User Manual TriboMAM Drilling System
Contents
1. User Manual TriboMAM Drilling System Micro Mini Meso Standard Kilo Mega TriboMAM Drilling System User Manual Version 02 20 14 Page 1 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge m4sciences com M4 Sciences TriboMAM drilling system Thank you for purchasing a TriboMAM drilling system Together with the MEC PA08082 Controller the TriboMAM drilling system uses Modulation Assisted Machining MAM to enable the improvement of drill soeeds and feed rates for high aspect ratio centerline drilling in CNC lathes This manual provides information regarding safety precautions installation procedures and operating protocols in the use of the TriboMAM drilling system These products are covered by United States and foreign patents issued and pending Information in this publication supersedes that in all previously published material Specifications are subject to change without notice Copyright 2014 all rights reserved Printed in the U S A TriboMAM Drilling System User Manual Version 02 20 14 Page 2 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge mA4sciences com TABLE OF CONTENTS t SARL REDE SEES DSE SE PEEL FEET se Seven teins EEN Te E Aa 4 1 1 Critical Installation and Operation Notes cc ccccceescceeecceeeccceecceeeeceeeceeeees 4 1 2 Safety Term2. 6 6 TriboMAM mega Drilling diameter Feed rate Maximum spindle speed Maximum coolant pressure Standard Dimensions not to scale ELECTRICAL CONNECTION HIDDEN HIGH PRESSURE S COOLANT FITTING a MAX 86BAR 1250PSI TT a a i 5 0 mm to 12 0 mm up to 0 060 mm rev flute 6 000 rpm 1 250 psi 86 bar 8 6 MPa 5 000 psi 345 bar 34 5 Mpa available as option 31 50 1 24 222 00 8 76 330 50 13 01 Dimensions are in mm inches These dimensions may vary depending on the approved configuration See Section 7 for Reference Materials Consult the MEC PA08082 User Manual for specifications of the MEC Controller TriboMAM Drilling System User Manual Version 02 20 14 Page 32 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge m4sciences com 7 Spare Parts Spare parts list Eon P004 0167 Fitting Pre swage 19097 0241 Tool font P004 0240 Ferrule Coolant Tubing P004 0238 Compression Fitting P004 0212 Straight Compression Fitting P004 0211 Elbow Full Description Stainless steel coolant fitting 1 8 compression tube to 10 32 male Pre swaging tool for Beswick fitting New ferrules required for new compression connection Front ferrule for MCB 18 1 303 compression fitting replaces ferrule for new compression connection Rear ferrule for MCB 18 1 303 compression fitting replaces
3. The following guidelines outline four different types of drilling processes commonly used for industrial drilling applications Each of these examples refers to an existing drilling process as a reference condition and utilizes incremental changes in the drilling process to achieve increased drilling productivity using the TriboMAM drilling system As in practical machining process engineering the drill tool life must be considered when defining a new production drilling process using the TriboMAM drilling system 1 Single flute gun drilling with high pressure through tool coolant Follow the drill tool manufacturer s recommended conditions for pilot hole drilling After proper installation of the TriboMAM drilling system install a new drill for process testing Incrementally increase the feed rate by 10 increments and drill several parts at each increment of feed rate verify that the CNC program conditions match the MEC PA08082 controller conditions Continue to incrementally increase feed rate until 1 the quality requirements are exceeded and or 2 an acceptable level of drilling cycle time and drill wear rate is achieved Drill breakage can occur as feed rate is incrementally increased If drill tool failure occurs then reduce the feed rate to a condition that achieves acceptable production rate and or drill tool life 2 Twist flute drilling with high pressure through tool coolant no peck cycles Follow the drill tool manufactu
