TBT ML700 Series Manual

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General

General .......................................................................................................................... 1

1.1

Introduction .................................................................................................................... 2

1.1.1

Structure of the operating instructions ........................................................................... 2

1.1.2

General notes ................................................................................................................ 4

1.2

Safety ............................................................................................................................. 6

1.2.1

General safety instructions............................................................................................. 6

1.2.2

Intended application ..................................................................................................... 11

1.2.3

General hazard potential with this machine ................................................................. 11

1.2.4

Definitions .................................................................................................................... 15

1.2.5

Other precautionary measures ..................................................................................... 16

1.2.6

Requirements imposed on the user/operator ............................................................... 17

1.2.6.1

Requirements for safety devices .................................................................................. 18

1.2.7

Personal protective equipment ..................................................................................... 19

1.2.8

Safety during repair and maintenance ......................................................................... 20

1.2.9

Safety during tool change and set-up .......................................................................... 21

1.2.10

Behaviour in an emergency ......................................................................................... 21

1.2.11

Danger zones ............................................................................................................... 22

1.3

Technical Specifications: ............................................................................................. 24

1.3.1

Description of the system ............................................................................................. 24

1.3.1.1

Basic machine .............................................................................................................. 24

1.3.1.2

Coolant system ............................................................................................................ 26

