine, its ancillary equipment, i-ts tooling and. the concrete baseitself.The soil should be consolidated with crushed rock, pebbles and stones.

With the machine in position on the factory floor, leve1 using thejacking screws provided in the machine tray. ft is recommended thatsteel plates be placed between the floor and the screws. Longitudinaland lateral alignment Ievels can be checked wLth a precision level onthe facings provided at both ends of the machine tray and on top ofthe spindle drum housing, see Foundation Drawing Fig.1.l-. Wedgesshould be placed at the positions shown.

Foundation bolt holes are also provided for use where required, boltsto be embedded in the floor approximately 5in (125mm).

Where not bolted-down, machines can be grouted or cemented by any shopapproved method.


7 PLFR5/6809/07 /88

mm\

t670 mm

t

--1---

+

Ilg: 1: 1 - g9s3g3!193- 9r3y13g

USE LEVEL O,iI500Y 50 c PAD6 ON ENO OF TRAY

SHAF

14-4 - 4370 mml9'-{B3mm DTMENSIONS OF SWARF APERTUREIN IHE IRAY SIANDARO MACHINESUPPLIEO WITH FIITED Ccn€R PLATE

o 9',rl'7'- lrl

26 mm

3O3O mm2'.6

780 mmorc Nc

I 243i'

T99-2515mm

WIDTH OVER SPLASH GUARDS5" O'-t52a mm

5'- E'17

USE LEVEL TOP OF MACHINEDORUM HOUSING

c1613 mm

a.

t,SE LEVEL ONMACHINED

END OF TRAY

mOPEN MORSm

LEVEL THE MrcHIN WITH THE SCREWS PROVIDED.USE WEDGES WHERE SI-IOWNGROUT OR BOLT lN POSITIONMACHINE SHOULD REST ON CONCRETE T{oTLESS THAN 6, 152 mM. THICK,

MACHINE WEIGHT (LESS STOCK CARRIAGE)12 ENG TONS: 'l? 2 METRIC TONNES

x

"g8'-4' OPEN DOOR2560 mm

5'- 6'1672 mm

lT ts@

RECOt"f'/E NDED THAT THEMACHINE IS PLACED SO AS TO

ALLOW RE},IOVAL OF THE

CENIRE.SHAFT.

WIDTH OVE?'..7'2311

mm

ltI

(-

III

F€ OVERRAISED COVER8' 9'- 2867 rrm

@GHT

9..^

8-O2rl38rnrn

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T OVERSPLPSH GIJARDS7'.O'-A3a mm

FOR LOADINGBARS

5'5i 1664 mm

TWO

AT EACH ENOSECURE gY SETSCREWS

OPTONAL MOTOR RATINGS22 kw30 kw

LE VELL

mm.

8'. O'

l-r:I 914

CNDED

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PUSH FIT ONE END & DRIVE FII THEOIHER ENO

3'- 4'p16 mm

LIFT INGHOLES ,'@li -31 7mm

I E RECOMME IHAT PLATESFITTED UNDER THE LEVELLING

SCREWS PLATES IO BE SUPPLIEO

Bv CTJSTOMER t

I E+ 3,DIA76 mm.

FOR 1'- ?5mmBOLIS

irorE. BoLr

203iltn.

'2430nm.LIFTIIIG BAR SUGGESTED NSloNS.

@CE

mm

NTRES ACROSS THE MACHINE 4 6:'

Fig. L .1


I PLFRs/ 6B0e/07/88

N

:"aI

DI 25mm

BOLTSTOCKRIAGE

coENCTOSURE

o 75kw

L--

1' 5OB mm

o.25 kw

ING PADCONVEYOR

SWARFcoNvEloR

rTY r8o GALL O {'82O LITRE

COOLANT 1321 mm

1388 mm.r! - rz--.

ga

t04

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1---

n

Il

t\

PLATE No. I

(Drawing50l ZlAl

SECTION TWO - LUBRICATTON CHARTS AT{D SPECIFICATTONS

2.1 General Description

The lubrication system has two separate parts with the two plungerpumPs contained in the same unit and chain driven from the consiantspeed shaft. Access to the unit is through a cover on the lower faceof the motor end of the main drive housing.

one side of the Pump raises oil from the main drive housing sump andpasses j.t through the lower Purolator filter to distributois whichsupply all points in the main drive housing. The circuit contains apressure relief valve set at 10-L5lbs/square inch(0.703-1.055k9/square cm)r the excess oiI being fed to the uppercamshaft oil bath. The bath supplies a number of drip pointsl- andshould be kept clean of dirt and grease. A strainer box fitted to thePump intake must not be allowed to become choked. Examine twice a yearand clean the sump if necessary. check the oi1 revel in the sumpthrough a sight glass situated in the front of the main drive housingand fill at reqular intervals.The other side of the pump unit draws oil from the tank in the beamthrough the upper Purolator filter and passes it to sight feed headersfor the spindles and to distributors for drum housing and cross slidefeeds. The circuit contains a pressure relief valve set at 10-15lbs/square inch (0.703-1".055 kglsquare cm.) and contained in a block.When a "Flush" button in the block is pressed, the relief valve isblocked and a surge of oil is passed to the spindles and drum housingfeeds. The "Flush" button should be pressed daily on machine startuP.

Oil in the d.rum housing should be maintained to the level indicated onthe rear inside face of the drum housing. Keep clean of grease andsoluble coolant contamination.

A priming plug is provided on the Purolator housing for filJ-ing or forreleasing air Locks. Purolator handles should be turned clockwise twoor three turns each day to clear the element of foreign matter. Theunits should be removed twice a year and the element cleaned withparaffin and a soft brush. Use a solvent on gurnmy deposits.

A Summary of Lubricants, fig. 2.L specifies the I.S.O. standard forall the lubricants used on the machines.

Fi1l aI1 grease nipples with grease, etc., as indicated on the chartsFigs.2.2 &.2.3. Use ball bearing grease sparingly in the spindlenose labyrinth seal nipples.

Concerning Lubrication

(a) Check all oil levels in tanks and sumps. They must not fal1below the levels indicated.

(b) Frequent checks of the spindle sight-feeds are necessaryi alsocheck that the main drive oil is circulating.

(c) Turn Purolator filters daily: apply oil gun to all nipples andoil parts not served by the automatic system.


9 PLFR5/ 6B09/07/88

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SECTION TEREE - PREVENTATIVE IIAINTENATiICE SCEEDULE

3.1 L000 Hour Procedures

Work Schedule to be carried out after 200,1,000, 21000, 31000 hoursrunning, dt 1r000 hour intervals thereafter.Cross Slide FeIt Wipers & Aprons: Inspect and check for damage. Remove

swarf particles.

Change Gear Securing Nuts: Check tightness.

Attachments and Tooling EquipmentSecuring Nuts: Check tightness.

Chasing Attachment Drive (iffitted) 3 fnspect drive chain, check tension,

Remove covers and check lubrication.Push back gaiter covers on universaljoints and inspect.