4. Version 02 20 14 Page 11 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge m4sciences com If the machine coolant manifold port is an appreciable distance from the TriboMAM connection point route the line as appropriate and anchor the coolant line using straps or ties to a rigid point 100 mm 150 mm 4 inches 6 inches from the TriboMAM connection point to provide strain relief for the line If the coolant line is routed to an off slide connection verify that the coolant line will not be pinched or snagged and has sufficient slack when the slide is moved through its maximum range Tighten the hex nut on the coolant line to the coolant manifold with a 3 8 inch open wrench as shown in Figure 9 This will swage the ferrules in the pre assembled fitting to the coolant line For the hex nut on the coolant line to be fixed to the TriboMAM body care must be exercised in properly tightening so as to not damage the threads that secure the compression fitting to the TriboMAM Using a 5 16 inch open wrench to secure the compression fitting on the TriboMAM body tighten the hex nut on the coolant line with a 3 8 inch open wrench until the coolant line is secured tightly to the TriboMAM This will require holding the 5 16 inch wrench in place on the compression fitting coolant port base while using the 3 8 inch open wrench to tighten the hex nut This is shown schematically
5. 000 87 a h i ih al Wi oe E p Ro prai 112 40 4 43 a O 120 70 4 75 Wy U 233 10 9 18 N ER16 COLLET NOSE Dimensions are in mm inches These dimensions may vary depending on the approved configuration See Section 7 for Reference Materials Consult the MEC PAO8082 User Manual for specifications of the MEC Controller TriboMAM Drilling System User Manual Version 02 20 14 Page 30 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge m4sciences com 6 5 TriboMAM kilo Drilling diameter Feed rate Maximum spindle speed Maximum coolant pressure Standard Dimensions not to scale ELECTRICAL CONNECTIO HIDDEN HIGH PRESSURE COOLANT FITTING x MAX 86BAR 1250PSI a ER16 COLLET NOSE 5 0 mm to 10 0 mm up to 0 060 mm rev flute 6 000 rpm 1 250 psi 86 bar 8 6 MPa 5 000 psi 345 bar 34 5 Mpa available as option 29 36 1 16 260 36 10 25 289 36 11 39 Dimensions are in mm inches These dimensions may vary depending on the approved configuration See Section 7 for Reference Materials Consult the MEC PAO8082 User Manual for specifications of the MEC Controller TriboMAM Drilling System User Manual Version 02 20 14 Page 31 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge m4sciences com
6. 5 0 mm up to 0 040 mm rev flute Feed rate Maximum spindle speed 9 960 rom Maximum coolant pressure 1 250 psi 86 bar 8 6 MPa 5 000 psi 345 bar 34 5 Mpa available as option Standard Dimensions not to scale ELECTRICAL _ OPTIONAL HIGH PRESSURE COOLANT FITTING 32 50 1 28 MAX B6BAR 1250PS Pe is j _ we N F i i we le EA i rd 19 05 0 75 106 00 4 17 ee ee 2 63 172 70 6 80 yA G 20 00 0 79 dl 22 00 0 87 R16 COLLET NOSE Dimensions are in mm inches These dimensions may vary depending on the approved configuration See Section 7 for Reference Materials Consult the MEC PAO8082 User Manual for specifications of the MEC Controller TriboMAM Drilling System User Manual Version 02 20 14 Page 29 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge m4sciences com 6 4 TriboMAM standard Drilling diameter 2 0 mm to 6 5 mm Feed rate up to 0 080 mm rev flute Maximum spindle speed 7 200 rom Maximum coolant pressure 1 250 psi 86 bar 8 6 MPa 5 000 psi 345 bar 34 5 Mpa available as option Standard Dimensions not to scale ELECTRICAL CONNECTION gt a N PTIONAL HIGH PRESSURE Pa i J fi COOLANT FITTING we je LA H MAX S6BAR 1250PSI A7 a Pa f an a Ed wae a Pa Oo 5 S i we i rd F 19 05 0 75 y 20 00 0 79 n N me 22
7. ER Sealing Disks DS ER 20 type Partno finch Sealing Capacity mm _ Sealing Capacity Inch DS ER20 4 5mm 39200050 550 500 01772 01575 DS ER20 6 0mm 392000600 600 550 02362 0 2165 DS ER20 7 0mm 392000700 700 650 02756 0 2559 DS ER20 8 5mm 392000850 850 800 0 3347 0 3150 DS ER20 10 0mm 392001000 10 00 950 0 3937 0 3740 DS ER20 110mm 392001100 1100 1050 04330 04134 DS ER20 12 5mm 392001250 1250 1200 04921 0 4724 TriboMAM Drilling System User Manual Version 02 20 14 Page 38 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge m4sciences com Supplier contact information 1 Beswick Engineering Co Terry Theberge ttheberge beswick com 284 Ocean Rd Greenland NH 03840 2442 603 433 1188 office 603 433 3313 fax 2 Transmission and Fluid Equipment Ethan Bergman 6912 Trafalgar Street Fort Wayne IN 46803 260 493 3223 office 260 493 4085 fax 3 MSC Industrial 1 800 645 7270 www mscdirect com TriboMAM Drilling System User Manual Version 02 20 14 Page 39 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge mA4sciences com
