ZEUS - HOMMEL KELLER| KL-TECH s.r.o. |

Transkript

1 zeus knurling technology Knurling tools Special tools Burnishing rolls

2 No compromises! Knurling process 4 Tool characteristics 5 Tool selection 6 zeus form knurling tools 8 zeus form knurling tools RD1 9 zeus form knurling tools RD2 12 zeus form knurling tools RD3 16 zeus form knurling tool sets 18 zeus cut knurling tools 20 zeus cut knurling tools RF1 21 zeus cut knurling tools RF2 22 zeus cut knurling tools RF3 23 zeus cut knurling tool sets 24 zeus special tools and interfaces 26 zeus knurling wheels 34 Profiles and knurling pitches 35 Form knurling non-cutting process 36 Cut knurling cutting process 38 Special knurling wheels 39 Brunishing rolls 40 Features 41 Technology 42 Process characteristics 43 Wheel geometries 44 Conversion to inches 45 Material displacement non-cutting forming 46 Reference values for cutting speed and feed rate 47 Optimization of knurling 48 Influencing factors 50

3 Our product range offers tool solutions for the diverse applications of knurling technology. In addition to standard profiles, zeus knurling tools can also be used to manufacture conical, conve, concave and special profiles (e.g. bead knurling). The eample below shows the most important manufacturing applications. Application Profile (DIN 82) Marking Tool Eamples Knurling wheels / marking rolls Cut knurling, aial RGE AA Cut knurling, aial RGE BL15 1 BR15 Cut knurling, aial RAA BR30 Form knurling, radial RKV KE Form knurling, radial RKE KV Form knurling, radial RGE BL45 1 BR45 Form knurling, radial + aial up to a shoulder RAA AA Form knurling, radial RHE HV Form knurling, radial RE C Form knurling, radial RC E Form knurling radial + aial RKAA KAA Form knurling, aial RAA-face AA Form knurling RKGV KGE Continuous roll marking Spring return marking zeus W hommel+keller.de W

4 Knurling process Knurling technology is divided into two processes: form knurling and cut knurling. Both processes have their special applications and areas of utilisation. A basic difference in the two marking technologies is the possible direction of machining and the capability of manufacturing knurling profiles on the workpiece. For more details on manufacturing the individual profiles see the tool view. Possible knurling profiles on the workpiece RAA RAA RAA RAA RBR RBL RBR RBL RBR RBL RBR RBL RGE RGV RGE RGE RGE RKE RKV Plunge knurling Radial machining direction Plunge and feed knurling starting on the face Radial and aial machining direction Plunge and feed knurling in the middle of the workpiece Radial and aial machining direction Feed knurling Aial machining direction Form knurling Non-cutting process Cut knurling Cutting process Knurling process 4

5 Tool characteristics Different characteristics based on machine types and machine properties Knurling tools for CNC lathes / automatic lathes Knurling tools for conventional lathes / automatic lathes Knurling tools for Swiss-type lathes / automatic lathes Knurling tools for aial machining The knurling tools for CNC lathes / automatic lathes features an integrated centre height (centre height = top edge of shank). This makes it possible to use them in CNC lathes / automatic lathes without the capability of adjustment (fied tool holder) of the centre height. In general, these knurling tool series are also suitable for conventional lathes / automatic lathes as long as the centre height can be adjusted on the machine. The tool holder is not height adjustable. The centre height is integrated in the tool. Knurling tools from zeus for conventional machine types are designed so that the centre height must be adjusted by the tool holder in the machine. This results in a simplified design of these knurling tools. The tool holder is adjustable. The centre height of the tool must be adjusted. In the case of knurling tools that are suitable for Swiss-type lathes / automatic lathes, the knurling wheel must not protrude beyond the front edge of the shank, in order to prevent collision with the guide bush. Most knurling tools with a shank height of mm are suitable for Swiss-type lathes / automatic lathes. In general, they can also be used in CNC lathes and conventional lathes / automatic lathes. Guide bush Knurling tools for aial machining of the workpiece can be clamped aially to the workpiece on all conventional and CNC lathes / automatic lathes with a tailstock. Machining takes place by means of a rotating workpiece in a stationary tool that is mounted in the tailpiece. On rotary indeing machines, indeing tables and automatic transfer machines, a stationary workpiece is machined by means of an aially rotating tool. View X Centre height is integrated View X The zeus product range includes special versions for (R) right- and (L) left-oriented lathes / automatic lathes. If the construction allows, zeus knurling tools are available in a modular (M) or universal (U) design. The (M) versions can be converted from counterclockwise to clockwise rotation by simply turning the knurling head. The (U) versions can be used for both clockwise and counterclockwise rotation without conversion. Knurling tools from zeus for conventional machine types are designed for universal use and can therefore be used with both clockwise and counterclockwise rotation. In the case of Swiss-type lathes / automatic lathes the knurling wheel should be positioned as close to the workpiece clamping as possible to allow machining of workpieces with small diameters. The knurling wheels of the zeus RD1 and RD2 series with shank dimensions of to are therefore offset instead of centred. Machining possibilities: Tool is stationary Workpiece rotates Direction of rotation is universal Tool rotates Workpiece is stationary Direction of rotation is universal L = left R = right L = left R = right L = left R = right 5

6 Tool selection Symbols: LD = Swiss-type lathes (CNC / conventional) KD = Automatic-short-turning lathes / universal lathes / turning/ milling centres (CNC / conventional) MS = Multi-spindle lathes (CNC / conventional) RT = Rotary indeing machines / indeing tables / automatic transfer machines = Process is not possible with this application = Length of knurling is limited * = For cut knurling RBR / RBL possible only to a limited etent Eplanation of arrows: Knurl can be manufactured in radial direction (plunge knurling) Knurl can be manufactured only in aial direction (feed knurling) Knurl can be manufactured in both aial and radial direction Knurling profile (DIN 82) Form knurling Manufacturing process Cut knurling Machine type Knurling on workpiece centre / without plunge cut Knurling starting at workpiece beginning / 131 / 141 / 161 / RAA knurl LD 130 / 131 / 141 / / 192 / 391 Knurling RAA 130 / 131 / 141 / 161 / KD 130 / 131 / 141 / 161 Workpiece 162 / 192 / 391 Knurling wheel AA 130 / 131 / 141 / 161 / MS 130 / 131 / 141 / / 192 / 391 RT 192 / 391 RBL left-hand knurl RBR right-hand knurl RGE left / right-hand knurl / raised points / 30 RGV left / right-hand knurl / lowered points / 30 RKE cross knurl / raised points / 90 RKV cross knurl / lowered points / 90 Workpiece Workpiece Workpiece Workpiece Workpiece Workpiece Workpiece Knurling RBL Knurling wheel BR Knurling RBR Knurling wheel BL Knurling RGE Knurling wheel GV Knurling wheel BR Knurling RGE Knurling wheel BL Knurling RGV Knurling wheel GE Knurling RKE Knurling wheel KV Knurling RKV Knurling wheel KE Workpiece Knurling RAA Knurling wheel BR, swivelled 30 Knurling wheel AA, swivelled 30 Knurling wheel BL, swivelled 30 Knurling RBL Workpiece Workpiece Knurling wheel AA, swivelled 30 Workpiece Knurling RAA Knurling RGE Workpiece Knurling RBR Knurling wheel AA, swivelled 30 Knurling wheel AA, swivelled 30 LD 231 KD 231 MS 231 RT LD 130 / 131 / 141 / / 131 KD 130 / 131 / 141 / / 131 MS 130 / 131 / 141 / / 131 RT 130 / 131 LD 231* KD 231* MS 231* RT LD 130 / 131 / 141 / / 131 KD 130 / 131 / 141 / / 131 MS 130 / 131 / 141 / / 131 RT 130 / 131 LD 231* KD 231* MS 231* RT LD 130 / 131 / 132 / 161 KD 130 / 131 / 132 / 161 MS 130 / 131 / 132 / 161 RT LD 141 / / 161 / 162 / 192 KD 141 / / 161 / 162 / 192 MS 141 / / 161 / 162 / 192 RT 161 / 162 / 192 LD 241 / 291 KD 241 / 291 MS 241 / 291 RT 291 LD 130 / 131 KD 130 / 131 RGV: only plunge knurling MS 130 / 131 possible RT LD 130 / 131 KD 130 / 131 MS 130 / 131 RT LD 130 / 131 KD 130 / 131 MS 130 / 131 RT RKE: only plunge knurling possible RKV: only plunge knurling possible