Erstelldatum: 03.02.2012

ML700 - 1 - 22 000 / 106582 -11

Contents

Version: 1_0

File: 106582_1

27.03.2012

Inh. 1

Table of Contents

Summary of Contents for TBT ML700 Series

Page 1: Table Of Contents
General Contents General .......................... 1 Introduction ........................2 1.1.1 Structure of the operating instructions ................2 1.1.2 General notes ........................ 4 Safety ..........................6 1.2.1 General safety instructions..................... 6 1.2.2 Intended application ..................... 11 1.2.3 General hazard potential with this machine ..............11 1.2.4 Definitions ........................
Page 2 General 1.3.2 Machine diagram ......................27 1.3.2.1 Machine identification ....................28 Technical data ......................29 1.4.1.1 Deep-hole drilling machine................... 29 1.4.1.2 Electrical system ......................30 1.4.1.3 Machine drive (deep-hole drilling/conventional) ............31 1.4.1.4 Workpiece clamping ..................... 36 1.4.1.5 Coolant system ......................40 Drilling technique BTA ....................
Page 3 General 1.6.6 Utilisation of standard accessories ................64 1.6.6.1 Submersion method ..................... 64 1.6.6.2 Seal housing method ....................65 1.6.7 General remarks with regard to bottle boring ............... 66 Version: 1_0 Erstelldatum: 03.02.2012 File: 106582_1 ML700 - 1 - 22 000 / 106582 –11 27.03.2012 Inh.
Page 4: General
General General This chapter is subdivided into three sections:  Introduction: Chapter 1.1 Structure of the operating instructions, general notes  Safety: Chapter 1.2 Safety instructions, hazard potential  Technical Specifications: Chapter 1.3 Short description, machine diagram, technical data, drilling procedure Version: 1_0 Preparation date: 03.02.2012 File: 106582_1...
Page 5: Introduction
General Introduction 1.1.1 Structure of the operating instructions The present operating instructions manual is intended for different groups of persons thus consisting of separate chapters. You find the structure of the documentation and an over- view of the chapters in the table of contents below. Additionally, each chapter begins with its own table of contents.
Page 6 General Chapter Description Group of persons Operating personnel, Description commissioning person- Mechanical assembly groups – nel, service personnel Coolant system – Hydraulic system – Pneumatic system – Operation and set-up Operating personnel, installation personnel, Data relating to specific safety devices –...
Page 7: General Notes
Service addresses: Customer Service Spare parts service Mr Klein, R.: ++49 7123 / 976-302 Mr Roszick: ++49 7123 / 976-131 E-MAIL: R.Klein@tbt.de E-MAIL: R.Roszick@tbt.de Mr Hadolt: ++49 7123 / 976-301 Mrs Dieterle: ++49 7123 / 976-130 E-MAIL: M.Hadolt@tbt.de E-MAIL: A.Dieterle@tbt.de...
Page 8 General operation of the plant or its parts. Damages caused by a third party. – Damages caused by the use of the plant or its parts under altered con- – ditions (e.g. materials, workpieces, tools, clamping devices, operating materials, cutting parameters, programmes, etc.), especially without consultation of and written release by the manufacturer.
Page 9: Safety
General Safety 1.2.1 General safety instructions This operating instructions manual contains important information prereq- uisite for safe and efficient working with the machine. It should be kept readily accessible in the vicinity of the machine. Before installation and commissioning, carefully read and observe the op- erating instructions.
Page 10 General CAUTION This symbol/signal word indicates hazards that cause light injuries. This note is shown next to work instructions or operating instructions, that are to be complied with exactly, in order to avoid damage to the machine or its components. NOTE This symbol/signal word stands for technical requirements and important information (tips), that must be specially complied with in order to prevent...
Page 11 General This symbol/signal word indicates direct hazards that may cause death or serious injuries. In areas where this symbol is fitted to the machine, only qualified and trained personnel (operating; maintenance and repair per- sonnel) may carry out all work and repairs. WARNING of laser beams Failure to heed these safety instructions can result in serious injury.
Page 12 General inoperative. Minimum distance: 1 m PROHIBITION Do not touch PROHIBITION persons with metal implants PROHIBITION carrying magnetic or electronic data carriers PROHIBITION carrying tramp metal or clocks PROHIBITION Keep out! Telescopic covers may only be entered on channelled plates or on a non- slip support with lateral limit stops (e.g.