8. TE E T RENEE ES TE edaeeete 33 8 ER Collets and Clamping Nuts REGO FIX sssssssssessrrssssrerserrrrserrersesrrrsssrrressrrreeses 34 8 1 TAHOMA M mMicr and MIN enserir eaaa A aa E 34 8 2 TriboMAM standard and Meso cccccceseccesecceeecececcceecceeneceeeceuecseeceeeeeees 35 83 TriboMAM kilo and mega 222427 a a a 37 TriboMAM Drilling System User Manual Version 02 20 14 Page 3 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge m4sciences com 1 Safety Review the following precautions to maintain safety and prevent damage to the instrument or equipment connected to it The safety features of this instrument may be ineffective if the equipment is not operated in the manner stated in this manual Refer all maintenance procedures to qualified personnel Failure to conform to the following requirements can lead to damage to the TriboMAM significant personal injury and possibly death 1 1 Critical Installation and Operation Notes e Refer to the MEC PA08082 User Manual for specific safety precautions and protocols associated with use and installation of the MEC PA08082 Controller e Ensure that the MEC PA08082 Controller is properly grounded If the power source does not have a ground connection available ground the Controller using the ground stud connection on the rear panel of the Controller e Do not attempt to disassemble repair the TriboMAM or ME
9. dA 109 93 4 33 R11 COLLET NOSE Dimensions are in mm inches These dimensions may vary depending on the approved configuration See Section 7 for Reference Materials Consult the MEC PA08082 User Manual for specifications of the MEC Controller TriboMAM Drilling System User Manual Version 02 20 14 Page 27 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge m4sciences com 6 2 TriboMAM mini Drilling diameter 0 2 mm to 3 5 mm Feed rate up to 0 040 mm rev flute Maximum spindle speed 9 960 rom Maximum coolant pressure 1 250 psi 86 bar 8 6 MPa 5 000 psi 345 bar 34 5 Mpa available as option Standard Dimensions not to scale OPTIONAL ELECTRICAL SEN ELECTRICAL CONNECTIO A Ns OPTIONAL HIGH PRESSUR COOLANT FITTING Pt MAX 86BAR 1250PS gt 67 23 2 65 24 60 0 97 KS p l a W S 19 05 0 75 J 20 00 0 79 jj 22 00 0 87 R11 COLLET NOSE Dimensions are in mm inches These dimensions may vary depending on the approved configuration See Section 7 for Reference Materials Consult the MEC PA08082 User Manual for specifications of the MEC Controller TriboMAM Drilling System User Manual Version 02 20 14 Page 28 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge m4sciences com 6 3 TriboMAM meso Drilling diameter 0 5 mm to
10. ferrule for new compression connection Nylon Tubing 1 8inch OD for high pressure coolant 0 031 wall Uses pre swage tool TPSS 18 1 to pre swage compression fitting from Beswick No substitution available TriboMAM warranty void if alternative tubing is used Compression Tube Fittings Metal Type Male Connector Fitting Size 1 8 End Connections Comp x MNPT Tube Outside Diameter 1 8 Thread Size 1 8 Thread Type MPT Material Stainless Steel Compression Tube Fittings Metal Type 90 Elbow Fitting Size 1 8 End Connections Comp x MNPT Tube Outside Diameter 1 8 Thread Size 1 8 Thread Type MPT Material Stainless Steel Supplier seer on See i MCB 18 1 FF stainless Beswick Beswick for MCB 18 1 303 FR j stainless Beswick Beswick for MCB 18 1 303 TE 4212 231 Fluid Eaton Equi Synflex eae q p y 233 Inc wee Hamlet 86760519 Industrial wee Hamlet 85552727 Industrial TriboMAM Drilling System User Manual Version 02 20 14 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge mA4sciences com Page 33 of 39 8 ER Collets and Clamping Nuts REGO FIX 8 1 TriboMAM micro and mini ER 11 UP Ultra Precision mm Collets type PartNo Clamping Range mm Clamping Range inch inch Cogis moso 150 100 ooroo Cupom umoo 200 250 onsoosm Cuga moso 450 400 O omo amur ssmm moso 550
11. replaces conventional drill holders and oscillates the drill using electro mechanical actuation The TriboMAM is connected to and electrically driven by the MEC PAO8082 controller through a coaxial cable The Tribo MAM has the capability to accommodate through tool coolant at a maximum rating of 1 250 psi 86 bar 8 6 MPa SSMB SSMC port optional 1 8 coolant port SSMB SSMC port standard ER11 collet Figure 1 Tribo MAM mini drilling system with 2 positions for the SSMB SSMC coaxial power cable connector LCD displa Home Power High voltage Emergency Emergency play button indicator output indicator stop indicator stop button Directional selection Stop Start Trip Reset SMB electrical Power switch buttons buttons indicator button port Power warning indicator Figure 2 MEC PA08082 Controller TriboMAM Drilling System User Manual Version 02 20 14 Page 6 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge m4sciences com 2 2 System Description The TriboMAM drilling system alters the mechanics of the chip formation that occurs during drilling by enabling Modulation Assisted Machining MAM In MAM the drilling process is divided into a series of cuts that are determined by the modulation conditions This forms the drilling chips into smaller fragments that are more easily evacuated from the drilling zone MAM also improves lubr