Inspect and check adjustment (seehandbook and machine plate).Check drive chain tension

Feed Drive - Brake Clutch:Feed - Fast Clutch:Threading:Drive Clutch:

Collet Operating Shoe:Bar Feed Shoe

Six Collet Operating Sleeves:

Bar Feed l{echanism:

Bar Feed Dlechanism AligningRing:

Cyc1ic System:

Upper Camshaft:

l,lain Block Positive Stop:

Independent Slides Positive Stop:

Cross Slide Positive Stops:

Drum Housing:Main Drive Housing:

Coolant System:

Bar Feed Tube Assemblies:

Collet Tubes, Collets:


Inspect for correct alignment andlubrication. (Renew when worn).

Inspect for correct alignment andmovement to avoid overheating.

Check adjustment.

Inspect for alignment.

Inspect for leakage caused by looseconnections and damaged tubing.

Check tightness of bolts on couplingbetween wormwheel and shaft.

Check for excessLve pressure.

Check for excessive pressure.

Check for excessive pressure.

Clean lubricating oil sumps.

Clean tray, taps, pipes and ducts(including manifolds) .

Remove and thoroughly clean.Inspect Feeders.

Remove and thoroughly c1ean.Inspect Collets.

PLFRs /680e/07 /88

llllll

13

Spindle Bore and Collet Seating: Clean. fnspect co1let keys forexcessive wear.

Longitud.inal S1ides: Pull quadrants back, push forwardto check free movement. Adjust gibstrip if required.

Spindle Speed and FeedChange Gears:

Main Drive Housing:

All Cams and Cam Rollers:

Spindle Drum:


Inspect lubrLcation.

All chain drives, checl< adjustmentand sprocket alignments.

Inspect for excessLve wear, oil,rollers and pins.

Check end float (see handbook).

PI,FRs/ 6809/07 /88

L4


Work Schedule to be carried out after 2OO, 2,OOO,at 21000 hour intervals thereafter.

4r000 hours running,

Intake Strainer for Pump onContinuous Lubrication System:

Interlube Cyclic MeteredLubrication System if fitted:Main Drive Belts:

Handwind Interlock System:

Bar Feed Spring:

Control Panel Wire Connections:

Control Panel:

TPUROLATOR' Metal- Edge Filter:TPUROLATORT "llicronic" CartridgeFilter:Upper and Intermediate CrossSlides:

4th & 5th Station LongitudinalSlides:

Chasing Attachment (if fitted):

Stock Carriage:

Feed Tube:Steady Bushes:

Spindles, Col1et OperatingToggles:

Pulley Shaft:

Spindles:

Conveyor:

Spindle Drum:


Inspect and C1ean.

Check frequency of operation.

Remove cover, check belt tensionand inspect for excessive wear.

Inspect and check (see handbook).

Check setting.Check for tightness.

Hand operate contactors and relays,ensure free action.

Remove, clean filter and case, refit.

Remove bowI,

Strip, C1ean,strip.

renew cartridge.refit and adjust gib

Strip, Clean, refit and adjust gibstrip.

Strip, Clean, inspect for wear,refit.Remove springs, clean, regrease,renew as necessary.

Examine and renew if worn.

Strip and examine for wear.(Renew in matched pairs).

Check for oil leak adjacent topulley, and renew oil seal ifnecessary.

Remove collet operating sleeve,examine internal form. Check forcorrect movement.

Remove from machine and cleanthoroughly. Examine for damage,adjust and refit as necessary.

Check indexing, measure over index.(see handbook).

PLFR5 / 6B09/07/88

15

Drum Locking:

Drum Lat,ch:

Interlube Cyclic MeteredLubrication if fitted:

Centre Block:

Attachments:

Switches:

Lower Cross Slides:

I Conveyor Drive lt{otor Bearinqs:

Upper Camshaft Housing:


Check setting (see handbook) .

setting, inspect for excessiveCheckwgar.

Drain and clean reservoir.Draln and flush. Clean Strainer onguide block. Adjust gib strip ifrequired. Do not over-tighten.Strip attachment slides, clean,refit and adjust. Inspect, replaceworn j.tems. Gears , bearings , splinedshafts, clutch parts etc.

Check setting, ensure free action,inspect for mechanical damage, checksecuring screws.

F1exib1e Electrical Conduits: Inspect for damage.

Strip, clean, refit andstrip.Replace aprons and felt

adjust gib

if worn.

See manufacturerrs Service Sheetsor follow a known procedure for lowpower motor maintenance.

Check oil supply to drip tray andoutlets.

PLF'R5/6B09/07/88

16


Work Schedule to be carried out after 41000 and 8r000 hours running,at 4,000 hour intervals thereafter.Coolant Pump (Gear Type OnIy): Strip and Clean, examine gears,

shafts and gland. Renew as required.Refit.

Continuous Lubrication System: Remove and strip pump, clean andexamine for wear. Renew as required.Refit.

Main Drive Housing: Examine lower and upper camshaft.Worm and Wormwheel. Drives for wear.Replace worn gears.

Spindle Drum, Spindle:Drive Gears:

Examine for wear. Renew if worn.

Cross Slides, Upper andIntermediate: Replace return springs.A11 Chain Drives: Renew worn chains.

Drum Locking: Renew Cam Roller and Pin ifnecessary. Examine Cam and Renew ifworn.

Bar Stop lvlechanism: Strip Covers and examine cams,rollers and pins. RepJ-ace if worn.

Spindle Assembly: Remove feed tube assemblies andexamine. Replace worn bearings.Remove spindle nose caps, examinepiston ring sea1s, replace if worn.


PLFR5/6B09 / 07 /88

L7


work schedule to be carried out after L2,000 hours running.

Longitudinal Motion:

Camshafts:

Cross Slide Operation:

Dtain Drive Housing:

Drum Housing & Drum:


Examine bushes, and pins, replaceas necessary.

Examine for worn keys and kelnrays.

Dismantle front and rear cam leversand renew bushes. Remove links andcross slide levers and renew bushesand pins and worn shafts.Examine initial drive shaftsReplace if worn.

(3).

Withdraw spindle drum, exam5-ne frontbearing area on drum & in housingfor excessive wear and damage.(Consult Wickman Engineer) .Examine drum seal, replace if worn.

PLFR5/ 6809/07/88

18

SECTION FOUR CONSTRUCTION AND PROCEDURES

4.L Spindle Speed. Drive

The initial machine drive described below covers that part of thedrive from the motor to the spindles and indicates where the drive istaken off for further reduction for the feed and the fast motiondrive. This is d.escribed j-n section 4.L0. The motor, fLg.4.2 ismounted on a platform pivoted on the tray and situated at the rear ofthe main drive housing.

The drive to a constant speed pulley shaft in the main drive housingis by vee belts. To adjust the belt tension the motor platform israised or lowered by means of two adjusting bolts. Fig.4.2 arsoshows the direction of rotation of the pulleys.

The constant speed pulley shaft drives the "second" shaft through therange change gears, providing an initial high and low speed range.These gears have a neutral position to disconnect the drive for safetypurposes when checking motor rotation.The drive from the "second" shaft is transmitted by spindle speed pickoff gears to the centre shaft. A list of gears is given on fig. 4.3.The centre shaft extends along the main drive housing through thehollow centre guide between the main drive and spindle drum housingsand through the centre of the spindle drum to a gear on the rear faceof the spindle drum.