Page 13 General This symbol is a warning against possible environmental hazard. Failure to heed this direction can result in serious damage to the environ- ment. Other Signs directly attached to the machine such as signs arrows indicating the direction of rotation, signs for fluid connections must always be observed and kept in a completely legible state.
Page 14: Intended Application
The machine is not suitable for any other applications. Every constructional modification of the machine to use it for other purposes is permitted only after consulting and approval by TBT - Tiefbohrtechnik GmbH+Co. Only workpieces determined for the respective application may be machined.
Page 15 General The general hazard potential in improper and careless use of the machine consists Mechanical danger through  impact, due to the kinetic energy of the moving masses  pinching, shearing and cutting  grabbing and wrapping and drawing-in  penetration or piercing ...
Page 16 General Danger through pumps Protective devices and mountings may only be removed when  the pumps are emptied,  motors and driven machines are stationary,  the plant is electrically dead and protected against restarting. Danger through emission  The equivalent continuous sound pressure level of the deep-hole drilling machine is less than _ see Noise level measurement report _dB(A).
Page 17 General Residual risk The plant is equipped with safety devices and has been checked for safety. How- ever, certain residual risks cannot be excluded. Residual dangers, i.e. potential, not obvious danger are:  Human error  Noise  Ejection of parts ...
Page 18: Definitions
General 1.2.4 Definitions Danger zone The area within or in the vicinity of the machine in which the safety or – health of a person staying in the zone may be endangered. Endangered person A person responsible for the installation, operation, conversion, mainte- –...
Page 19: Other Precautionary Measures
General 1.2.5 Other precautionary measures CAUTION Tools rotating at high speed are located on the machine. These tools can cause major maiming and cutting injuries. Under no circumstances may rotating tools be touched or approached with the hands, other parts of the body or objects.
Page 20: Requirements Imposed On The User/Operator
General 1.2.6 Requirements imposed on the user/operator WARNING Risk of injury in the event of any insufficient qualification of the op- erator / maintenance person If insufficiently qualified persons work on the machine or are present within the environment of the machine, this may cause serious injuries and seri- ous damage or the destruction of the machine or its components.
Page 21: Requirements For Safety Devices
General WARNING Without providing adequate fire protection (fire protection system), the ma- chine must not be operated without being monitored (manless operation). Should the operator intend to run the machine in "manless operation", the manufacturer highly recommends installing a fire extinguishing system to prevent damage or destruction of the plant while the cooling lubricant "deep-hole drilling oil"...
Page 22: Personal Protective Equipment
General 1.2.7 Personal protective equipment Wear appropriate protective clothing when working with the machine. Wear closely fitting clothing when operating the machine. – Operators with long hair must wear a hair net. – Use suitable protective gloves and safety goggles when cleaning the –...
Page 23: Safety During Repair And Maintenance
Spare parts must comply with the technical requirements of TBT - Tiefbohrtechnik GmbH + Co. Recommendation: Use only genuine spare parts. After completed maintenance and repair work to machines, units or fixtures,...
Page 24: Safety During Tool Change And Set-Up
General 1.2.9 Safety during tool change and set-up CAUTION Prior to every tool change and during set-up work on the machine, the main spindle motor must be switched off (protective door open). During tool changing operations or set-up work the machining slide can be moved in inching mode with reduced feed speed.
Page 25: Danger Zones
General 1.2.11 Danger zones The danger zone is composed of the following danger points: Danger point Endangering Command unit There is a bumping risk in the swivelling range of the command unit. Faulty operations may cause: the tools to fall out –...
Page 26 General Danger point Endangering Clamping table/ workpiece Sharp edges at the workpiece. Pinching and shearing points between: workpiece/table – support – workpiece/table – column slide – workpiece – tool – workpiece/table – spindle – workpiece/table – operator protection. – Chip conveyor, chip disposal unit Grabbing of the operator, drawing in –...