7 This matri provides you with a selection of tool series that can be used for your application. You can use the table to define the profile, process and machine type. Then you can choose the application based on the pictograms. Starting on page 9 you will find details of the products and tool features. / / Knurling starting in centre of workpiece / after plunge cut Knurling starting in centre of workpiece / without plunge cut Knurling up to a shoulder Knurling starting at workpiece beginning up to a shoulder Conical knurling Knurling on the front face Knurling in a bore 130 / 131 / 141 / / 131 / 141 / / / 142 / 162 / / / / / 131 / 141 / / 131 / 141 / / / 142 / 162 / / / / / 131 / 141 / / 131 / 141 / / / 142 / 162 / / / / / / / 131 / 141 / / 131 / 141 / / / 142 / 162 / / / / / 131 / 141 / / 131 / 141 / / / 142 / 162 / / / / / 131 / 141 / / 131 / 141 / / / 142 / 162 / / / / / * 231* 231* 130 / 131 / 141 / / 131 / 141 / / / 142 / 162 / / / / / 131 / 141 / / 131 / 141 / / / 142 / 162 / / / / / 131 / 141 / / 131 / 141 / / / 142 / 162 / / / / / * 231* 231* only plunge knurling possible / / / 162 / / / / / / 162 / / / / / / 162 / / / / / RGV: only plunge knurling possible RKE: only plunge knurling possible RKV: only plunge knurling possible RGV: only plunge knurling possible RKE: only plunge knurling possible RKV: only plunge knurling possible / / / RGV: 311 / / / 332 only plunge knurling 132 possible 311 / / / / / / RKE: 330 / 332 only plunge knurling 132 possible 330 / / / 332 RKV: / 332 only plunge knurling 132 possible 330 / / 332 7

8 8 zeus Form knurling tools

9 f f Form knurling tools RD1 Ideal for all knurling profiles Series 130 Knurling profiles on DIN 82 workpiece: Plunge knurling RAA RBL RBR RGE RGV RKE RKV AA BR BL GV GE KV KE Feed knurling RAA RBL RBR AA BR BL Product series Shank size mm For right and left use U A State of development Design for knurling wheels (Ø width bore) Product features: Centre height must be adjusted Set screws in shank for clearance angle correction Carbide pins TOOL VERSIONS: Other variants available on request c a b Working area Ø Dimension a b c d e f (Ø b b) U A / 4 10 / U A / 4 10 / U A / 4 10 / U A / / U A / / U A / 4 10 / U A / / U A / / U A / / a a d b b e c c 9 a

10 f f f Form knurling tools RD1 Ideal for all knurling profiles, features eceptionally easy handling Series 131 Knurling profiles on DIN 82 workpiece: Plunge knurling RAA RBL RBR RGE RGV RKE RKV AA BR BL GV GE KV KE Feed knurling RAA RBL RBR AA BR BL Product series Shank size mm Right-hand version R VS-A State of development Solid shank Design for knurling wheels (Ø width bore) Product features: All holders equipped with Click-Pin system for fast retooling of the knurling wheels Set screws in shank for clearance angle correction Carbide pin Modular shank design: Shank size mm optionally adaptable TOOL VERSIONS: ADAPTER BRACKET FOR BASE SHANK mm: Working area Ø Other variants available on request Left-hand version of all shank dimensions available on request Dimension (Ø b b) a b c d e f R VS-A / 4 10 / R VS-A / 4 10 / R VS-A / 4 10 / Working area Ø Dimension a b c d e f (Ø b b) U A-Z / / U A-Z / / Shank size 21BHR BHR a a a d b b 10 d 2 mm 2 mm e e c c b e e c c b

11 f f f f Form knurling tools RD1 Ideal for all knurling profiles and applications up to a shoulder Series 132 Knurling profiles on DIN 82 workpiece: Plunge knurling RAA RBL RBR RGE RGV RKE RKV AA BR BL GV GE KV KE Feed knurling RAA RBL RBR AA BR BL Product series Shank size mm Right-hand version TOOL VERSIONS: R A11-VS-A State of development Solid shank Stepped bore Design for knurling wheels A11 (Ø width bore) Product features: Knurling wheel fied by means of carbide collar studs Set screws in shank for clearance angle correction Modular shank design: Shank size mm optionally adaptable Other variants available on request Left-hand version of all shank dimensions available on request ADAPTER BRACKET FOR BASE SHANK mm: Working area Ø Dimension (Ø b b) a b c d e f R150606A11-VS-A A R150606A11-VS-A A R150606A11-VS-A A11 Working area Ø Dimension (Ø b b) a b c d e f U200806A13-A A U200806A13-A A13 Shank size 21BHR BHR d d e e c c b b a a d d e e c c b b a a 11

12 Form knurling tools RD2 Ecellent for aial profiling, features fleible centring Series 141 Knurling profiles on DIN 82 workpiece: Plunge / feed knurling RAA RBL RBR RGE30 RGE45 2 AA 2 BR 2 BL 1 BL30 / 1 BR30 1 BL45 / 1 BR45 Product features: Shank size mm and mm with Click-Pin system for fast retooling of the knurling wheels Modular design: Tool can be used as right-hand and left-hand version Knurling head with fleible centring Set screws in shank for clearance angle correction Carbide pins Modular shank design: Shank size mm optionally adaptable Product series Shank size mm Modular M VS - A Solid shank Design for knurling wheels (Ø width bore) State of development TOOL VERSIONS: Working area Dimension (Ø b b) Ø a b c d e f M VS-A M VS-A M VS-A M VS-A Other variants available on request Working area Dimension (Ø b b) Ø a b c d e f M B M B M B Tools of series 141 can be converted to series 142 and vice versa by replacing the knurling head, with a shank size of mm or larger ADAPTER BRACKET FOR BASE SHANK mm: Shank size 21BHR BHR KNURLING HEADS 142: Series 142 Shank size (Ø w b) 21BHR A11 21BHR A13

13 f Form knurling tools RD2 Ecellent for all aial profiling and applications up to a shoulder Series 142 Knurling profiles on DIN 82 workpiece: Plunge / feed knurling RAA RBL RBR RGE30 RGE45 Selection of knurling wheels 2 AA 2 BR 2 BL 1 BL30 / 1 BR30 1 BL45 / 1 BR45 Product features: fied by means of carbide collar studs Modular design: Tool can be used as right-hand and left-hand version. Retooling by simply turning the knurling head Knurling head with fleible centring Set screws in shank for clearance angle correction Product series Shank size mm Modular M A13-A State of development Stepped bore Design for knurling wheels A13 (Ø width bore) TOOL VERSIONS: Working area Ø Working area Ø Dimension a b c d e f Dimension a b c d e f (Ø b b) M150606A11-VS-A A M150606A11-VS-A A M150606A11-A A11 Other variants available on request (Ø b b) M200806A13-A A M200806A13-A A13 Tools of series 142 can be converted to series 141 and vice versa by replacing the knurling head, with a shank size of mm or larger ADAPTER BRACKET FOR BASE SHANK mm: Shank size 21BHR BHR KNURLING HEADS 141: e Series 141 Shank size (Ø w b) 21BHR BHR BHR d c a b d f e c a b 13