Access to the speed pick off gears is at the motor end of the maindrive housing. Gear changing is described in the Operators Handbook.Standard attachments are driven from the centre shaft to keep a directspeed relationship with the spindle. The gears and the chain wheelsrequired are supplied fitted. The initial drive for the feed gearingis taken from the centre shaftr so that tool feed for each spindlerevolution remains constant with any change of spindle speed, and theoverall cycle time will vary with spindle speed changes.

Drives requiring constant speed are taken from the constant speedpulley shaft. These are the fast motion drive, coolant pump drive andthe lubrication oi1 pump drive. A11 the chain drives and the positionof the chain wheels can be seen on fig.4.4. A11 the chain drives,with the exception of the oi1 pump drive, are provided with jockeysprockets to tension the chains. The oil pump is mounted on a swingingbracket and chain tension is adjusted by moving this bracket. Thechain drives are illustrated with directions for adjustment on fLg.4.4

Do not overtighten chains. Correct adjustment should allow the middleof the longer run of any one chain to be moved sideways a minimum of3/4Ln (Lgmm).

For layout of gearing and camshafts, see figr.4.1.


PLFR5/ 6B09/07/88

19

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PLFR5 / 6B09/07/88

24

4.2 Drum

The drive from the motor was described to the point where the centreshaft Passes through the hollow centre guide to the spindle drum.

Fig.4.5 illustrates this end of the centre shaft, with the spindledrLve gear keyed to it and the driven gears mounted directly on eachwork spindle.

The spindle drum carries the work spindles and the centre guide onwhich the main tool block slides. This arrangement ensures consistantalignment of the work spindles with the main tool block. The endthrust of the tools upon the spindle drum is taken by the stop ringsecured to the front of the spindle drum. This stop rLng also carriesstop screws which are adof the cross slides, 9ivslide and spindle in each

Hardened steel thrust pads are fitted in the rear flange of thespindle drum to eliminate end float and are ajusted by screws andlocknuts. These should be set with no clearance between the pad andthe drum housing face when drum j.s coId.

The drum is supported at both ends in machj.ned diameters in the drumhousing. A gear on the rear (bar feed end) of the drum, meshingdirectry with the Geneva gear, relays the motion of the Genevamechanism to the drum to index the d.rum through 60 degrees. A furthergear is taken from the drum J.ndexing gear to drive the indexing of thestock carriage. See fig.4.1.

jLustable dead stops for the innermost positionng independent setting between each crossindexed station.

PLE R5/ 6809/07/88


25

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26

4.3 Works indles (2.5/8-6 and 2.5/8-6 arran for double bar feed)p

The workspindles are mounted in a pair of Timken precision taperroller bearings at the front and an extra precision parallel rollerbearing at the rear, see fi9.4.5. The front bearings are protectedagainst the ingress of coolant and swarf by a piston ring seal and alabyrinth seal. A front cap covering the seals is provided with greasenipples so that the seal assembly can be filled with grease for theexclusion of foreign matter. Inspection of the seal assembly can bemade by the removal of this cap and the short spacer sleeve whichcontains the piston ring within its seal assembly, the piston ringbeing lightly sprung in the bore of the sleeve. As with any pistonring assembly, careful dismantling and assembly ls required and as theend cap clamps the outer race of the front bearing, end float checkingof the bearings is essential after reassembly. Where fitted, removecoolant thrower rings from the spindle nose to obtain access to theend caps.

4.4 Front Bearing End Float

The Timken taper roIler bearings are adjusted by a slotted lock nutaccessible by removing the front upper cover on the drum housing. Theslotted lock nut is split and clamped by a cap screw. The cap screwshould be kept lightly clamped whiLst adjusting the bearings. Thefollowing procedure is recommended when checking and adjusting:-

a) Check end float with a clock indicator (preferably a magnetic basetype) mounted on the spindle drum and feeling against the spindle.

b) Check with bar gripped in the collet.

c) Use a short lever to exert pressure on the spindle, pushing thespindle the extent of the end float to obtain a reading.

d) The end float should be very gradually reduced by adjusting thelocknut with short sharp taps on a wrench or a broad punchIocated in the slotted locknut. Remember, actual nut movementshould be smaII, a 1/L5in(1.5mm) turn on the outside of the nutwill reduce the end float approximately 0.00017in(0.004mm). Anend float of 0.0005 to 0.0008in(0.015 to 0.020mm) should be setfor normal speeds.

e) The end float can be increased to 0.0008 to 0.0010i.n(0.020 to0.025mm) for high sPeeds.

f) The cap screw in the slotted locknut should be tightened aftereach adjustment before reading the end flot and only slackenedsufficiently to allow the nut to turn when adjusting.

g) After each adjustment, before reading the value of the end f1oat,the spindles should be jogged to settle the rollers.

h) When over-adjustment reduces end float below 0.0006in(0.0L5mm) itis necessary, after turning the slotted locknut back, to separatethe bearings a small amount by mallet blows on the rear (bar feedend) of the spindle. By this means it is possible to jolt thefront bearing and the piston ring carrier away from the spindleshoulder so that mallet blows struck in the opposite directionre-seats the front bearing and piston ring carrier against thespindle shoulder. This procedure ensures that the correct endfloat reading is obtained and if not fu11y applied it may give afalse reading which will increase under operating load as thebearings re-seat.


PLE R5/ 6809/07/88

27

j) When adjusted satisfactorily run the machine at about 150 r.p.m.gradually increasing to the spindle speed required, observing thetemperature at regular intervals on a thermometer placed in anend cap screw ho1e. Temperature should not exceed shoptemperature, + 70 degrees F (2L degrees C) at approximately400 f.p.ttl .

The following information applies if spindles and bearings aredismantled from the drum:-

a) Check that the oil feed and circulation holes are clear.b) Assemble bearings on the spindle with the biggest bore for the

adjustable bearing nearest to the locknut. This makes the endfloat adjustment easier.

c) Eccentric marks on the outer races to be in line and radiallyoutwards.

d) Eccentric marks on the inner races to be in line.e) The front bearing and piston ring carrier to be pressed hard

against the spindle shoulder.

The front and rear bearings are lubricated in the 4th and 5th stationson six spindle machines by oil from a pressure header on the beamabove the drum housing. Slight drip feeds mounted on the beam areprovi.ded for checking the flow. Spacing rings on the spindle assemblyretain the lubricant to a suitable leveI and drj.Iled passages in thedrum aIlow internal oil flow around the front bearing assembly.

Collets are of the draw back type and are opened and closed by atoggle mechanism on the rear end of the spindles and a springcompensator is included to accommodate small variations in bar size.The collet may be removed from the spindle by releasing the springplunger and turning the col1et adjusting sleeve until the collet isscrewed clear.The tension on the collet is adjusted by means of the collet adjustingsleeve, and after fitting new collets, must always be tested by handbefore running under power.

When adjusting the collet tension, extra clearance for the spanner(item No. 573x106) may be obtained by placing a spacing block (itemNo. 573x113) between the stop collar on the front guide rod and thebar feed slide, see fig.4.6. The spacing block should be placed intoposition when the bar feed slide withdraws.

On the 2.5/8-6 arranged for double bar feeding, the spacing blockshould be placed into position when the bar feed slide withdraws.