Page 27: Technical Specifications
General Technical Specifications: 1.3.1 Description of the system This deep-hole drilling machine has been designed for the machining of cylindric parts by using the ELB (single-lip drilling) and BTA drilling procedures (percussive; percus- sive/tractive; tractive). Workpiece clamping and workpiece holders, drilling oil supply ap- paratus, drill bushes, drilling tools, workpiece steady rests and vibration dampers must be selected to suit the respective workpiece (additional equipment).
Page 28 General Guide slide (W axis) The guide slide has been installed on the guideways (linear guideways) of the machine bed. Optionally, it is equipped with a drilling oil supply apparatus (BOZA) or a drill bush carrier. The drilling oil supply apparatus (BOZA) has been mechanically/hydraulically clamped on the guide slide (clamping claw).
Page 29: Coolant System
General 1.3.1.2 Coolant system The coolant system, consisting of coolant tank, high pressure pump unit, chip con- veyor and gravity filter feeds the cleaned cooling lubricant to the drilling tools. For cooling purposes, the cooling lubricant passes an individual continuous flow recool- ing unit.
Page 30: Machine Diagram
General 1.3.2 Machine diagram See below: Drawing No.: 106582-9901-00 (A3) Version: 1_0 Preparation date: 03.02.2012 File: 106582_1 ML700 - 1 - 22 000 / 106582 –11 27.03.2012...
Page 31: Machine Identification
General 1.3.2.1 Machine identification The opposite plate is attached to the switch cabi- net for the identification of the machine. The type plate shows the following specifications: 1 Manufacturer's address 2 Machine type 3 Machine number 4 Supply voltage 5 Nominal power 6 Year of manufacture Machine rating plate Version: 1_0...
Page 32: Technical Data
General Technical data 1.4.1.1 Deep-hole drilling machine General ML 700 – 1 - 22 000 Type Unit Deep-hole drilling Number of spindles – Centre height above ground 1240 – Rotating diameter above bed – Drilling slide lift (nominal) – Drilling depth min. 500 (3 steady rests must be re- –...
Page 33: Electrical System
General 1.4.1.2 Electrical system Electrical system connection requirements The electrical system has been designed and installed in accordance with the appli- cable regulations, in particular DIN EN 60 204. Voltage Unit Operating voltage V AC Auxiliary voltage V AC Frequency Control voltage V DC Total connected load...
Page 34: Machine Drive (Deep-Hole Drilling/Conventional)
General 1.4.1.3 Machine drive (deep-hole drilling/conventional) Main spindle drive unit Unit Three-phase current geared motor (M1510) Type 1PH7184-7EF33-OBJ5 – Power – Speed 1500-2000 – Encoder 2048 S/R absolute – Gearbox Desch Type 1023S – Ratio 2-stage – 1st stage Planetary change-speed gearbox –...
Page 35 General Type TS2229 – Temperature sensor Type TS2251 – Spindle mount with short cone Size 8 (DIN ISO 702-1) shape A2 Proximity switch, inductive S88.5 Spindle positioning – Type IT 5034 – Hydraulic system / gear switching Mewesta Unit Motor rating 0.37 –...
Page 36 General Indicating range 0.1-0.6 l/min. – Flow indicator Honsberg – Type OT-020AM035 – Indicating range 1-3.5 l/min. – Submersible pump / spindle cooling Brinkmann Unit Type SB20-G – Motor rating 0.17 – Pump delivery – Delivery pressure – High-speed spindle / ELB Henninger Unit Type...
Page 37 General Ratio 1 : 29 – Driving torque 1830 – Feed infinitely 1- 4 500 mm/min – Rapid traverse 25 000 mm/min – Engine Siemens – Type 1FK7103-5AF71-1FH3 – Motor rating – Speed (motor) 3000 – Brake V DC – Absolute encoder 2048 S/R –...
Page 38 General Speed (motor) 3000 – Brake V DC – Absolute encoder 2048 S/R – Elastomer coupling – Type ZAE-150-268-20-38 – Feed force 3000 – Proximity switch Anti-collision protection Type BNS819-FD-60-101-FD – Drilling oil supply apparatus clamp- Unit Clamping claw Römheld –...
Page 39: Workpiece Clamping
General 1.4.1.4 Workpiece clamping Workpiece clamping Plane spiral clamping chuck Schunk Type Rota Classic W Typ WAF – Speed max. 1220 1/min – True running 0.04 – Planning accuracy 0.02 – Through bore – Clamping range – Clamping force torque at the spanner –...
Page 40 General Inv No. 01.1710711701.0001.11 – Braking torque – Motor rating – Speed – Total gear ratio – Lubricating oil CLP PG 220 – Central lubrication system Vogel Unit Type MFE5/BW7/S – Tank capacity – Motor rating 0.075 – Speed 3200 –...
Page 41 General Type 56 23 007 – 6.75:1 – Gearwheel Atlanta – Type 24 45 520 – Number of teeth – Single-position limit switch (anti-collision Balluff – protection) Type BNS819-FD-60-101-FD – Servo motor Siemens – Type 1FK7063-5AF71-1EH5 – Motor rating – Speed (motor) 3000 –...