14 f Form knurling tools RD2 Ideal for very small workpiece diameters, features gentle tangential profiling Series 161 Knurling profiles on DIN 82 workpiece: Plunge / feed knurling RAA RBL RBR RGE30 RGE45 2 AA 2 BR 2 BL 1 BL30 / 1 BR30 1 BL45 / 1 BR45 Product features: Knurl holder is easily adjustable to workpiece diameter by means of synchronous spindle Set screws in shank for clearance angle correction Carbide pins with surface secured by set screw Modular shank design: Shank size mm optionally adaptable Product series Shank size mm Right-hand version R VS -A Solid shank Design for knurling wheels (Ø width bore) State of development TOOL VERSIONS: Working area Ø Dimension (Ø b b) a b c d e f R VS-A R VS-A R VS-A Working area Ø Dimension a b c d e f (Ø b b) M Other variants available on request Left-hand version of all shank dimensions available on request ADAPTER BRACKET FOR BASE SHANK mm: Shank size 21BHR BHR a a JAWS: d b Series 162 Shank size 21BHR / / BHR BHR BHR mm e c

15 f Form knurling tools RD2 Ideal for very small workpiece diameters and applications up to a shoulder Series 162 Knurling profiles on DIN 82 workpiece: Plunge / feed knurling RAA RBL RBR RGE30 RGE45 2 AA 2 BR 2 BL 1 BL30 / 1 BR30 1 BL45 / 1 BR45 Product features: fied by means of carbide collar studs Knurl holder is easily adjustable to workpiece diameter by means of synchronous spindle Set screws in shank for clearance angle correction Modular shank design: Shank size mm optionally adaptable Product series Shank size mm Right-hand version State of development Solid shank Stepped bore Design for knurling wheels A11 (Ø width bore) R A11- VS-A TOOL VERSIONS: Working area Ø Dimension (Ø b b) a b c d e f R150606A11-VS-A A R150606A11-VS-A A R150606A11-VS-A A11 Working area Ø Other variants available on request Left-hand version of all shank dimensions available on request Dimension (Ø b b) a b c d e f g M200806A A13 a ADAPTER BRACKET FOR BASE SHANK mm: Shank size 21BHR BHR d a b JAWS: Series 161 Shank size 21BHR / / BHR BHR BHR1672 e c 15

16 i j Form knurling tools RD3 Maimum stability for eact precision Series 191 Knurling profiles on DIN 82 workpiece: Feed knurling RAA RBL RBR RGE30 RGE45 3 AA 3 BR 3 BL 1 BL30 / 2 BR30 // 1 BR30 / 2 BL30 1 BL45 / 2 BR45 // 1 BR45 / 2 BL45 Product features: Easy and precise fine adjustment Modular echangeable knurl holder jaws for conversion to knurling up to a shoulder (192) or a cut knurling tool (291) Carbide pins Product series Shank size Ø 12 Modular M B Design for knurling wheels (Ø width bore) State of development TOOL VERSIONS: M B Other variants available on request Working area Ø a Ø d ma. Ø e h Dimension i Ø j Ø k Ø (Ø b b) d = for ma. workpiece Ø n = ma. workpiece length (with Ø) l n ma Ø d ma. k a l n ma. e h JAWS: Form knurling up to a shoulder 21BHR1128 Cut knurling 21BHR

17 j Form knurling tools RD3 Maimum stability up to a shoulder Series 192 Knurling profiles on DIN 82 workpiece: Feed knurling RAA RBL RBR RGE30 RGE45 3 AA 3 BR 3 BL 1 BL30 / 2 BR30 // 1 BR30 / 2 BL30 1 BL45 / 2 BR45 // 1 BR45 / 2 BL45 Product features: Easy and precise fine adjustment Modular echangeable knurl holder jaws for conversion to a form knurling tool (191) or a cut knurling tool (291) Carbide collar studs Product series Shank size Ø 12 Modular M A8-B State of development Stepped bore Design for knurling wheels A8 (Ø width bore) TOOL VERSIONS: Working area Ø a Ø d ma. Ø e h Dimension i Ø j Ø k Ø l n ma. Ø Knurling wheels (Ø b b) M150606A8-B A8 Other variants available on request d = for ma. workpiece Ø n = ma. workpiece length (with Ø) d ma. k a i l n ma. e h JAWS: Form knurling 21BHR1096 Cut knurling 21BHR

18 Form knurling tools SETS Maimum fleibility in combination the perfect standard equipment Set SET consisting of: 1 tool: knurling wheel: mm 3 profile: AA Pitches: 0.5 / 0.6 / 0.8 mm Knurling profiles on DIN 82 workpiece for tool 131: Plunge / feed knurling RAA RBL RBR AA BR BL TOOL VERSIONS: 1 tool: knurling wheel: mm 6 profile: AA 3 profile: BL30 3 profile: BR30 Pitches: 0.5 / 0.6 / 0.8 mm Knurling profiles on DIN 82 workpiece for tool 141: Plunge / feed knurling RAA RGE30 2 AA 1 BL30 / 1 BR30 Set Holder Working area Ø Dimension a b c d e f (Ø b b) R VS-A / 4 10 / M VS-A Set SET consisting of: 1 tool: knurling wheel: mm 3 profile: AA Pitches: 0.6 / 0.8 / 1.0 mm Knurling profiles on DIN 82 workpiece for tool 131: Plunge / feed knurling RAA RBL RBR AA BR BL 1 tool: knurling wheel: mm 6 profile: AA 3 profile: BL30 3 profile: BR30 Pitches: 0.6 / 0.8 / 1.0 mm Knurling profiles on DIN 82 workpiece for tool 141: Plunge / feed knurling RAA RGE30 2 AA 1 BL30 / 1 BR30 TOOL VERSIONS: Set Holder Working area Ø Dimension a b c d e f (Ø b b) R VS-A / 4 10 / M VS-A

19 Form knurling tools SETS Set SET consisting of: 1 tool: knurling wheel: mm 3 profile: AA Pitches: 0.8 / 1.0 / 1.5 mm Knurling profiles on DIN 82 workpiece for tool 131: Plunge / feed knurling RAA RBL RBR AA BR BL TOOL VERSIONS: 1 tool: knurling wheel: mm 6 profile: AA 3 profile: BL30 3 profile: BR30 Pitches: 0.8 / 1.0 / 1.5 mm Knurling profiles on DIN 82 workpiece for tool 141: Plunge / feed knurling RAA RGE30 2 AA 1 BL30 / 1 BR30 Set Holder Working area Ø Dimension a b c d e f (Ø b b) U A-Z / / M B Set SET consisting of: 1 tool: knurling wheel: mm 3 profile: AA Pitches: 0.8 / 1.0 / 1.5 mm Knurling profiles on DIN 82 workpiece for tool 131: Plunge / feed knurling: RAA RBL RBR AA BR BL 1 tool: knurling wheel: mm 6 profile: AA 3 profile: BL30 3 profile: BR30 Pitches: 0.8 / 1.0 / 1.5 mm Knurling profiles on DIN 82 workpiece for tool 141: Plunge / feed knurling RAA RGE30 2 AA 1 BL30 / 1 BR30 TOOL VERSIONS: Set Holder Working area Ø Dimension a b c d e f (Ø b b) U A-Z / / M B