The feed fingers are fitted to feed tubes carrying on their outer endsthe bar feed bobbins mounted on anti-friction bearings. In order toremove the feed fingers it is first necessary to slide back the stockcarriage tubes. These are held in the stock carriage indexing gear byclamps which must be slackened and turned clear to release the stockcarriage tubes. By turning the plate on the rear of the centre stopthe feed tubes may be removed from the machine complete.

On the 2.5/8-6 standard machine and the 2.5/8-6 arranged for spi-ndlestopping, in order to extract the feed tube in station 1 it isnecessary to withdraw the bar feed shoe. The machines are fitted witha screwed knob which can be pulled down to withdraw the shoe or turnedto retain it in the withdrawn position.

Frame 5, 6-SpindleBaf,, Parts

PLFR5 /6809/07/88

28

On the 2.5/8-5 arranged for double bar feed, ln order to extract thefeed tube in either statlon 3 or 6 it ls necessary to withdraw the barfeed shoe. This is again effected in either statl.on by pulling ascrewed knob to srithdraw the shoe or by turning same to retain it inthe withdrawn position.

Bar steady bushes are fitted in the end of the feed tubes and areretained by a screwed sleeve and slotted locknut.

Frame 5, 6-SpindleBar- Parts

PLER5/680e/07/88

29

i

Centre Stop

Lot:krrtg Plun0er Collet irrrrJ ArlJustrrerrt rql.=lEro Slrrrrrllo Enrl Thrtrst Acllustnrent

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PLFR5/6B0e/07 /88

Collet Closing Sleeve

Bar Feed Tubes

Collet,Adjusting Sleeve

Bar Feed Roller Bracket

I

lndex Clutch Lever

Itiv.,/l

30

4.5 Work gPll9ls:r 2.5/8-6 S 1eS rThe spindle stopper version of the 2.5/8-6 spindle machine enablesspindles to be stopped and held in stations 2,3, 4 and 5. Allcombinations of stopping and starting can be arranged between thesestations.

standard machines cannot be converted to a spindre stopper andprovision must be made at an early stage of manufacture.

Fig.4.7 shows the spindle drum assembly; each spindle gear isdriven from the central gear and runs loosely on ball and rollerbearings when the multi-p1ate brake is engaged. The brake contains aseries of pre-Ioaded cushion springs whLch limit and maintain thebrake torque and is sufficient to brake the spindles to a standstill.The multi-plate drive clutch on each spindle is engaged by the axialthrust imparted by a row of balls, sgueezed inwards against conicaland frat faces by the crutch bobbin when l-t is moved by the camoperated clutch glut. The clutch is adjusted by turning the slottednut from serration to serration on its right hand thread, theserrations being maintained in engagement by a series of clutch plateseparation springs. The clutch is accessible for adjustment in the 6thstation and an adjustment of one serration at a time can be made by asharp hammer blow on the clutch punch 573X1-55. After adjustment theclutch must be checked using the hand lever 502X25L and a springbalance reading between 50 and 701b (22.73 and 3L.8 kgs) measured atthe knob end of the lever should be maintained.

The clutch gluts are operated during indexing of the spindle drum by aseries of cams secured in housings at the bar feed end of the drumhousing. The cams may be selected. to suit varying tooling requirementsand are supplied to order. A cam housing and one set of cams forstopping in the following conditions are supplied as standard:-

a) Stop ib) Stop i

start instart in

5th or6th

,,

rhth

n4n5

When fitting new cams handwind through index to ensure that therollers pass freely all round the cam track.

Cross slide attachments and drives for use with spindle stoppingmachines are usually designed for a special and limited application tosuit customerts components. Fig. 4.8 shows the cams for the 2.5/8'r-65.

4.6 Dismantli (2 .5 / 8-5S Machine)

It is recommended that spindle removal be und.ertaken by WickmanBennett Service Engineers who are fulIy traj-ned and highly skilled inmachine reconditioning.

A brief guide to the procedure is given below:-

The drive clutch and brake clutch gluts and operating shaft should befirst removed, preferably in the 6th station. Unscrew the drive clutchglut retaining nut and the end nut at the brake glut (accessiblethrough the drum housing). Withdraw the shaft through the glutssufficiently to remove the half collars on the drive glut end and thekey in the shaft at the brake glut end. Dismantle the shaft bearing atthe drive glut end and withdraw the shaft, graduallu unscrewing theremaining nuts.


PLTR5/ 6809/07/88

31

Remove the feed tube, collet tube, collet ad.justment assembly, col1etsleeve, toggre carrier and toggles. unscrew from the spindre thethrust pad retainer nut, remove pads and the drive clutch baIIassembly. Retaining clips in the shape shown 2.L/L6in,fitted over theoperating sleeve will hold the ball thrust ring and retain the 33operating baIIs. Drive clutch plates can then be stripped and thebearing retaining nut unscrewed. Radial access to the- nut lockingscrew is through a hole in the spindle gear (5/32Ln A/Flats hexagonwrench is required).

Unscrew the brake clutch sleeve stop fitted radially to the spindleand the adjacent front bearing adjusting nut.Dismantle the spindle nose thrower ring (where fitted) and unscrew thefront cap covering the piston ring seal and carefully remove the shortspacer sleeve.

The spindle may then be withdralrn, stripping the drive gear andbearings, the rear bearing spacer, brake plates and operating sleeveand the front bearing nut and spacer, leaving in the drum the rearroller bearing and spacer and the brake spring assembly. The frontbearings and spacers should withdraw with the spindle.The brake spring assembly is retained in the drum with a taper pointscrew and locknut and if the assembly is removed care is needed whenreplacing to align the keyway with the torque pin fitted in the drumbore.

The rear rolIer bearing is held between an end cover and a spacerIocated against a circlip in the drum bore. This circlip should haveits deepest section over the oilway recess in the spacer.

Assemble bearings as d.irected for the standard machine spindle,section 4.3 page 27.

Replace the spindle and its component assemblies in the reverse orderto dismantling, ensuring correct order of replacement as the spindleis fed through the bearings. Front bearing end float will- needadjustment as directed in section 4.4. Other adjustments are asfollows: -Hold the glut shaft in the brake position by screv, and collar in theend of the glut shaft and adjust the brake glut retaining nut toobtain 3/32Ln(2.38mm) compression of the brake springs.

Thrust pads to be assembled according to marks. Clutch to be inneutral when tightening the thrust pad retaining nut.


PLFRs/6B09/07/88

32

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PLFR5/ 6B09/07/88

55

4.L3 Centre Tool Block and Lo itud.inal Slides ra Mechanism

The mechanism derives its motion from cErms on the upper camshaft, thethree slides being operated. by a series of racks and levers to giveeach slide a constant fast approach stroke and an infinitely variablefeed stroke; centre block 0 to 5in (O to 127mm), independentlongitudinal slides Oin to 5.5/8in (0 to 143mm). A sliding block withprovislon for three sets of pinions and slideways for racks is carriedin guides on the top of the main drive housing and when cam operated,imparts the fast motion stroke to the three slides. The block islocked in its forward position and three separate quadrant levers arecam operated to provide the feed motion through the racks and pinionsto the slides.At the end of the fast motion stroke the sliding block lockbolt entersa tapered setting on the block; if the seating is not directly underthe lockbolt the block will be moved and consequently double themovement on the toolslides. The setting is shown on figure 4.2L.UnIessdismantled or cam wear has occurred, adjustment should not normally benecessary. The adjusting procedure is as follows:-

Stop the machine at the end of the fast approach stroke with thelockbolt t'IN'r and remove the sheet metal covers. Dismantle theIockbolt operating lever by removing its eccentric pivot pin.