Page 42 General 6.75:1 – Gearwheel Atlanta – Type 24 45 520 – Number of teeth – Single-position limit switch Balluff – Type BNS819-FD-60-101-FD – Servo motor Siemens – Type 1FK7083-5AF71-1FH3 – Motor rating – Speed (motor) 3000 – Brake V DC –...
Page 43: Coolant System
General 1.4.1.5 Coolant system Coolant tank Unit Cooling lubricant HSD 400 Coolant tank (dirty oil) 1200 (with level switch) – Coolant tank (clean oil) 10 000 (with level gauge) – High pressure pump unit / ELB Moog Unit Type Radial piston pump II –...
Page 44 General Cooling lubricant pump / BTA Knoll Unit Type KTS60/120-T5-A-G-KB – Motor rating 18.5 – Speed 3000 – Delivery range – Pump delivery 590 at 15 bar / 2900 rpm – Chip conveyor Knoll Unit Type Slat-band conveyor type S –...
Page 45 General Plate heat exchanger Alva Laval Unit Type M10-MFM 25 PL – Cooling capacity 432000 KJ/H – Oil flow rate 855 at 0.9 bar – Water flow rate 172 at 0.03 bar – Water recooling unit Riedel Unit Type PC 1401.1M6LE.I –...
Page 46 General Submersible pump / recirculation Schmalenberger Unit dirty / clean oil tank (gravity filter) M33.4 / M33.5 Type Z50-16/2-7.5 – Motor rating – Pump delivery – Delivery pressure – Submersion depth – Submersible pump / recirculation Schmalenberger Unit dirty / clean oil tank (gravity filter) M33.6 / M33.7 Type Z50-16/2-7.5...
Page 47 General Compressed air unit Bosch Unit Pressure 5 - 8 – Filter fineness (central) µm – G ¼“ Connection – Pressure switch Bosch – 1 – 16 Pressure – Hydraulic system / clamping drilling Unit oil supply apparatus and vibration damper Motor rating –...
Page 48: Drilling Technique Bta
General Drilling technique BTA All deep-hole drilling processes use a high rate of cooling lubricant supply in order to accomplish chip transport in addition to cooling and lubricating. With the BTA drilling technique (BTA = Boring and Trepanning Association) the cooling lubricant is supplied by the drilling oil supply apparatus behind the drill bush.
Page 49: Cutting Speed
General 1.5.2 Cutting speed The cutting speed must be selected from the following diagram depending on the material to be machined. By way of the drill diameter it is then possible to determine the required speed. Aluminium Brass C steels Alloyed steels Grey cast iron Diagram: Speed as function of drill diameter/cutting speed...
Page 50: Programmed Feed Rate
General 1.5.3 Programmed feed rate The feed speed is dependent on the drill diameter and can be determined from the following diagram. 0,018 0,118 0,18 0,219 0,25 0,27 0,28 S´ 0,211 0,152 0,116 0,092 0,075 0,06 0,05 0,04 0,25 0,15 S´...
Page 51: Coolant Lubricant Pressure - Flow Rate
General 1.5.4 Coolant lubricant pressure - flow rate In addition to tool cooling and lubrication, the coolant lubricant also ensures chip removal. The chips must be short in order to facilitate transport (long chips plug the drill). Small drill diameter: High pressure / small volume ...
Page 52: Drilling Tool
General 1.5.5 Drilling tool The tools (boring heads) are screwed onto the boring tube. During drilling, a part of the cutting forces is transmitted to the bore wall by the guide strips. The bore surface is thereby smoothened and work hardened. BTA drilling tools Boring head Trepanning head...
Page 53: Drilling Procedure
General Drilling procedure All deep-hole drilling processes use a high cooling lubricant flow rate in order to ac- complish chip transport in addition to cooling and lubricating. In the single-lip drilling method (ELB), cooling lubricant is fed through the drilling spindle and drill shaft.
Page 54: Principle Of Single-Lip Drilling Method (Elb)
General 1.6.1 Principle of single-lip drilling method (ELB) NOTE Refer to the following diagram. Single-lip drills are tools with one cutting edge, which are guided through a drill bush when starting to drill a hole. The cooling lubricant is fed to the tool edge from the coolant tank (13) through the high pressure pump (10), the drilling oil feed (7), the spindle and the drilling tool (5).
Page 55: Cutting Rate
General 1.6.2 Cutting rate The cutting rate must be selected from the following table according to the material which is to be processed. Zugfestigkeit Schnittgeschwindigkeit (m/min) Werkstoff in N/mm B < 700 Bau- und Automatenstahl B < 900 Vergütungsstahl B < 1100 Vergütungsstahl B <...
Page 56: Feed Speed
General 0,0060 0,0180 0,0325 0,0510 0,0715 0,0940 0,1160 0,1380 0,1600 0,1800 1 All cast iron (e.g. Cast Iron 26 Cr) 0,0057 0,0168 0,0300 0,0460 0,0640 0,0830 0,1020 0,1210 0,1400 0,1600 0,1800 2 Alloyed Al. (GK-Al Si) 1.6.3 Feed speed 0,0053 0,0156 0,0275 0,0410 0,0565 0,0730 0,0900 0,1070 0,1240 0,1410 0,1570 0,1705 0,1800 3 GGG, GGL, GTS, GTW-HB<2400 N/mm 0,0050 0,0144 0,0250 0,0370 0,0495 0,0620 0,0740 0,0870 0,0990 0,1100 0,1200 0,1280 0,1345 0,1400 0,1440 0,1470 4 Structural and free cutting steel...