20 20 zeus Cut knurling tools

21 Cut knurling tools RF1 Perfect efficiency due to modular design, convincing process reliability due to sturdy construction Series 231 Knurling profiles on DIN 82 workpiece: Feed knurling RAA RBL RBR 1 BR30 (right-hand use) 1 AA (left-hand use) 1 AA (right-hand use) 1 BL30 (left-hand use) Product features: Scaling and positioning aids Adjusting spindle for fine adjustment of the knurl profile Set screws in shank for clearance angle correction Coated carbide bearing bushes for improved antifrictional property Modular shank design: Shank size mm optionally adaptable Product series Shank size mm Modular M VS -A State of development Solid shank Design for knurling wheels (Ø width bore) TOOL VERSIONS: Working area Ø Dimension a b c d e f (Ø w b) M VS-A M VS-A M VS-A Other variants available on request Working area Ø Dimension a b c d e f (Ø w b) M B M B ADAPTER BRACKET FOR BASE SHANK mm: Shank size 21BHR BHR

22 Cut knurling tools RF2 Ecellent for stringent requirements convincing stability in harsh continuous use Series 241 Knurling profiles on DIN 82 workpiece: Feed knurling RGE30 RGE45 2 AA 1 BL15 / 1 BR15 Product series Shank size mm Modular M VS -A Design for knurling wheels (Ø width bore) State of development Solid shank Product features: Modular design: Tool can be used as right-hand and left-hand version. Retooling by simply turning the cut knurling head Conversion to alternative full shank dimensions is possible Modular shank design: Shank size mm optionally adaptable Fine adjustment of centre height of the cut knurling head Fine adjustment of the clearance angle by means of synchronous adjustment spindle Coated carbide bearing bushes for improved antifrictional property Vertical height adjustment for use of shank size 20 mm on 25 mm (version M A1) TOOL VERSIONS: Other variants available on request Working area Ø Dimension a b c d e f (Ø w b) M VS-A M VS-A M VS-A Working area Ø Dimension a b c d e f (Ø w b) M A M A M A ADAPTER BRACKET FOR BASE SHANK mm: Shank size 21BHR BHR

23 j Cut knurling tool RF3 Maimum stability for eact precision ideal for thin-walled workpieces Series 291 Knurling profiles on DIN 82 workpiece: Feed knurling RGE30 RGE45 3 AA 1 BL15 / 2 BR15 or 1 BR15 / 2 BL15 Product features: Easy and precise fine adjustment Modular echangeable knurl holder jaws for conversion to a form knurling tool 191 / 192 (knurling up to a shoulder) Coated carbide bearing bushes for improved antifrictional property Product series Shank size Ø 12 Modular M B State of development Design for knurling wheels (Ø width bore) TOOL VERSIONS: Working area Ø a Ø d ma. Ø M B Other variants available on request d = for ma. workpiece Ø n = ma. workpiece length (with Øi) e h Dimension i Ø j Ø k Ø l n ma. Ø Knurling wheels (Ø w b) d ma. k a i l n ma. e h JAWS: Form knurling 21BHR1096 Cut knurling up to a shoulder 21BHR

24 Cut knurling tools SETS Best efficiency in combination the perfect standard equipment Set SET consisting of: 1 tool: knurling wheel: mm 3 profile: BL30 3 profile: BR30 Pitches: 0.5 / 0.6 / 0.8 mm Knurling profiles on DIN 82 workpiece for tool 231: Feed knurling RAA RBL RBR 1 BR30 (right-hand use) 1 AA (left-hand use) 1 AA (right-hand use) 1 BL30 (left-hand use) TOOL VERSIONS: 1 tool: knurling wheel: mm 6 profile: AA Pitches: 0.5 / 0.6 / 0.8 mm Knurling profiles on DIN 82 workpiece for tool 241: Feed knurling RGE30 2 AA Set Holder Working area Ø Dimension a b c d e f (Ø b b) M VS-A M VS-A Set SET consisting of: 1 tool: knurling wheel: mm 3 profile: BL30 3 profile: BR30 Pitches: 0.6 / 0.8 / 1.0 mm Knurling profiles on DIN 82 workpiece for tool 231: Feed knurling RAA RBL RBR 1 BR30 (right-hand use) 1 AA (left-hand use) 1 AA (right-hand use) 1 BL30 (left-hand use) 1 tool: knurling wheel: mm 6 profile: AA Pitches: 0.6 / 0.8 / 1.0 mm Knurling profiles on DIN 82 workpiece for tool 241: Feed knurling RGE30 2 AA TOOL VERSIONS: Set Holder Working area Ø Dimension a b c d e f (Ø b b) M VS-A M VS-A

25 Cut knurling tools SETS Set SET consisting of: 1 tool: knurling wheel: mm 3 profile: BL30 3 profile: BR30 Pitches: 0.8 / 1.0 / 1.5 mm Knurling profiles on DIN 82 workpiece for tool 231: Feed knurling RAA RBL RBR 1 BR30 (right-hand use) 1 AA (left-hand use) 1 AA (right-hand use) 1 BL30 (left-hand use) TOOL VERSIONS: 1 tool: knurling wheel: mm 6 profile: AA Pitches: 0.8 / 1.0 / 1.5 mm Knurling profiles on DIN 82 workpiece for tool 241: Feed knurling RGE30 2 AA Set Holder Working area Ø Dimension a b c d e f (Ø b b) M B M A Set SET consisting of: 1 tool: knurling wheel: mm 3 profile: BL30 3 profile: BR30 Pitches: 0.8 / 1.0 / 1.5 mm Knurling profiles on DIN 82 workpiece for tool 231: Feed knurling RAA RBL RBR 1 BR30 (right-hand use) 1 AA (left-hand use) 1 AA (right-hand use) 1 BL30 (left-hand use) 1 tool: knurling wheel: mm 6 profile: AA Pitches: 0.8 / 1.0 / 1.5 mm Knurling profiles on DIN 82 workpiece for tool 241: Feed knurling RGE30 2 AA TOOL VERSIONS: Set Holder Working area Ø Dimension a b c d e f (Ø b b) M B M A

26 26 zeus Special tools and interfaces

27 Special tools Specially designed for maimum stability and precision Series 391 Knurling profiles on DIN 82 workpiece: Feed knurling RAA RGE30 RGE45 3 AA 2 BL30 / 1 BR30 2 BL45 / 1 BR45 Ø 25 mm Product features: No lateral contact pressures minimum load on the workpiece Custom production designed for workpiece diameter and pitch Dimensions correspond to standard for thread-cutting dies For use in standardised thread-cutting die holders Base shanks are not included in scope of delivery, but are available on request Available sizes: Ø 30 mm Ø 25 mm Ø 30 mm Ø 38 mm Ø 45 mm Ø 55 mm 27

28 Special tools Series 311- Conical knurling Face knurling Conical / inner / face knurling up to a shoulder Knurling profiles on DIN 82 workpiece: Plunge knurling RAA RBL RBR RGV AA BR BL GE Series 312- Conical knurling Knurling profiles on DIN 82 workpiece: Plunge knurling RAA RBL RBR RGV AA BR BL GE

