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Summary of Contents for Mirage MM200e
- Page 1 MM200e EXTERNALLY MOUNTED FLANGE FACING MACHINE OPERATION & MAINTENANCE MANUAL FOR MIRAGE MACHINES LTD Tel: 1300 795 096 Page 1 of 37 E: sales@psssa.com.au Web: www.psssa.com.au...
- Page 2 Version History All Mirage Machines Ltd. documentation is quality controlled and audited in accordance with BS EN ISO 9001:2008; the scope of which covers design, manufacture and repair of in-situ machine tools. Version Implemented Revision Approved Approval Comments Date Date...
- Page 3 Introduction ..........................4 Overall Equipment Description ....................4 Machine Warranty ........................4 Health and Safety ........................5 Mandatory Safety Signs (for the purpose of trials at Mirage Machines Ltd) ......5 Machine Hazards Signs ......................6 Safety Procedures ........................6 3.3.1.
- Page 4 Introduction Overall Equipment Description The MM200e has been predominantly designed for the facing of ‘Pipeline’ coupling flanges but can also be used for any application that suits its externally mounting base. It features An 800 watt (1.1hp) pneumatic motor which is powered from an external power source.
- Page 5 Health and Safety Mirage Machines Ltd. has made every effort to ensure that the Information given in this Operation & Maintenance manual, and other publications relating to this machine is correct and understandable. However it is acknowledged that there may be errors or omissions in this publication.
- Page 6 WARNING KEEP HANDS CLEAR Safety Procedures Detailed in this chapter is a list of good Health and Safety practices that Mirage Machines Ltd. advise users to adhere to. Due to the nature of portable machine tools, not every eventuality can be catered for and the following is not exhaustive, as such Mirage Machines Ltd.
- Page 7 Operational Safety Checks 1. Operator is fully conversant and trained in use of equipment Keep clear of moving machine parts 3. Never leave the machine running unattended 4. Follow correct clamping procedures - keep overhangs as small as possible and check work piece is secure 5.
- Page 8 Handling Customers, users and operators of the machines must be aware of the nature of the equipment supplied. Although inherently robust, the machine is a precision tool and may be damaged by poor handling, tipping and falling, inadequate transport arrangements over e.g. rough terrain, misuse by operators and use outside its design specification.
- Page 9 Machine Specification The Mirage Machines Ltd. MM200e Machine has been modularly designed for accurate in-situ machining of work surfaces, to this end the constituent parts are easily manipulated by hand or crane. Description Value Clamping Range 90mm - 205mm 3.5” - 8”...
- Page 10 General Assembly Drawings Tel: 1300 795 096 Page 10 of 37 E: sales@psssa.com.au Web: www.psssa.com.au...
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- Page 20 Installation The MM200e has been designed to fit onto a circular work piece, for example a pipe or flange. It can be fitted onto work pieces that range in size from 76 to 205mm (3-8in) diameter. Manually adjustable, clamping jaws (M/C Mount Assemblies) are used to secure the machine to the work piece.
- Page 21 6. Adjust the machines perpendicularity to the work piece by adjusting the four adjusting screws & lock nuts located on each of the four ‘Setting Straps’. Adjusting Screw & Lock Nut Adjusting Screw & Lock Nut 7. Whilst maintaining contact between ‘Setting Straps’ & the work piece tighten each of the four ‘M/C Mount Assemblies’...
- Page 22 9. If any adjustments are required following the initial installation ensure that the setting straps are re-fitted to the ‘M/C Mount Assemblies’ before releasing the four ‘Clamp Screws’. This will prevent the machine slipping or falling down the work piece when the screws are released.
- Page 23 Service and Supplies The MM200e Facing Machine uses a 1.1hp motor that requires a pneumatic supply capable of supplying 1.415 Mᶟ of air per minute (50 CFM) at a pressure of 6 Bar (87 Psi). 6.1.1. Personnel As a specialist portable machine the minimum standard for an operator is to be: ...