Page 57: Cooling Lubricant Pressure And Flow Rate
General 1.6.4 Cooling lubricant pressure and flow rate The cooling lubricant system is subdivided into a high-pressure range and a low- pressure range. The high-pressure range (up to 160 bar max., depending on the high-pressure pump type) feeds the machining location. The cooling lubricant pres- sure thereby depends on the drill tool diameter.
Page 58: Standard Application
General 1.6.4.1 Standard application Cooling lubricant pressure p for VHM single-lip drill (deep-hole drilling oil) Bohrdurchmesser in mm Drilling depth 100 x D Drilling depth 75 x D Drilling depth 50 x D Drilling depth 25 x D Drilling depth 10 x D Deutsch / German Englisch / English p (bar)
Page 59 General Cooling lubricant pressure p for soldered single-lip drill (deep-hole drilling oil) Bohrdurchmesser in mm Drilling depth 200 x D Drilling depth 100 x D Drilling depth 50 x D Drilling depth 10 x D Deutsch / German Englisch / English p (bar) p (bar) Bohrdurchmesser in mm...
Page 60: Comparison Table Deep-Hole Drilling Oil / Emulsion
General 1.6.4.2 Comparison table Deep-hole drilling oil / emulsion Diagram 1 for deep-hole drilling Diagram 2 for emulsion: oil: Cooling lubricant pressure/volume Cooling lubricant pressure/volume flow rate depending on the drilling flow rate depending on the drilling diameter diameter Drilling diameter [mm] Drilling diameter [mm] Drill length [mm] Drill length [mm]...
Page 61: Drilling Tool
General 1.6.5 Drilling tool The tools are manufactured with solid carbide head. During drilling, part of the cutting force is transmitted to the bore wall by the guide bevel of the carbide head. The borehole surface is thereby smoothed and hardened. Single-lip drill Full drill Stepped drill...
Page 62: Tool Regrinding
General 1.6.5.2 Tool regrinding The standard grinds for TBT single-lip drills depend on the drill diameter and the ma- terial to be processed. It is recommended to use the TBT universal grinder for re- grinding the tools. NOTE The universal grinding machine does not belong to the scope of delivery for the deep-hole drilling machine.
Page 63 General Terminology of the axes All angular adjustments of each axis are specified with plus (+) and minus (-). The angular adjustments are always viewed from the operator’s position with a clamped drill. The adjusted angles are fixed in their respective positions. Swivel axis "A"...
Page 64 General Standard grind for single-lip drills up to 5 mm Grinding No. 004: Standard 40°/30°-D/4 Grinding sequence: Diagram Axis A Axis B Axis C Measure Note -40° +25° +12° >D/4 +30° +20° -7° +35° +20° +55° 0° +38° 0° Bevel the edges at the circumference.
Page 65 General Standard grind for single-lip drills between 5 and 30 mm Grinding No. 001: Standard 30°/20°-D/4 Grinding sequence: Diagram Axis A Axis B Axis C Measure Note Set the C axis such that the bevel in work step 2 -30° +12°...
Page 66 General Standard grind for single-lip drills greater than 30 mm Grinding No. 009: Standard 20°/15°-D/4 Grinding sequence: Diagram Axis A Axis B Axis C Measure Note Set the C axis such that the bevel in work step 2 -20° +12° +5°...
Page 67: Utilisation Of Standard Accessories
General 1.6.6 Utilisation of standard accessories Standard accessories are available for general drilling tasks. Work is thereby carried out either by the submersion method (see Section 1.5.6.1) or in a seal housing (see Section 1.5.6.2). 1.6.6.1 Submersion method Clamping cone Body retainer ELB drill Immersion sleeve...
Page 68: Seal Housing Method
General 1.6.6.2 Seal housing method Clamping cone Seal disc ELB drill Seal housing Clamping cone Steady rest bush Drill bush Setting device Drill bush holder Tool holding fixture Body retainer Tool length = Drilling depth + 330 mm (without steady rest) = Drilling depth + 370 mm (1 steady rest) = Drilling depth + 403 mm (2 steady rests) Drilling depth...
Page 69: General Remarks With Regard To Bottle Boring
General 1.6.7 General remarks with regard to bottle boring Bottle boring creates a contoured bore in workpieces. The following basic compo- nents are necessary for bottle boring:  Bottle boring tool  Special drill pipes  NC controlled tool operation. Machining steps for bottle boring Drilling of the guide bore, e.g.
Page 70 General Finish the chamber end, retrieve the blade, then take out the tool: 6 Chamber 7 Damping rail How to create a machining programme The machining steps for contouring the inner sides have to be determined in a parts programme. Dimensions, cut partitioning, blade geometry and surface quality are determined by the operator who sets up the programme.