29 Special tools Series 330 Knurling within a bore Knurling profiles on DIN 82 workpiece: Plunge knurling RAA RBL RBR RGE RGV RKE RKV AA BR BL GV GE KV KE Feed knurling RAA RBL RBR AA BR BL Series 332 Knurling within a bore up to a shoulder Knurling profiles on DIN 82 workpiece: Plunge knurling RAA RBL RBR RGE RGV RKE RKV AA BR BL GV GE KV KE Feed knurling RAA RBL RBR AA BR BL Series 342 Knurling within a bore up to a shoulder Knurling profiles on DIN 82 workpiece: Plunge knurling RAA RBL RBR RGE30 RGE30 AA BR BL 1 BL30 / 1 BL45 / 1 BR30 1 BR45 Feed knurling RAA RBL RBR AA BR BL 29

30 Special interfaces SK Characteristics: Standardised to DIN with retention knob Torque transmission by means of the friction contact of the taper with low strain For larger torques and sudden loads, driving keys are primarily responsible for the transmission The driving keys are arranged asymmetrically on the spindle face for clear orientation for the tool Easy production Self-centring due to steep taper High speeds can epand the spindle cone and the resulting centrifugal force can cause aial distortion of the tool The centrifugal force distortion reduces the contact surfaces and therefore the frictional transmission of torques HSK / HSK-C Characteristics: Standardised to DIN No retention nob Smaller (ca. 30 %) and lighter (ca. 50 %) than the steep taper (SK) Faster and easier tool change Rigidity 5 to 7 times higher than with steep taper holders due to support on the tool holder over the collar Force-closing due to the taper and contact surface Form-closing by means of drive slots Ecellent change accuracy (3 μm) Face contact on collar ensures aial wobble accuracy Close taper tolerance minimises radial run-out HSK-C has a shorter shank with a flatter taper angle 30

31 Special interfaces CAPTO (Sandvik) Characteristics: Transmission of high torques High bending strength Central supply of high-pressure cooling lubricant from the machine to the cutting edge Balanced and concentric Self-centring Fleible due to high level of modularity High basic stability and accuracy Reduced setup time VDI Characteristics: Universal tool system for all production areas Tool change within seconds Form-closing for reliable torque transmission Very short design Internal coolant supply is possible Presetting of tools outside the machine s in different sizes High rigidity GRAF holding systems Characteristics: Tool change within seconds Very short design Presetting of tools outside the machine s in different sizes High rigidity All zeus tools can be manufactured with a special holder on request 31

32 Special tools Series 161-S Integrated turret holder Epanded work area Knurling profiles on DIN 82 workpiece: Plunge knurling RAA RGE30 RGE45 2 AA 1 BL30 1 BR30 1 BL45 1 BR45 Product features: Fleible work area Etremely stable design Direct machine connection Conical application Carbide pins Working area: Ø 0 15 mm Series 161-S Conical knurling Adjustable jaws 4 12 Knurling profiles on DIN 82 workpiece: Plunge / feed knurling RAA RBL RBR RGE30 RGE45 2 AA 2 BL 2 BR 1 BL30 1 BR30 1 BL45 1 BR45 Product features: Adjustable jaws 4 12 Star turret holder Fleible work area conical surfaces Reduced strain on workpiece and machine Knurling head with fleible centring Modular shank design Carbide pin Working area: Ø 8 36 mm Series 161-S in special size / form Knurling profiles on DIN 82 workpiece: Plunge / feed knurling RAA RGE30 RGE45 2 AA 2 (1 ) BL30 / 1 (2 ) BR30 2 (1 ) BL45 / 1 (2 ) BR45 32 Product features: HSK holder No lateral contact pressure reduced load Centre height adjustable due to synchronous spindle Carbide pins Working area: Ø 0 20 mm

33 Special tools Series 142-S Special Capto holder Knurling profiles on DIN 82 workpiece: Plunge / feed knurling RAA RGE30 RGE45 2 AA 1 BL30 1 BR30 1 BL45 1 BR45 Product features: Knurling up to a shoulder Capto holder Knurling head with fleible centring Modularity application independent Carbide pins Working area: Ø mm Series 192-S Special HSK 32 holder Knurling profiles on DIN 82 workpiece: Feed knurling RAA RGE30 RGE45 2 AA 2 (1 ) BL30 / 1 (2 ) BR30 2 (1 ) BL45 / 1 (2 ) BR45 Product features: Knurling up to a shoulder HSK holder No lateral contact pressure reduced load Modular echangeable knurl holder jaws Suitable for very small workpieces Echangeable shank Easy and precise fine adjustment (synchronous) Carbide pins / bearing bolts Working area: Ø 4 30 mm Form knurling / marking Special facing slide head holder Knurling profiles on DIN 82 workpiece: Plunge / feed knurling RAA RBL RBR RGE30 1 AA 2 BL 2 BR 1 BL30 1 BR30 RGE45 1 BL45 1 BR45 Product features: Holder for facing slide head Special width for custom applications (knurling wheel / marking roll) Carbide pins Working area: Dependent on facing slide head 33

34 34 zeus

35 Profiles and knurling pitches DIN 403 describes and specified the knurling profile on the knurling wheel. DIN 403 defines knurling forms AA, BL, BR, GE, GV, KE and KV. that deviate from DIN 403 are considered special knurling tools and are custom manufactured by Hommel+Keller based on customer drawings. AA Knurling wheel with aially parallel grooves BL Left-hand knurling wheel BR Right-hand knurling wheel GE Left / right-hand knurling wheel, raised points, 30 GV Left / right-hand knurling wheel, lowered points, 30 KE Cross knurling wheel, raised points, 90 KV Cross knurling wheel, lowered points, 90 The knurling profile on the knurling wheel according to DIN 403 is based on the desired knurling profile on the workpiece (DIN 82) and the tool holder that is used. The knurling pitch p refers to the distance between tooth crests. The pitches = 0.5 / 0.6 / 0.8 / 1.0 / 1.2 / 1.6 are standardised according to DIN 403. The Hommel+Keller product spectrum includes other pitches as well. They are listed below in mm and TPI. Other pitches are available as custom manufactured versions. Standard pitches from Hommel+Keller mm TPI mm TPI mm TPI mm TPI

36 Form knurling non-cutting process AA BL30 BL45 BR30 BR45, milled, with 45 chamfer PM Standard Dimension Pitches Profile variants Ø Width Bore No No No No A8 No A11 No AA No No A13 No No No No No No BL 30 No No No No. 11 BL No No No BR 30 No No No No. 11 BR No Variants Knurling wheel variants (PM) Knurling wheel variants (HSS) Standard pitches / profile angle / 0.4 / 0.5 / 0.6 / 0.7 / 0.8 / 1.0 / 1.2 / 1.5 / 1.6 / / 0.4 / 0.5 / 0.6 / 0.7 / 0.8 / 1.0 / 1.2 / / 0.6 / 0.8 / 1.0 / 1.2 / 1.5 / 1.6 / / 0.6 / 0.8 / 1.0 / 1.2 / / 0.6 / 0.8 / 1.0 On request Other variants available on request Knurling wheel variants (HM) No. Version No. Version No. Version 13 milled, without chamfer 30 ground with 45 chamfer 32 ground, without chamfer 95 milled, with 60 chamfer 10 milled, with 45 chamfer 12 milled, without chamfer 94 milled, with 60 chamfer 50 ground with 45 chamfer 52 ground, without chamfer Form knurling with 60 chamfer When forming knurling profiles with a larger pitch in the aial machining direction it can be advantageous to apply a 60 chamfer to the knurling wheel. The flatter chamfer achieves a better material flow. Wheel geometries see Technology, page 44 36