Release the spring load on the lockbolt by unserewing the retainingcap. The spring load is approximately 601b. (27Kgf) and the cap can beheld down by an assistant if the two opposing screws are firstremoved.

Fit a long B.S.f. fine thread bolt or stud in the thread in thelockbolt to enable it to be pulled clear of its seating. With the lockbolt withdrawn handwind the machine backwards until the sliding blockstart,s to retract, then carefully forwards until the block is just atthe maximum forward position on the fast motion cam.

The block should then be moved with gentle blows from a mallet until a0.003in (0.076mm) feeler can be trapped between the outer part of thecam and the rol]er. In this position the lockbolt should fit exactlyin the tapered seating without moving the sliding block setting. Inorder to reset the sliding block, release the pad bolt holding the camroller pin and turn the pin by the hexagonal end to obtain the exactseating condition. The eccentricity must be kept in the lower half asshown on fig.4.2L.

After making the adjustment, the pad bolt nut must be tightened to amaximum to prevent pin movement.

Re-assemble t,he lockbolt operating lever and adjust its eccentricfulcrum by the squared end to just nip the lockbolt down in theseating with the roller on the inner cam. See figs. 4.19, 4-20and 4.21.


PLFR5 / 6B0e/07/88

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4.15 fast motion ch stroke

Two alternative cams are available for 3.1/2Ln (88.9mm) and 5in(L27mm)stroke. Changing involves the removal of the upper camshaft.

Auxiliary motions are available for the 3rd and 6th stations on thesix spindle machines, see Operator's Handbook,

4.16 Centre block and longitudinal slides

The centre tool block, fitted with bushes and scraper rings, slides onthe centre guide which indexes with the spindle drum. Torque loads aretaken against guide faces in the beam by a guide block on top of theguide arm, adjustment for wear be5-ng provided by a gib strip. Whenadjusting the gib strip carefully check the adjustment throughout thetravel as wear will tend to occur on the portion covered by shortstrokes. Access is through the covers on top of the beam, see fig.4.20 .

Oil is fed from drip points in the beam to a strainer on the guideblock and down a pipe to the reservoir between the bushes in thecentre tool block. brain and filler plugs are provided for periodicaldraining and flushing out.

The centre tool block is pushed by a double link from the lower centrerack and no endwise adjustment is provided. The stop rod is providedto control length accuracy. Stop nuts should be slackened off wellclear before adjusting slide strokes as the final position of the toolblock is not constant for all strokes.

The faces and the tenon slots of the tool block are ground to closetolerances and standard toolholders and attachments may be fitted toany face without selection for height or centrality.

The longitudinal slides are mounted on vee guides fitted on the beamwhich are accurately adjusted for alignment and centrality by a tenonblock secured to each end of the vee guide. Screws in the beam clampthe blocks to one side of a beam slot.Tapered gib strips are provided and the headed screws at each end ofthe slide should be adjusted with the tool (573x108) supplied in thetool kit.

Each slide is pushed by a rod screwed into the pusher bar and isadjustable for position 3.L/2Ln(88.9mm) by means of nuts on the rod. Aspacer between the nuts is slightly wider than the bracket on theslide to allow for slight misalignment of the pusher rod.

As with the centre tool block, stops should be well clear beforeadjusting strokes.


PLFR5/ 6Boe/07/88

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4.1.7 Cross Slide O ration Mechanism

The mechanism is situated in the drum housing and consists of a seriesof levers and pivoted links operating upon gear quadrants and racks togive the slides a two part motion of fast approach and withdrawal anda slow feed similar to the longitudinal slides.The fast approach is by cam operated toggles, actuating two heavy"rocking" levers through a short arc. A cam on the main camshaftextends a toggle, swinging the front lever pivot on two stop screws inthe drum housing floor. A second cam on the main camshaft imparts asimilar motion to the rear rocking lever. Adjustment to the stopscrews should only be required after a long period of service, fig.4.22 illustrates and explains the adjustment.

Clamped into the tee slots on the rocking levers are adjustable linkpivots with links extending to suitable levers on the cross slideoperating shafts. An extension on each rocking lever carries a camroller controlled by the feed motion cams on the maj.n camshaft.

Figure 4.23 shows the adjustment provided for meshing the gearquad.rants and racks on the lower cross slides.All cross slides have independent feed stroke setting, adjustable bysliding the appropriate link pivot along the rocking lever tee slot toa setting indicated by a pointer on a scale. See also "OperatingAdjustments" in the Operatorrs Handbook.

The upper cross slides have a double range of feed strokes, the "Iong"range being equal to twice the scale reading. The change-over isobtained by transferring the upper link pivot connection from theouter hole rtB, to an inner hole'An in the operating lever. It isnecessary to remove a retaining circlLp on the pivot pin and torestrain the slide spring load with a pressure on the top of theoperating lever to withdraw the pin.

Changing intermediate cross slide feed stroke range

The changeover, as on the upper slides, is by transferring the linkpivot from an outer hole nBr in the operating lever to an inner hole,Att.

Access to the operating lever is by removing the screwed cover on theside of the drum housing.

Set the maximum stroke on the rocking lever scale and with the slidesin the withdrawn position adjust the micrometer head to bring theslides to the maximum back position. A hexagon headed bolt clamps theIink pivot to the operating lever, the bolt passi.ng through the leverinto the threaded pivot. Unscrew and withdraw the bolt and slide thelink and pivot along a slot in the lever to the alternative holesetting. ft is necessary to restrain the slide return spring withpressure on the operating lever or the end of the slide. Replace the-lamp bolt and set the feed stroke and the slide position as required.


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4.LB Bar S and Operation on the 2.5/ 8"-5, 2.5/ 8"-65 and 3.L/4"-6Operating adjustments are described in the 'rOperator's Handbook".The bar stop movement is derived from two cams on the main camshaft,operating on a lever fitted with two cam rollers. One cam and roIlerswings the bar stop into position and the other returns the bar stopafter bar feeding. The lever is connected to an upper operating leveron the bar stop shaft by a spring box link, the bar stop shaft beingcarried on brackets between the housings. The mechanism is protectedby a front and rear cover secured to the main drive housing attachmentface. Normal operation swings the bar stop up from between the lowercross slides to the first station spindle centre, the upper operatinglever contacting an adjustable stop and compresssing the spring box1/8in (3.17m).

The bar stop can be arranged to sw5-ng over the first station slide byfitting the upper spring box pivot connection and operating lever onthe opposite side of the bar stop shaft. The front cover should beremoved, the adjustable stop in the support bracket released andwithdrawn, and the lock-nut on the top of the spring box linkunscrewed. The spring link can then be disconnected from the lever byturning the hexagon on the sprj.ng shaft at the top of the tubeclockwise. This should detach the operating arm which together withthe shaft, can be turned over and reconnected. to the spring box. Thebar stop and the bar stop arm should then be re-aligned to the spindleand the dead stop fitted in the location provided and adjusted tocompress the spring box 1/8in (3.17mm). The bar stop is formed with ashaft end which is clamped in the bar stop arm. A square headed screwacts on the shaft end for fine adjustment.