12. the actual and programmed values for these parameters will affect the performance of the TriboMAM drilling system Programming Example for TriboMAM drilling system and MEC PA08082 controller In this sample program the TriboMAM was programmed to eliminate the peck drilling cycle and the G83 command was removed from the CNC program and replaced with a G1 command In some drilling applications peck drilling may not be completely eliminated and the optimal process conditions must be established by actual drilling results 1 Baseline drilling process peck drilling cycle Material Oxygen Free High Conductivity Copper Alloy 101 Drill Diameter 3 0 mm 2 flute drill with thru tool coolant Coolant pressure 1 500 psi 103 bar Spindle 6500 RPM Feed rate 0 050 mm rev CNC code G83 peck drilling cycle 0 150 mm peck depth feedrate 0 050 mm rev M3 S1 6500 X0 0 21 0 G83 Z 75 0 RO 100 Q0 050 F0 050 GO Z1 0 TriboMAM Drilling System User Manual Version 02 20 14 Page 21 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge mA4sciences com 2 TriboMAM drilling process Coolant pressure 1 250 psi 86 bar Select Setup Menu in MEC controller choose Model Mini Program 1 Dia 3 0000 mm Flutes 2 RPM 6480 Feed 0 050 mm rev Changes to CNC code M3 S1 6480 G1 Z 75 0 FO 050 GO Z1 0 Important The machine coolant pressure was reduce
13. 500 ono Cuaron uno 700 650 ozo Hi Q ERMC 11 Clamping Nuts with Built In Sealing System for Coolant through Tools type e o naa ad arainn sealing Capacity inch _ bra enme1 45mm 35112050 sso ommo hra ermeir somm 3512060 60 559 02302 02155 Hra enmem 7omm 35112070 700650 027620259 TriboMAM Drilling System User Manual Version 02 20 14 Page 34 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge m4sciences com 8 2 TriboMAM standard and meso ER 16 UP Ultra Precision mm Collects Type PartNo Clamping Range mm Clamping Range Inch Inch ER1GUP LSMM 11160150 150 100 0 0591 0034 ER16 UP 30mm 11160300 300 200 01181 00787 ER16UP 4SmMm 1116 04501 4so 350 01772 01378 ER16 uP 55mm 116 05501 550 450 02165 01772 ER16 uP 70Omm 1m6 07001 700 600 02756 02362 ER16UP SSMm 116 08501 850 750 03347 02953 ER16 uP 9 5mm 1116 09501 9 50 8 50 03740 03347 ER Clamping Nuts Tye PartNo Hi Q ERMC 16 3516 20000 TriboMAM Drilling System User Manual Version 02 20 14 Page 35 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge m4sciences com ER Sealing Disks DS ER 16 type PartNo linch Sealing Capacity mm _ Sealing C
14. AM micro gt 0 015mm gt 0 0006 inches TriboMAM mini meso gt 0 050mm gt 0 0020 inches TriboMAM standard gt 0 100mm gt 0 0040 inches FE TriboMAM kilo mega gt 0 070mm gt 0 0028 inches On machine testing The protocol for on machine testing is similar to that of bench testing with the exception that the TriboMAM is tested after machine installation Mount the test indicator on a magnetic moveable base and repeat the above instructions for bench testing Figure 16 Functional test using test indicator on machine Note the strain relief tie down for power cable TriboMAM Drilling System User Manual Version 02 20 14 Page 24 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge m4sciences com 5 Installation Checklist This checklist includes important items for a new installation of the TriboMAM This checklist does not to include all necessary steps for installation and is only a supplement of the documentation Please refer to Section 2 of this manual and also to the MEC PA08082 User Manual for installation protocols Baseline process checks e Note the positions and types of the external coolant lines e Locate safety equipment in the plant fire extinguishers safety PPE etc know where fire suppression is activated if applicable e Record baseline drilling cycle time and G code lines TriboMAM installation e Verif