37 Form knurling non-cutting process GE30 GE45 KE, milled, with 45 chamfer PM Standard variants Variants Profile Dimension Ø Width Bore Pitches No No GE 30 No No No. 11 GE No. 11 KE Knurling wheel variants (PM) Knurling wheel variants (HSS) Knurling wheel variants (HM) No. Version No. Version No. Version 13 milled, without chamfer 30 ground with 45 chamfer 32 ground, without chamfer 10 milled, with 45 chamfer 12 milled, without chamfer 50 ground with 45 chamfer 52 ground, without chamfer Standard pitches / profile angle 90 GV30 GV45 KV, formed, with 45 chamfer PM 0.3 / 0.4 / 0.5 / 0.6 / 0.7 / 0.8 / 1.0 / 1.2 / 1.5 / 1.6 / / 0.4 / 0.5 / 0.6 / 0.7 / 0.8 / 1.0 / 1.2 / / 0.6 / 0.8 / 1.0 / 1.2 / 1.5 / 1.6 / / 0.6 / 0.8 / 1.0 / 1.2 / / 0.6 / 0.8 / 1.0 On request Other variants available on request Standard variants Variants Profile Dimension Ø Width Bore Pitches No No GV 30 No No No. 21 GV No. 21 KV Knurling wheel variants (PM) Knurling wheel variants (HSS) No. Version No. Version 23 formed, without chamfer 20 formed, with 45 chamfer 22 formed, without chamfer 37

38 Cut knurling cutting process AA BL15 BL30 BR15 BR30, milled, without chamfer PM Standard variants Profile Dimension Ø Width Bore Pitches No No No AA No No No No No BL 15 No No No No No. 16 BL No No No No BR 15 No No No No No. 16 BR No No Standard pitches / profile angle / 0.4 / 0.5 / 0.6 / 0.7 / 0.8 / 1.0 / 1.2 / 1.5 / 1.6 / / 0.4 / 0.5 / 0.6 / 0.7 / 0.8 / 1.0 / 1.2 / / 0.6 / 0.7 / 0.8 / 1.0 / 1.2 / 1.5 / / 0.6 / 0.8 / 1.0 / 1.2 / / 0.6 / 0.8 / 1.0 On request Other variants available on request Variants Knurling wheel variants (PM) Knurling wheel variants (HSS) Knurling wheel variants (HM) N o Version N o Version N o Version 18 milled, with 10 chamfer 35 ground, without chamfer 37 ground with 10 chamfer 15 milled, without chamfer 17 milled, with 10 chamfer 55 ground, without chamfer 57 ground with 10 chamfer Form knurling with 10 chamfer When cutting knurling profiles with a larger pitch in the aial machining direction it can be advantageous to apply a 10 chamfer to the knurling wheel. For wheel geometries, see Technology on page 44 38

39 Special knurling wheels Bead knurl No. 60 HV HHV Note: Please indicate the bead diameter when ordering. KAA KGE Conical knurling wheels No. 70 KBR KBL Note: The completeness of the teeth on the workpiece is always dependent on the width / pitch of the knurling wheel. C* DL 20 * DR 20 * * Only radiuses > 3 mm are possible. E FL 20 FR 20 Concave and conve knurling wheels No. 80 In the DL, DR, FL and FR versions the spiral angle must not eceed 20. Nr. 90 Special knurling wheels No. 90 / 92 / 93 Nr. 92 Nr. 93 Note: The picture of knurling wheel no. 90 is provided as an eample. It represents all special forms not covered by no. 92 (single stepped) and no. 93 (double stepped). Wheel geometries see Technology, page 44 39

40 Burnishing rolls RRA RRE zeus burnishing rolls can be used in standard zeus form knurling tools. On request, we can develop and produce a custom holding system. Use in this tool system is suitable for machining cylindrical workpieces, bores, end faces, conical workpieces and for conve and concave outer contours. Applications: zeus burnishing rolls are used primarily for roller-burnishing and supporting round material during machining on lathes. Advantages: Burnished workpieces ehibit low friction and increased resistance to corrosion after machining Reworking, such as grinding, honing and lapping can be replaced by simple roller-burnishing machining When used as support rolls, they reduce wear on the bearings and clamping devices and minimise the pressure on the workpiece Result: Improved surface quality Increased dimensional stability Increased hardness of surfaces Burnishing roll type RRA cylindrical Type RRA Dimension Ø Width Bore N o 04 turned & polished, Rz 4 µm Version N o 05 ground, Rz 2 3 µm N o 06 ground & polished, Rz 1 µm Burnishing roll type RRE conve Type RRE Dimension Ø Width Bore R N o 04 turned & polished, Rz 4 µm Version N o 05 ground, Rz 2 3 µm N o 06 ground & polished, Rz 1 µm

41 Features Advantages: Longer tool life Reduction of tool costs Reduction of set-up costs In addition to the standard variants of powder metal, HSS, and carbide versions are also available on request. zeus Premium materials As your supplier of premium tool products we insist on materials that allow machining of hard-to-machine and pressure resistant materials. All knurling wheels in the standard zeus product line are therefore made of power metal. The material features high hot hardness and compression strength, as well as durability and resistance to wear. Surface treatment Suitable treatment based on your individual application can have a positive effect on the life of the knurling wheel. We offer different treatment processes. TENIFER salt-bath nitriding heat treatment Treatment of the knurling wheel in a salt bath based on the TENIFER process increases the resistance to wear and the fatigue strength. The salt-bath nitrocarburising process achieves a high case hardness. PVD coatings Suitable PVD coating of the knurling wheels offers the user additional possibilities for increasing tool life. These variants are available on request. PVD coatings are suitable primarily for cut knurling applications. Polished knurling wheels The use of finely polished knurling wheels can be effective for machining of adhesive materials that require optimal chip sliding. This process achieves very smooth surfaces, with a low coefficient of friction. Edge radiusing on the tooth flanks prevents built-up edges from forming and therefore premature tooth breakage. 41

42 42 Technology

43 Process characteristics Form knurling Knurl profiles on DIN 82 workpiece RAA RBL RBR RGE RGV RKE RKV Application: Non-cutting forming Processing of workpieces suitable for cold forming All knurling forms and profiles can be manufactured Suitable for face and knurling within a bore Knurling up to a shoulder is possible Tool can be started at any location on the workpiece Handling: Only minimal preparation of workpiece required Very easy handling of tool (short setup times) Features: Material displacement increases the outer diameter of the workpiece The surface is compacted Form knurling of small diameters is possible only to a limited etent Cut knurling Knurl profiles on DIN 82 workpiece RAA RBL RBR RGE Application: Alternative cutting process Material removal at aial feed drive Machining of thin-walled, soft and hard-to-machine materials is possible Only cylindrical workpieces can be machined in aial direction Machining of small diameters is possible Maimum precision and surface quality, therefore suitable primarily for visible knurling A plunge cut is necessary for applying the tool in the middle area of the workpiece Knurling up to a shoulder is not possible Handling: Requires precise tool adjustment and fine adjustment Requires precise preparation of the workpiece Features: Minimal change in the outer diameter Minimal surface compaction Lower strain on machine than in form knurling Minimum pressure on the workpiece and machine 43