Bar stop operation on the 2.5/8"-6 arranged for double bar feeding atstations 3 and 6:

Operating adjustments are described in the Operatorrs Handbook. Thebar stop movement is derived from two cams on the main camshaft,operating on a lever fitted with two eam rollers. One cam and rollerswings the two bar stops, one in station 3 and the other in staton 6,into position for bar feeding and the other returning the bar stops totheir parking positions after bar feeding.

The lever is connected to two upper operating levers on the bar stopshafts with spring box links, the bar stop shafts being carried onbrackets between the housings. The mechanj-sm is protected by a frontand rear cover secured to the main drive housLng attachment face. Theoperation of the mechanism swings the bar stops and their bar stopbrackets downwards over the 3rd and 6th slides to the 3rd and 6thspindle centres, the upper operating levers contacting adjustablestops and compressing the spring boxes 1/8in (3.17mm).

4.L9 Feed brake Interlock and Bar Exhaustion Bar Feed Tr IP

See fig. 4.24.


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4.20 Coolant

The coolant is supplied from the machine tray by a gear pump, chaindriven from the constant speed shaft. Chain adjustment is described atfig. 4.4. An adjustable gland is fitted. to the driving shaft toprevent leakage and this should be adjusted as lightly as posslble toprevent overheating and pump seizure. A relief valve is fitted in thepipe system to return excess coolant to the tray. Coolant taps arearranged adjacent to the lower cross slides and on headers on eachside of the machine beam and additional plugged holes are provided inthe headers.

The chain drive should be removed when the machine is to be runwithout coolant in the machine tray.The strainer box and weir must be in position at all times to preventswarf entering the supply pipe. The strainer is fitted with a looselid and should be inspected and cleaned at regular intervals, seefig. 4.25.

Machines constantly working on operations requiring oil fed cuttingtools can be equipped to special order with an additional highpressure pump and a filtration system, either of the magnetic drumtype or one of the centrifugal type dependent upon the material to bemachined and the type of coolant to be used. For these systems, pipework is installed to draw the supply from a strainer in the machinetray or from a separately piped supply. Filtration systems usingproprietary items should be cleaned and serviced as directed by themakerrs instructions.


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The two main parts, the sLand and. the tube assembly, are erected andaligned as described in the Operatorrs Handbook. The tube assemblyhas a central tube to which are secured two tube carriers to space andguide the stock tubes. The rear carrier is supported on rollels inthe stock carriage stand.

At the machine end, the front carrier is gear driven during indexingby a pinion from the drum indexing mechanism and must be correctlymeshed to the marks on the gears. The stock tubes are located by a!y . flanged sleeve secured to each tube and clamped in pairs,to thefront carrier.

The tubes should be handled carefully; bent or distorted tubes willmake it more difficult to slide the tubes through the carriers.Convoluted spring linings to provide resilient support for the barstock are not normally required, but are available in the followingsizes to order:- 2.5/8"-6, 2.5/8rr-5s and 2.5/9"-6DBF machines, up toincluding 2.5/8" diameter bar, and up to an including l.L/2" diameterbar. Where supplied, springs should be kept well lubricated. with softgrease. The 3.L/4-6 machines are fitted with steady bushes, caried inthe end caps on the machine end of the stock tubes and retained by alatch fitted to the end cap. Bushes can be replaced by loosening a capscrew in the end of the cap and pivoting the latch out of a locatingslot cut in the bush. The bush can then be withdrawn from the tube anda new bush fitted.4,22 Swarf Conveyor

The swarf conveyor is fitted as an optional extra, but conduit andwiring is normally fitted to aII machines, from the panel terminals toa junctS-on box on the beam to simplify later installation. A conveyorunit supplied separately includes control buttons and contactor forpanel mounting and conduit, wiring and a "Niphon" socket forinstallation to the machine.

The screw type conveyor is driven by a L/4 h.p. motor and a reductiongear box, controlled by push buttons on the pendant control paneldoor.

A shear pin in the coupling adjacent to the motor gear box providesoverload protection in addition to that provided by thermal trips inthe motor starter. Spare silver steel shear pins are supplied in acontainer clipped to the side of the conveyor. Before replacing ashear pin, the cause of the overload should be found and removed.Holes are provided in the end of the conveyor screw so that it can beturned by hand.

Steel chutes are fitted in the tray between the housings to guide theswarf into the conveyor. When the conveyor is fitted the coolantintake pipe extends to the drum housing end of the machine, asillustrated on fig. 4.26. The main overflow of coolant is dischargedj,nto a basket under the main drive housing collecting the fineparticles of swarf held in suspension in the coolant. The basket isaccessible from the end of the machine and should be emptied atregular intervals.


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4.L2 r Camshaft

The upper camshaft is transversely mounted across the top of the maindrive housing. It carries disc cams which operate the centre toolblock and the longitudinal slides. Cam carriers are also fitted forcams to operate the 3rd and 6th station longitudinal motions on thesix spindle machines.

The cam dogs controlling the fast motion clutch are mounted in acircular tee slot machined in the face of the worm-wheel; a timingdial is provid.ed at the front and rear ends of the upper camshaft.

The worm-wheel drives the upper camshaft through serrations on theface of the wormwheel and a serrated plate engaging a tenon slot inthe upper camshaft. By releasing the centre screw and the two outerscrews this serrated plate may be disengaged from the worm-wheel. Byhand winding the machine, the lower camshaft and the upper worm-wheeImay be turned while the upper camshaft remains stationary, thusenabling the timing of the main camshaft and the upper camshaft to bealtered or corrected as required. ft is vitally important that theserrations engage properly and that the screws are fulIy tightenedafter altering the timing.

A vee groove is cut across the periphery of the cam discs and isvertically above the centre of the camshaft at 0 degree timing ang1e.See figs. 4.L7 and 4.18.

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4.'7 Collet ration and Bar Feed (2.5/8-6 and 2.5/ 8-5S only)

After the workpiece is cut off in 6th station the machine is indexedto the 1st station, the collet opened, bar stock fed out to the barstop and the collet closed just before the advancing tools startcuttingi see timing diagram fig. 5.6.2 in the 'Operatorrs Handbookr.

The collet operation mechanism consists of a cam operated slide movingon two round guide bars mounted between the drum housing and the end.bracket.

A bonded fabric shoe carried in a slot in the slide engages in agroove in the collet sleeve on the work spindle. It is spring loadedso that if a co1Iet sleeve indexes out of position the shoe will bedepressed and rendered inoperative.

The collet slide is operated by a roller and barrel cam direct fromthe main camshaft and can be disengaged by loosening a pad bolt andpulling the roller carrier outwards clear of the cams, see sheet 6.20.Adjustabre nuts carried on a rod provide a stop for the operatinqrslide and enable the mechanism to close the collets to a constantposition, with either hand or cam operation. Fig.4.9 shows thecorrect adjustment for these nuts.