- Page 24 Machine Operation Ensure pneumatic supply is turned off & isolated correctly before making adjustments to the machine prior to operation. 2. Adjust the ‘Tool Post’ assembly on the lead screw to an approximate position at the start of the required cut. To do this, ensure the ‘Selector Knob’ is pushed down, rotate the ‘Selector Knob’...
- Page 25 5. To set the tool in a vertical position, place a straight edge across both the side faces of the “Tool Post” and the “Tool Post Carriage”, set the faces flush with each other and tighten the shoulder screws Carriage locking screws Tool Post Carriage Ensure these two faces are flush...
- Page 26 11. Repeat the above processes until the work piece is correct to your required dimensions. Note: The MM200e has not been designed to machine to its clamping diameter. Due to the design of the ‘M/C Mount Assemblies’ if the tool was allowed to cut all the way to the circumference of the work piece there is a danger that the ‘M/C Mount Assemblies’...
- Page 27 Machine Maintenance General wear and tear items should be replaced with like for like components as per the machine general assembly drawings detailed in this manual. Failure to do so may result in a machine that is not fit for purpose and is outside the design intent it was supplied for. Items that require specific maintenance regimes and products will be detailed here in.
- Page 28 Component Weights The table below lists the weights of the main components of the MM200e for your reference Part Number Description Weight MM200e-1….6 Assembled Machine 20.7kg LARGE ALK Large Air Lubrication Kit 6.0kg MM200e-TK Tool Kit 1.6kg MT10LT0271JCL1F Air Motor 2.3kg...
- Page 29 Troubleshooting Guide Before making adjustments and measurements or before cleaning swarf accumulations, switch off and bring the machine to a complete standstill Issue Reason for wear Flank & notch wear a) Rapid flank a) Cutting speed Reduce cutting wear too high or speed.
- Page 30 Issue Reason for wear Thermal cracks Small cracks Thermal cracks Select a perpendicular to due to tougher grade the cutting edge temperature with better causing frittering variations resistance to and poor surface caused by: thermal finish. Intermittent shocks machining Varying Coolant coolant supply should be...
- Page 31 7. Too much play in main hub Adjust bearing dampers bearings 8. Worn drive motor Check motor 9. Poorly adjusted surfacing arm Check and adjust 10. General poor machine condition Refer to Mirage Tel: 1300 795 096 Page 31 of 37 E: sales@psssa.com.au Web: www.psssa.com.au...
- Page 32 Appendices Recommended torque settings for fasteners Thread Tensile Strength Torque Setting Ø in - lbs 6.54 1470 11.4 2560 18.5 4160 26.1 5870 47.6 10700 75.4 17000 24700 1200 33700 1900 45900 2900 68800 5750 83950 7725 99100 1100 9700 158000 2250 19900...
- Page 33 Cutting feed and speed calculations To Find Using Metric English Cutting RPM, Dia m/min V = RPM x 0.00314 x Ft / min V = RPM x Dia speed 3.82 V , Dia Revs/min RPM = V x 1000 Revs /min RPM = V x 3.82 3.14 x Dia Feed rate...
- Page 34 Table 1 (Use FPT number in feed rate calculation to obtain cutting edge constant C) Feed in Feed in Feed Feed 0.002 1.40 0.018 0.94 0.02 1.40 0.45 0.94 0.004 1.25 0.020 0.90 0.10 1.25 0.50 0.90 0.006 1.15 0.025 0.86 0.15 1.15...
- Page 35 M8 x 50 Socket Cap Heads MM200e-1-009 2. Attach the motor mount to the right angled gearbox (MM200e-9) using the two M8 x 50 Socket Cap Head screws. Bolt the right angled gearbox to the MM200e assembly using the two M8 x 80 Socket Cap Head Screws.
- Page 36 M4 x 10 Button Head Screws MM200e-9-007 2. Secure the MM200e-9-007 bearing housing cap to the other side of the assembly using the four M4 x 10 button head screws. Push the MM200e-9-008 bearing housing cap into position on the other side.
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