15. C Controller Servicing of TriboMAM system equipment should only be conducted by M4 Sciences or other qualified personnel e Do not drop the TriboMAM drilling system Impact loading can damage the TriboMAM e Coolant line is rated at 1 250 psi 86 bar 8 6 MPa Coolant system pressure needs to be at or below this maximum setting Only high pressure coolant tubing specified by M4 Sciences may be used for supplying high pressure coolant to the TriboMAM Use of non specified tubing may result in unexpected rupture of the line e Use caution in setting tool offsets e g touch off procedures e Set Spindle Override to 100 Feedrate Override should not be more than 100 e Do not cycle the power of the HV output on off during a drill cycle e Cleaning of the TriboMAM drilling system should be done only with electrical contact cleaner or an alternate method approved by M4 Sciences Do not submerge the TriboMAM in a liquid solution for cleaning TriboMAM Drilling System User Manual Version 02 20 14 Page 4 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge mA4sciences com 1 2 Safety Terms and Symbols e These terms may appear in this manual Warning Warning statements identify conditions or practices that could result in injury or loss of life Caution Caution statements identify conditions or practices that could result in damage to this product or other e
16. apacity Inch pos eri645mm 3916 00450 00 450 400 01772 01575 DS ER16 6 0mm_ 39160060 600 550 02362 0 2165 DS ER16 7 0mm_ 391600700 700 650 02756 0 2559 DS ER16 8 5mm 391600850 850 800 03347 03150 DS ER16 10 0mm_ 391601000 1000 950 03937 0 3740 TriboMAM Drilling System User Manual Version 02 20 14 Page 36 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge m4sciences com 8 3 TriboMAM kilo and mega ER 20 UP Ultra Precision mm Collets type PartNo Clamping Range mm Clamping Range Inch Inch ER20UP LSMM 112001501 150 100 0 0591 0 034 ER20 UP 3 Omm 12003001 300 200 01181007 ER20 UP 4 S5mm 112004501 450 350 01772 01378 ER20 UP S Smm 112005501 550 450 02165 01772 ER20 uP 7Omm 1120 0701 700 600 02756 02362 ER20 UP 8 5mm 112008501 850 750 03347 02953 ER20UP 9S5mm 12009501 950 850 03740 03337 eR20 uP 110mm 112011001 1100 1000 04330 03937 ER20 uP 125mm 112012501 1250 1150 04921 04528 ER Clamping Nuts Tye PartNo Hi Q ERMC 20 3520 20000 TriboMAM Drilling System User Manual Version 02 20 14 Page 37 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge mA4sciences com
17. ble against the male connector of the TriboMAM Controller will secure the electrical connection For SSMC type connections shown below the female connector is screwed in to the male connector using a 5 32 inch wrench until the connection is snug Figure 11 Tightening of power cable to TriboMAM body with 5 32 inch wrench TriboMAM Drilling System User Manual Version 02 20 14 Page 13 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge m4sciences com 2 Anchor the power cable to a point on the slide 100 mm 150 mm 4 inch 6 inch from the TriboMAM connection point to provide strain relief for the cable Anchor the power cable to a convenient location from the lathe interior e g through grommet hole coolant tank along coolant lines etc Ensure that the cable will not be pinched or snagged and has sufficient slack when the slide is moved through maximum range Warning Verify that power cable does not interfere with machine movements or other tools Figure 12 Strain relief of power cable provided by anchoring cable to tool block left and routing of power cable away from TriboMAM connection point right Anchor points shown in red circles Warning Ensure that the power is off at the MEC PA08082 Controller Warning The high voltage output connector carries high voltage DO NOT touch the high voltage output connector or the load circuit wh
18. d to 1 250 psi 86 bar to meet the specifications of the TriboMAM drilling system Important The spindle RPM must be a multiple of 60 and the CNC spindle RPM must be programmed to match the TriboMAM program TriboMAM Drilling System User Manual Version 02 20 14 Page 22 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge mA4sciences com 4 TriboMAM Functional Test Note This functionality is only available in MEC PAO8082 software V9 22 and later Contact M4 Sciences for further instructions if a functional test is to be performed using controllers with earlier software versions The TriboMAM drilling system oscillates in the axial direction of the body During operation of the TriboMAM tool the total stroke or amplitude of the oscillation is dependent on both the drilling process and the actual programmed conditions at the MEC PA08082 Controller interface In some cases the TriboMAM drilling system emits an audible sound These audible sounds are normal However for some programs and drill conditions no sound is audible and the oscillation of the drill tool may not be visible or sensible by human systems These cases are most common when the drilling feed rates are lower than 0 025 mm rev 0 001 inch rev and the work spindle RPM is lower than 2400 rpm If damage to the TriboMAM tool is suspected then verify proper operation using the following test verificatio