The bar feed mechanism is spring operated and controlled by a barrelcam on the main camshaft. The slide is mounted., as the colletoperation slider on the two guide bars and carries an aligning ringand a spring loaded shoe. The aligning ring encircles all the bar feedtubes and in the lst station restrains the feed tube bobbin betweenthe ring and the spring loaded shoe. The spring loaded. motion of theslide and the shoe feeds the bar feed. tube and the bar through thecollet tube to the bar stop. On the return cam stroke the aligningring returns the feed tube to a "ready to be fed" position and holdsit there, together with the other bar feed tubes. Any endwise movementof the tubes is limited by the aligning ring and the adjustable centrestop, carried on a shaft extension on the stock carriage and centrallyplaced between all the spindles, see fL9.4.9.

Trvo cams are needed to cover the bar feed stoke range; a L/2Ln to 5in(L2.7 to 127mm) cam is supplied as standard and a 5in to L0in {L27 to254mm) cam, 5441L06B is available to order.

For the 2.5/8"-65 machines only, two cams are available. The camsupplied as standard covers a range of L/2Ln to 5in(L2.7 to 127mm) anda l.L/4in to 6.L/4Ln (32 to 159mm) cam, 502Y258 is available to order.

Collet tension and bar feed. stoke adjustment is described underoperating adjustments, in the roperatorrs Handbookr.

The machines are fitted. with a limit switch operated by a rod and anadjustable clamp from the bar feed side. The function and the settingof this mechanism is covered under Auto-Stop Mechanism. See fiq. 4.18.


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4.8 Collet ratj.on and Bar Feed on 2.5/8"-6 DBF Machines

The double bar feed machine has the facility to open the collet, feedbar stock out to the bar stop and close the collet in stations 3 and 7or either in station 3 or 6. The machine timing differs to thestandard 2.5/8r'-6 single bar feed machine because of the double barfeed facility. Co1let opening, bar feeding and collet closing takesplace during the fast motion return of all the tool slides prior toindexing, see timing diagram in the rOperatorfs Handbookr.

The collet operation mechanism consists of a cam operated slide movingon two round guide bars mounted between the drum housing and the endbracket.

The collet slide is operated by a roller and barrel cam direct fromthe main camshaft and can be disengagred by loosening a pad bolt andpulling the roller carrier outwards clear of the cams, see fig.4.10.Adustable nuts carried on a rod provide a stop for the operatingslide and enable the mechanism to close the collets to a constantposit5-on, with either hand or cam operation. Fig. 4.10 shows thecorrect adjustment for these nuts.

Bonded fabric shoes carried in slots in the slide arm extensionsengage in a groove in the co11et operating sleeve on the workspindlesat stations 3 and 6. The shoes are spring loaded so that if a colletoperating sleeve indexes out of position the shoe/shoes will bedepressed and rendered inoperative.

The bar feed mechanism is spring operated and controlled by a barrelcam on the main camshaft. The slide is mounted, as the colletoperation slider oD two guide bars and carries an aligning ring andthe two spring loaded shoes. The aligning ring encircles all the barfeed tubes and in the 3rd and 5th stations restrains the feed tubebobbins between the ring and the spring loaded shoes. The springloaded motion of the slide and the shoes feed the bar feed tubes andthe bars through the collet tubes to the bar stops in stations 3 and6. On the return cam stroke the aligning ring returns the feed tubesto a "ready to be fed" position and holds them there, together witt'the other Lar feed tubes. Any endwise movement of the tubes is limitedby the aligning ring and the adjustable centre stop, carried on ashaft extension on the stock carriage and centrally spaced between allthe spindles.

The bar feed cam has a bar feed stroke range of 1 /2in to 5in (LZ toL2 7mm)

Collet tension and bar feed stroke adjustment is described underoperating adjustments, found in the 'Operator's Handbookr.

AII machines are fitted wi-th a bar exhaustion system. The function andsetting of these systems are covered under Auto-Stop Mechanism. Seefig. 4.18.


PLFR5/ 6B0e/07/88

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4.9 Indexi and Drum Loc

The spindle drum is indexed anti-clockwise (looking on the collets) bygearing from the Geneva wheel. The Geneva gear meshes direct with thedrum gear. The mechanism is mounted at the rear of the machine on thebar feed end of the drum housing, and is shown diagrammatically onfig. 4.1-. The four srot Geneva wheel and gear is driven by thepassage through one of the slots of a roller carried. on an arm mountedon the bar feed cam drum. During each fast motion cycle the drum isunlocked and indexed to the next station, 0.050j-n (f.ZZmm) past thefinal position. This allows a spring loaded latch in the spinate drumhousing to drop into position before the drum is clamped back againstthe latch and locator pads on the drum rocking mechanism.

The latch, which is accessible through the front upper cover, shouldbe adjusted with the latch sitting on the locator pad to give L/32Lnto L/LGLn (0.8 to 1.6mm) clearance to the nutsr €ts shown on fig.4.1-1-.

The drum locking mechanism, accessible through the rear upper cover,is essentially a toggle mechanism arranged to lock the spinate verynear to the dead centre position of the toggle.The toggle pivots on a shaft with eccentric adjustment to obtain thecorrect clamping pressure and a stop screw in the drum housing is set0.01-0in (0.25mm) clear of the toggle link to give the correct toggleoff-set when locked. The following procedure should be followed totest for correct adjustment and should preferably be done when thespindle bearings have reached their normal running temperature:-

Place a tommy bar approximately 12in (304.8mm) Iong 5/8in (L6mm)diameter, in a socket in the upper toggle link (a screwed cover on thetop of the drum housing will have to be removed). Disconnect the pinin the operating lever and the long spring box rod situated near theend bracket, fi9.4.11. PuII the tommy bar down slow1y by hand as faras it will go. The toggle should just bind on the drum and if correcta slight resistance can be felt as the toggle grips when the tommy baris slowly lifted. The high poi.nt of the eccentric is marked on the endof the shaft, visible from the collet end.

The toggle is operated by a link to a lever on the drum locking shaftwhich is connected to a cam lever by a pre-loaded spring box assembly,fig. 4.L2. The long connecting rod should be adjusted to compress thespring 1/8in (3.2mm) when the drum is locked.

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PLFRs/580e/07/88

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4. 1-0 Feed Drive

The feed drive is transmitted by chain from the centre shaft to ahollow sleeve carrying a gear reduction to the first feed pick offgear shaft; gear 'rFrr on the feed and speed charts. The mating gear trHrr

is mounted on one end of a shaft with gear rrJ, on the other end,meshing with gear rrKrr on the final pick off gear shaft. See figs.4.13A and 4.13B.

The final pick off gear shaft carries the feed overload slippingclutch to protect the drive during the feed portion of the cycle. Thesideways disengaging action of the spring loaded clutch de-activatesthe electro-magnetic multi-plate feed clutch and the electro-magneticmulti-p1ate brake allowing the brake springs to "brake" the feeddrive. The main motor then stops. Before the slipping clutch isre-engaged by sliding the driving dogs into mesh, the cause of theoverload should be located and comected. Access to the feed overloadslipping clutch is through the cover carrying the speed and feedplate, fig.4.L4.

