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Mount
base (Pt. 1) onto machine cross slide so that dovetail clamp screws (Pt.
13A) are accessible on turret side of holder, alignment plate (Pt. 7) is
on bottom of holder to fit cross slide "T" slot of machine and
spacer (Pt. 8) is on top side of holder under the "T" bolt
nut.
Loosen
2 dovetail clamp screws (Pt. 13A) and install 3/4" wide insert
slide into base so that cutting tool is either facing up or down as
required. At the same time, install adjusting screw (Pt. 15) in
threaded hole on top side of holder and engage flange of screw in slot
in insert slide. Rotate adjusting screw until cutting tool slide
is set approximately to center.
Loosen
clamp screw (Pt. 5) holding clamp wedge (Pt. 2) so that opening is wide
enough to accept formed insert.
Install
formed insert into opening. Be sure pocket is free of chips and
oil and that insert is pushed all the way in so that it bottoms out at
back end of opening. Insert pocket can be cleaned out with air
pressure through side openings.
Clamp
insert securely by tightening clamp screw (Pt. 5) so that wedge holds
insert evenly and fully.
With
dovetail clamp screws (Pt. 13A) snugged up, turn adjusting screw (Pt.
15A) until cutting edge of tool is adjusted to centerline of workpiece.
Then lock in place by securely tightening dovetail clamp screws (Pt.
13A).
Tool
is now ready for use. If part is tapered, tapers can be corrected by
adjusting alignment plate (Pt. 7) by turning adjusting screws (Pt. 12).
When
cutting edge needs resharpening, remove worn insert only (Do not disturb
holder settings.) and replace with sharpened insert as per previous
instructions. Since clamping pressure is upward on insert,
replacement insert will be on same centerline as original insert,
thereby eliminating the need to reset tool for center height. Also
since inserts are identical in form and have a parallelogram
configuration, they will maintain same workpiece lengths and
diameters. Machine should be producing perfect parts again in less
than a minute.
For
best size control and for longest life, insert should be sharpened as
soon as cutting edges start to show wear of .005" maximum.
When
approximately 3/32" has been resharpened off thickness of insert,
insert will no longer be able to be clamped in holder. However, a
3/32" thick matched form backup spacer is available that can be
placed under insert for support. This spacer allows for additional
resharpenable tool life of 3/64" to 3/32" depending on
configuration of insert.
To
sharpen dull insert, install insert into sharpening fixture and clamp
securely. Tap insert down to be sure it is fully seated against
bottom face. Mount fixture on magnetic chuck of surface grinder
horizontally or vertically depending on the wheel being used. **IMPORTANT:
If grinding horizontally, position fixture so that grinding wheel
pressure against insert is towards screw head stop in fixture that
contacts back end of insert, NOT towards end of insert with form.
Remove
stock evenly from entire top surface of insert so that top and bottom
surfaces are parallel within .001" and as smooth as possible. It is
essential that the top surface of the insert is flat and free of steps
since steps would cause insert to not repeat center setting when
remounted in holder and could also result in lack of rigidity and
possible breakage of insert and damage to holder.
Grind
off only minimum amount necessary to remove wear of cutting edges.
Remember, inserts should be resharpened prior to .005" wear.
Always
spark out final grinding passes for better finish and longer tool life,
honing of top surface will further increase tool life and improve
finish.
Wheel
grade recommendation for carbide inserts: CMD180 R100 B-1/8
Style
of wheel: If grinding horizontally Use D1A1
If grinding vertically
Use D11V9
Take
.0001/.0003" deep passes if grinding dry.
Take
.0002/0005" deep passes if grinding wet.
For
best results true up wheel as per grinding wheel manufacturer's
instructions as needed.
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WARNING ********************
It
is always important to be certain that insert is clamped securely in the
tool holder. If insert is not clamped securely, machine damage or
personal injury can result.
Extra
care must be taken when you have resharpened the insert (including the
3/32" spacer when used) down to about 7/32" total thickness
since it will no longer be possible to clamp the insert in the
holder. This is done intentionally so that insert will not be used
when it's thickness is less than that which is required to support the
cutting edge.
Therefore,
it is important to be certain that clamp is actually clamping on insert,
holding it securely in the holder and not merely bottoming out.
********************
WARNING ********************
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