19. e 4 Pre swage tool in vise left and appropriate configuration of coolant line components right Place assembled coolant line components into the pre swage tool as shown in Figure 5 and tighten with a 3 8 inch open wrench Coolant line diameter should swell near the tip of the swage as shown in Figure 5 TriboMAM Drilling System User Manual Version 02 20 14 Page 9 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge m4sciences com 4 If the compression fitting coolant port was not fixed to the TriboMAM body prior to receipt attach the fitting to the TriboMAM body and tighten with a 5 16 inch open wrench until the compression fitting is securely attached Swage tip Figure 5 Swaging of assembled fitting by tightening in the pre swage tool left and final swaged fitting on coolant line right 5 Connect the swaged coolant line to the TriboMAM coolant port and lightly tighten the connection until snug this will be firmly secured in a later step 6 The below procedure outlines the swaging and attachment of the coolant line to the machine s manifold block For this purpose straight and right angle 1 4 inch NPT x 1 8 inch compression fittings are provided with the coolant installation The fittings are shown in Figure 6 and are also composed of stainless steel ferrules as in step 3 wo 8 ey 2 0 te Right angle fitting set Straight fitting
20. eed feed rate into the MEC PAO8082 Controller per the instructions in the MEC PAO8082 User Manual 3 2 General Operation The TriboMAM is ready for operation after completing the initial steps of setting the TriboMAM drill tool offsets and programming the MEC PA08082 Controller with the baseline machining process parameters Follow the MEC PAO8082 User Manual for instructions on starting and stopping the TriboMAM operation as well as for emergency stops It is generally good practice to ensure that the baseline machining process is stable using the TriboMAM drilling system in the OFF position After this is verified optimization can be carried out by adjusting the machining parameters and updating the MEC Controller to reflect these adjustments Warning For proper operation the TriboMAM must be programmed correctly with the actual machining parameters Discrepancy between the actual and programmed values will affect the performance of the TriboMAM drilling system Any feed rate and spindle speed override controls should not be adjusted beyond 100 during the drill cycle TriboMAM Drilling System User Manual Version 02 20 14 Page 17 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge mA4sciences com 3 3 Process Optimization TriboMAM users with equipment capacity for process development can quickly explore the potential to make significant increases in drilli
21. ication of the contact interface These benefits enable improvements to drill soeeds and feed rates The TriboMAM drilling system is designed for high aspect ratio centerline drilling in CNC lathes length to diameter gt 7 The TriboMAM drilling system replaces existing drill collet extenders The MEC PA08082 controller enables MAM for the TriboMAM drilling system When installed properly the system will oscillate the drill in the direction of drill feed The oscillation conditions will depend on several factors including the drill diameter feed rate workpiece rotational soeed and number of drill flutes The MEC PAO8082 controller uses the programmed drilling conditions to determine the appropriate modulation conditions 2 3 Receiving Inspection Visually inspect the components for physical damage such as dents nicks scratches broken fittings etc External damage may indicate more serious damage has occurred within the instrument In the event of damage notify M4 Sciences and request instructions Do not attempt to use a damaged instrument 2 4 Hardware Installation The text below outlines the procedure for installing the TriboMAM with the MEC PA08082 Controller Prior to installation refer to operational checks in Section 4 of this manual for pre installation verification of the TriboMAM operation 2 4 1 Controller Setup The MEC PA08082 is designed for operation on a flat surface and is air cooled Allow a minimum of 50 mm 2