After passing through the feed. overload slipping clutch, the feeddrive is transmitted by a pair of gears to the feed side of the feedmotion-fast motion clutch.

A roller'freewheel" clutch is built into the gear on the feedmotion-fast motion clutch shaft in order to maintain the drive whilstthe clutch is in neutral when changing from fast to slow or slow tofast. The fast motion drive is taken from the constant speed puIleyshaft by chain directly to the fast side of the feed motion-fastmotion clutch.

The drive either fast motion or feed motion, then passes through thefast motion slipping clutch, to a pair of gears driving one side ofthe electro-magnetic multi-plate feed clutch on the final feed shaft.Adjacent to the feed clutch, mounted upon the final feed shaft is thechain d.rive sprocket for driving the upper longitudinal camshaft wormand wormwheel.

Bearing housing assemblies in the two outer walls and the inner wallof the attachment drive compartment of the main drive housing supportthe final feed drive shaft. In addition there is further bearingsupport between the inner wall and the motor drive end wa1l. Thebearing housing at the motor drive end of the main drive housing alsoprovides the means of mounting the electro-magnetic multi-plate brakewhich is outboard of the main drive housing.

Forward of the intermediate bearing support, the feed drive istransmltted through a dog clutch co-axially mounted upon and keyed tothe final feed drive shaft. This dog clutch is spring loaded intoengagement with the co-axial sleeve which provides journal supportfor, and to which J.s keyed the electro-magnetic feed clutch. Thepurpose of the dog clutch is to provide the means of disengagi.ng thefeed drive when hand winding the machine through its machining cycle.

The tensioning of the upper longitudinal camshaft worm chain drive isachieved by applying torque to an eccentric mounting for the chaintensioning sprocket. Access to the adjustment of the chain tensioningsprocket is from an external face of the main drive housing motordrive end. In order to adjust the chain tension loosen the hexagonclamping nut and apply a torsional load to the square provided on theeccentric mounting for the chain tensioning sprocket. On achieving thecorrect tension the hexagon clamping nut must be re-tightened.


PI,FRs/68oe/07/88

42

The drive, either fast or feed, then passes through bever pinionsmounted on the front walI of the attachment drive compartmEnt whichdrive the worm and wormwheel on the main camshaft, whose cams andmechanisms operate the cross slides, drum indexing and drum locking,collet opening and closing and bar feeding. The final feed shaft alsocarries the handwind gear which can be engaged by a handwind pinionwhen the feed and feed brake clutches are disengaged.

The feed-fast crutch is operated by a yoke and a rever from twoadjustable dogs in the rrT'r slot on the upper wormwheel. The timing ofthe dogs can be set as required, normally shifting the clutch at [,hestart of the feed period and at the end of dwell when the tools havefinj-shed cutting. A diagrammatic illustration of the feed motion and.fast motion clutch control is shown at fig.4.1g.The electro-magnetic brake on the final feed shaft brakes the drive tocamshafts when the electro-magnetic feed clutch is disengaged manuallyor by the auto stop control trip feed.

Instructions for adjusting mechanical multi-p1ate clutches are givenon plates fixed to the machine. To increase the driving power of aclutch, rotate the spring ring around the adjusting nut and withdrawthe locking plunger. Rotate the nut in the direction of the arrowstamped on the nut until the plunger can be engaged in the next holej-n the locking p1ate. Do not adjust more than one hole at a timebefore testing the clutch. Replace the spring ring.When testing the feed motion-fast motion clutches on theirtransmission shaft, the clutch actuating sleeve, when moved from itsmidway position should first move easily, build up resistance to amaximum just as the plates compress together and then ease slightly asthe internal clutch toggles move over their high point. Set theminimum adjustment to obtain this feel without obtaining obviousclutch slip or overheating.

The electro-magnetic feed clutch on the final feed drive shaft isfactory set and should require no further adjustment.

The electro-magnetic brake on the final feed shaft should be adjustedas follows:- Remove the cover to obtain access to the brake. Engergisethe brake. Refer to the diagram mounted on the cover. Release the grubscrew (A) in the centring ring (B). Introduce a resetting key (kept ina slot inside the cover) into a radial groove (C) in the centring nut(D) and turn the nut until the key can be smoothly withdrawn. Checkthe air gap with the brake de-energised using a 1.2mm(0.049in) feelergauge. Reclamp the grub screw (A) when the correct gap is obtained.

Emergency brake release:- fn order to release the brake forhandwinding when the electric power is not available, remove twoknurled plugs in the cover and remove metric screws from the tappedholes above the instruction pIate. Insert screws through the coverholes into holes in the brake body and turn the screws clockwise asfar as possible to release the brake. Remove the screws, replacemetric screws and plugs before connecting power to the machine.

Slipping Clutches:- These clutches are assembled with the minimumnumber of springs and plungers necessary to transmit the torque. Spareplungers, springs and screwed plugs are supplied in the equipment kitand can be fitted when required. It is recommended that the number ofplungers in use is kept to a minimum to ensure that the clutches willdisengage when necessary. Fit extra plungers, etc, in pairs equallyspaced around the clutch body.


PLFR5/6B0e/07/88

43

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PLTR5/6B09/07/88

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PLFR5/ 6B09/07/88

47

4.11 The llain Camshaft.

The main camshaft extends from the wormwheel in the main drivehousing, passing through the drum housing to the stock carriage endbracket of the machine. The camshaft is supported in plain bearings inthe main drive housing attachment d.rive compartment walls and thewalls of the drum housing and its tail end is supported by a ballbearing assembly in the stock carriage end bracket of the machine. Itcarries the cross slide feed and. approach stroke cams, bar stop/stops,bar feed and collet operating cams, spindle drum locking cams, theGeneva arm and roller and. the index clutch.A cam d.rum is fitted in the main drive housing to carry cams forspecS.al end working attachments when these are required and a 2in(50.8mm) bore is provided in both walls of the housing to carry ashaft upon which the necessary cam operating levers can be pivoted.

An auxiliary cam dj-sc is provided in the drum housing to accommodatespecial cams for varying independently the movements of individualcross slides or cross slide attachments when required. A timing holeis provided in this auxiliary cam disc which lines up with acorresponding hole in the drum housing wall when the camshaft is at 0degree timing angle.

The keyway in the shaft and. the vee grooves across the diameter of theauxiliary cam disc and the spare cam drum, are horizontal and to thefront of the machine.at 0 degree timing angle. At this point theGeneva roller is just entering the Geneva wheel. See figs. 4.15 and4.L6.

Index clutch operation.

The bar feed cam drum is driven by a dog clutch spring loaded intoengagement and carried on the main cam shaft. Lifting the index clutchlever until the plunger handle locates in a hole in an adjacentbracket, withdraws the clutch teeth and renders inoperative bar feed,collet operation, drum indexing and the drum locking mechanisms. Aninterlock tatch is fitted so that the clutch cannot be disengagedduring the indexing of the drum. See figs.4.L5 and 4.16.


PLFRs/6B09/07/88

48

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PLFR5/ 680e/07/88

parte list and - wickman group...9-l2 l3-1 8 l9-72 73 plfr5/5b 0e / 07 /88 summary section section...

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