44 Allgemeintoleranzen - Längenmaße Radien & Fase 0, über 6 ± 0,1 ± 0,1 ± 0,2 ± 0,3 ± 0,2 ± 0,5 ± 1 Angaben der Oberflächenbeschaffenheit Zust. Change/Änderungen Date / Datum Name Allgemeintoleranzen - Längenmaße Radien & Fase 0, über 6 general tolerances according to ± 0,1 ± 0,1 ± 0,2 ± 0,3 ± 0,2 ± 0,5 ± 1 Angaben der Oberflächenbeschaffenheit Projektionsmethode 1 Projection method DIN EN ISO 1302 Surface specifications Zust. Change/Änderungen Date / Datum Name Material general tolerances according to ± 0,1 ± 0,1 ± 0,2 ± 0,3 ± 0,2 ± 0,5 ± 1 Surface Angaben der Oberflächenbeschaffenheit Surface specifications Werkstückkanten nach Projektionsmethode 1 Work piece edges Blank DIN EN ISO 1302 Projection method DIN ISO HOMMEL KELLER PRÄZISIONSWERKZEUGE Ursprung HKP Erstellt Freig. Ursprung HOMMEL KELLER PRÄZISIONSWERKZEUGE Werkstoff: Material Oberfläche: Surface Werkstückkanten nach Halbzeug: Work piece edges Blank DIN ISO Büker HKP Sheet HOMMEL KELLER PRÄZISIONSWERKZEUGE Zust. Change/Änderungen Date / Datum Name Ursprung HKP In Benutzung : CAD-System - Inventor Allgemeintoleranzen - Längenmaße Angaben der Oberflächenbeschaffenheit Surface specifications DIN EN ISO 1302 Allgemeintoleranzen - Längenmaße Radien & Fase 0, über 6 Zust. Change/Änderungen Date / Datum Name HOMMEL KELLER PRÄZISIONSWERKZEUGE Ursprung general tolerances according to Weight Werkstückkanten nach Projektionsmethode 1 Work piece edges Projection method DIN ISO Scala Werkstückkanten nach Work piece edges DIN ISO HKP In Benutzung : CAD-System - Inventor In Benutzung : CAD-System - Inventor In Benutzung : CAD-System - Inventor Gewicht: Weight Maßstab: Scala Weight Scala Sheet Weight Scala Sheet Allgemeintoleranzen - Längenmaße Radien & Fase 0, über 6 ± 0,1 ± 0,1 ± 0,2 ± 0,3 ± 0,2 ± 0,5 ± 1 Angaben der Oberflächenbeschaffenheit Zust. Change/Änderungen Date / Datum Name general tolerances according to Werkstückkanten nach Projektionsmethode 1 Work piece edges Projection method DIN ISO HOMMEL KELLER PRÄZISIONSWERKZEUGE Ursprung HKP RB In Benutzung : CAD-System - Inventor Weight Scala Sheet Wheel geometries Abbreviation Abbreviation Outer diameter Bore diameter Width Pitch Stepped diameter Stepped diameter Collar stud bore diameter D1 D2 B1 p D3 D4 D5 Smallest diameter Average diameter Bore depth Step width Step width Knurl width Knurl width + chamfer Da Dm T1 B2 B3 RB RBF P Die enthaltenen Informationen in dieser Zeichnung, ist dass alleineignes Eigentum von Hommel+Keller GmbH +Co. KG. Jede nicht genehmigte, unerlaubte oder ohne schriftliche Genehmigung von Hommel+Keller GmbH +Co. KG ist untersagt. ØD1 A min. 0,1 A ØD1 ØD2 ØD5 ØDa ØDm A-A ( 5 : 1 ) ØD2 Bead knurl No. 60 Conical knurling wheels No. 70 Die enthaltenen Informationen in dieser Zeichnung, ist dass alleineignes Eigentum von Hommel+Keller GmbH +Co. KG. Jede nicht genehmigte, unerlaubte oder ohne schriftliche Genehmigung von Hommel+Keller GmbH +Co. KG ist untersagt. ØD1 ma. P/2 R R - P/2 Die enthaltenen Informationen in dieser Zeichnung, ist dass alleineignes Eigentum von Hommel+Keller GmbH +Co. KG. Jede nicht genehmigte, unerlaubte oder ohne schriftliche Genehmigung von Hommel+Keller GmbH +Co. KG ist untersagt. The information contained in this drawing is the sole property of Hommel+Keller GmbH +Co. KG. Any reproduction in part or as a whole without the written permission of Hommel+Keller GmbH +Co. KG is prohibited. ØD2 Allgemeintoleranzen nach DIN ISO 2768-mK ØD1 R + P/2 HKP PM B1 No.60 HV 2066 G7 T=2,1 Ø2,0 R ØD2 0,013 kg 5 : 1 (2: 1) Blatt: Sheet 2 A4 ØD1 B1 T1 ØD2 B1 B1 B1 Concave / conve knurling wheels No. 80 Special knurling wheels No. 90 The information contained in this drawing is the sole property of Hommel+Keller GmbH +Co. KG. Any reproduction in part or as a whole without the written permission of Hommel+Keller GmbH +Co. KG is prohibited. DIN EN ISO 1302 Surface specifications Allgemeintoleranzen nach DIN ISO 2768-mK Erstellt Freig Die enthaltenen Informationen in dieser Zeichnung, ist dass alleineignes Eigentum von Hommel+Keller GmbH +Co. KG. Jede nicht genehmigte, unerlaubte oder ohne schriftliche Genehmigung von Hommel+Keller GmbH +Co. KG ist untersagt. Büker The information contained in this drawing is the sole property of Hommel+Keller GmbH +Co. KG. Any reproduction in part or as a whole without the written permission of Hommel+Keller GmbH +Co. KG is prohibited. Werkstoff: Oberfläche: Halbzeug: HKP PM Erstellt No.80 C 2066 G7 T=0,6 R=3Freig. ØD1 RB Allgemeintoleranzen nach Gewicht: DIN ISO 2768-mK kg Maßstab: 5 : 1 (3 : 1) Blatt: 2 A4 RB Büker Werkstoff: Material Oberfläche: Surface Halbzeug: Blank HKP PM No.80 E 2066 G7 T=1,0 R=4,5 ØD2 ØD3 Gewicht: kg Maßstab: 5: 1 (2 : 1) Blatt: 2 A4 Die enthaltenen Informationen in dieser Zeichnung, ist dass alleineignes Eigentum von Hommel+Keller GmbH +Co. KG. Jede nicht genehmigte, unerlaubte oder ohne schriftliche Genehmigung von Hommel+Keller GmbH +Co. KG ist untersagt. ØD1 ØD3 RB ØD2 ØD4 (B3) B2 (B2) Special knurling wheels No. 92 B1 Special knurling wheels No. 93 RB = Rändelbreite B1 44 Knurl width and chamfer 0,545 (2) RB RBF RB The information contained in this drawing is the sole property of Hommel+Keller GmbH +Co. KG. Any reproduction in part or as a whole without the written permission of Hommel+Keller GmbH +Co. KG is prohibited. 0,5-3 ± 0,1 3-6 ± 0,1 Radien & Fase über 6 ± 0,2 ± 0,3 ± 0,2 ± 0,5 ± 1 0,545 (2) Allgemeintoleranzen nach general tolerances according to DIN ISO 2768-mK Erstellt Freig. RB = Rändelbreite The knurl width is always defined without the chamfer RB = Knurl Width / RBF = Knurl Width + Chamfer Projektionsmethode 1 Projection method RBF RB Büker RBF = Rändelbreite + Fase Die enthaltenen Informationen in dieser Zeichnung, ist dass alleineignes Eigentum von Hommel+Keller GmbH +Co. KG. Jede nicht genehmigte, unerlaubte oder ohne schriftliche Genehmigung von Hommel+Keller GmbH +Co. KG ist untersagt. The information contained in this drawing is the sole property of Hommel+Keller GmbH +Co. KG. Any reproduction in part or as a whole without the written permission of Hommel+Keller GmbH +Co. KG is prohibited. Werkstoff: Material Oberfläche: Surface Halbzeug: Blank RBF = Rändelbreite + Fase PM Gewicht: 0,010 kg Maßstab: No.92 AA 2066 G7 T=0,8 5 : 1 (2 : 1) Blatt: With 110 chamfer HKP A4 No. 17 / 18 P/2 60 Gez. 60 With 60 chamfer No. 94 / Büker P/2 Die enthaltenen Informationen in dieser Zeichnung, ist dass alleineignes Eigentum von Hommel+Keller GmbH +Co. KG. Jede nicht genehmigte, unerlaubte oder ohne schriftliche Genehmigung von Hommel+Keller GmbH +Co. KG ist untersagt. The information contained in this drawing is the sole property Keller GmbH +Co. KG. Any reproduction in part or as a whole without the tten permission of Hommel+Keller GmbH +Co. KG is prohibited. The information contained in this drawing is the sole property of Hommel+Keller GmbH +Co. KG. Any reproduction in part or as a whole without the written permission of Hommel+Keller GmbH +Co. KG is prohibited. 10 No. 94/ /18 DIN EN ISO 1302 Surface specifications 10 P/2 Allgemeintoleranzen nach DIN ISO 2768-mK Erstellt Freig Sheet: Blatt Büker Werkstoff: Material Oberfläche: Surface Halbzeug: Blank HKP PM No.93 AA 2066 G7 T=0,8 60 Gewicht: 0,010 kg Maßstab: 5 : 1 (2 : 1) Blatt: 1 A4

45 Conversion to inches Knurling based on CP (TPI) and DP CP (TPI) = Circular Pitch (Teeth Per Inch) This standard specifies the number of teeth over a distance of 1 inch (1~25.4 mm). To calculate the pitch, divide 1 inch by the number of teeth. The profile angle is defined as 70 or 90, depending on the number of teeth per inch. Conversion eample: Specification CP (TPI) = 20 Pitch (mm) = 1 inch (~25.4 mm) : 20 (number of teeth) = 1.27 mm a = flank angle DP = Diametral Pitch As opposed to CP (TPI) this standard specifies the number of teeth on the circumference of a circle with a diameter of 1 inch (1"~25.4 mm). To calculate the pitch, divide the circumference of a 1 inch circle by the number of teeth. The profile angle is defined as 80. Conversion eample: Specification DP = 64 Pitch (mm) = 1 inch (~25.4) π ( ) : 64 (number of teeth) = 1.25 mm 45

46 Material displacement non-cutting forming Our empirical values for enlargement of the workpiece diameter Knurling profile acc. to DIN 82: RAA (knurling profile on workpiece) according to DIN 403: AA (knurling profile on knurling wheel) RAA Material Free-cutting steel Stainless steel Pitch Workpiece Ø Enlargement of workpiece diameter in mm Brass Aluminium Knurling profile acc. to DIN 82: RBL30 / RBR30 (knurling profile on workpiece) according to DIN 403: BR30 / BL30 (knurling profile on knurling wheel) RBL30 RBR30 Pitch Material Workpiece Ø Enlargement of workpiece diameter in mm Free-cutting steel Stainless steel Brass Aluminium ! Important notice: This information represents empirical values. Deviations are possible. Knurling profile acc. to DIN 82: RGE30 (knurling profile on workpiece) according to DIN 403: BR30 + BL30 (knurling profile on knurling wheel) RGE30 46 Pitch Material Workpiece Ø Enlargement of workpiece diameter in mm Free-cutting steel Stainless steel Brass Aluminium

47 Reference values for cutting speed and feed rate Form knurling non-cutting process Material Free-cutting steel Stainless steel Workpiece Ø Cut knurling cutting process Knurling wheel Ø Vc [m/min] Radial from to from to f [mm/u] > 0.3 < 0.5 Aial Pitch > 0.5 < 1.0 > 1.0 < 1.5 > 1.5 < 2.0 < / / / / > < / / / / > Brass < / / / / > Aluminium < / / / / > Material Free-cutting steel Stainless steel Workpiece Ø Knurling wheel Ø Vc [m/min] Radial from to from to f [mm/u] > 0.3 < 0.5 Aial Pitch > 0.5 < 1.0 > 1.0 < 1.5 > 1.5 < 2.0 < / / / 32 / / 32 / > / < / / / 32 / / 32 / > / Brass < / / / 32 / / 32 / > / Aluminium < / / / 32 / / 32 / > / ! Important notice: This information represents reference values. The optimal values are to be found in the application. Ensure effective cooling / lubrication to prevent chips from being rolled into the profile and to prolong the life of the knurling wheels. 47

48 Optimization of knurling The pitch corresponds to the workpiece circumference In many cases the user does not notice the relationship between the pitch and the workpiece circumference, since the pitch already corresponds to the workpiece circumference. The knurling wheel can compensate the distortion of the pitch to produce good knurling (see Figure 1). The pitch does not optimally correspond to the workpiece circumference The more unfavourable the pitch corresponds to the workpiece circumference, the more the knurling wheel has to compensate. This results in knurling of poor quality and reduces the tool life. Effects on the knurling quality: Form knurling: The less favourable forming process (unnecessary strain on the material) results in a rough surface and reduced tool life. The sub-optimal penetration process causes material abrasion, which is formed into the knurling profile (indistinct profile flanks). This results in distortions of the knurling profile, which are evident in flattening of the profile and rounding of the tooth crest and tooth gullet (see Figure 2). Cut knurling: The sub-optimal penetration process of the knurling wheel results in indistinct profile flanks (shadowing). This results in distortions of the knurling profile, which are evident in flattening of the knurling profile and rounding of the tooth crest and tooth gullet (see Figure 2). The pitch does not correspond to the workpiece circumference This is an etreme case. The knurling wheel cannot compensate the unfavourable relationship between the pitch and the workpiece circumference, or the profile is heavily distorted. In the worst case this can result in double knurling. The knurling wheel then no longer engages in the knurling profile after one workpiece rotation, but instead engages between the profile. This is evident in the finer pitch of the knurling (see Figure 3). Figure 1: Optimal knurling profile Figure 2: Distorted knurling profile Figure 3: Double knurling p = pitch 48

49 Optimization of knurling The knurling quality and the tool life can be improved substantially by optimising the knurling by changing the rough-turn diameter and / or the pitch. The following procedure ensures systematic optimisation: Correction of the rough-turn diameter until optimal knurling is achieved. Note: Changing the rough-turn diameter by only a few hundredths of a millimetre has a substantial effect on the circumference {factor π ( )} and can improve the knurling quality significantly. If a correction is not possible (tolerances cannot be maintained; workpiece diameter should not be turned), then: Check whether the pitch can be changed. If it is not possible to change the pitch, it is necessary to manufacture a special knurling wheel with optimised pitch (defined number of teeth / outer diameter of knurling wheel). Consultation is provided by the Hommel+Keller application engineer on the basis of a workpiece drawing and information about the machine. Summary: Customer requirements: Clear, distinct knurling profile Fully formed teeth No double knurling / no incomplete knurling Solutions: 1) Optimisation measures by user: Correction of the rough-turn diameter Change of the pitch 2) Optimisation measures by Hommel+Keller: Optimisation by manufacturing a special knurling wheel: Calculation of the number of teeth allows development of a knurling wheel that is specially designed for the application based on the optimal relationship between the diameter and the number of teeth. The calculation of the optimal pitch is conducted on the basis of approimate formulas. Due to influencing factors (such as differences in materials) further optimisation may be necessary. 49