22. ile the MEC PA08082 is operating An electrical shock could result Always turn off the MEC PA08082 before making changes to the load connections The maximum voltage at the high voltage output connector is 150 V 3 Connect the opposite end of the high voltage cable to the high voltage output connector labeled HV OUT on the MEC PA08082 Controller as shown below TriboMAM Drilling System User Manual Version 02 20 14 Page 14 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge m4sciences com Attach power cable SSMB electrical port Figure 13 Attaching the Tribo MAM power cable to the front panel of the MEC PA08082 Controller 2 4 5 Drill installation Warning Special caution is needed while securing a drill to the TriboMAM and in tightening the ER 11 collet nut to avoid over torqueing Excessive torque during drill install may damage the TriboMAM 1 To prevent excessive torque from damaging the TriboMAM use a 17 mm open wrench on the flat surfaces at the front of the TriboMAM body while tightening the ER 11 collet nut as shown below E Hold in place 17 mm wrench Tighten z ER 11 spanner wrench gt Figure 14 Drill install procedure TriboMAM Drilling System User Manual Version 02 20 14 Page 15 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge m4
23. ill several parts verify that the CNC program conditions match the MEC PA08082 controller conditions Continue to incrementally reduce the number of peck cycles until 1 the quality requirements are exceeded or 2 an acceptable level of drilling cycle time is achieved Drill breakage can occur as the quantity of peck cycles decreases If drill TriboMAM Drilling System User Manual Version 02 20 14 Page 20 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge mA4sciences com tool failure occurs then increase the number of peck cycles to a condition that achieves acceptable production rate and or drill tool life NO existing baseline drilling process established The TriboMAM drilling system is designed to improve drilling operations that have already been established If the TriboMAM is installed into a new machining process where no baseline drilling process is already established then follow the drill tool manufacturer s recommended practices for pilot drilling and conditions for workpiece rotational speed and drill feed rate to establish a baseline drilling process After an acceptable baseline process is established the TriboMAM tool may be used to incrementally increase workpiece speed and or drill feed rate following the guidelines outlined below It is critical that the TriboMAM be programmed correctly with the actual machining parameters Discrepancy between
24. in of free space around the heat exchange fins on the rear panel TriboMAM Drilling System User Manual Version 02 20 14 Page 7 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge mA4sciences com 1 Place the MEC PA08082 Controller in a convenient location on a flat surface near or on the machine Follow all operation instructions in MEC PA08082 User Manual The standard coaxial power cable is 20 ft 6 m long 2 4 2 TriboMAM Installation and Setup Warning Verify that the tool pocket has been properly indicated and reference position for the tool centerline has been established prior to TriboMAM installation 1 Clean the tool post and the TriboMAM shank with a lint free cloth Do not use any solvents or abrasives to clean the TriboMAM 2 Install the TriboMAM in the tool post in an orientation such that the electrical connector and coolant fittings are easily accessible If the SSMB SSMC type electrical connector is in the optional port location the fitting will be attached at the TriboMAM rear as shown in Figure 3 Figure 3 TriboMAM installed with convenient access from machine front Standard SSMBR SSMCR port position shown in left optional port position shown in right 3 Verify that the TriboMAM shank and the TriboMAM nose do not interfere with the motion of all slides tools and other tool blocks 4 If the TriboMAM is installed on a sub spindle to
25. in Figure 9 i in place 16 incr wrench Figure 9 Tightening of the hex nut on the coolant line to the compression fitting on the coolant manifold left Tightening of the hex nut on the coolant line to the compression fitting on the TriboMAM body right Warning Verify coolant line installation by running high pressure system for at least 10 minutes after drill tool is installed Coolant line may burst or leak if installation is incorrect Follow all appropriate safety requirements with coolant line installation and high pressure coolant operation TriboMAM Drilling System User Manual Version 02 20 14 Page 12 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge m4sciences com 2 4 4 TriboMAM power cable The TriboMAM may be configured with one of two types of electrical connectors These are SSMB snap on and SSMC screw on types The SSMB connector is round in shape and is a snap on connection The SSMC connector is hexagonal and is a screw on connection The SSMC male connector can be readily identified as threads are present at its base to allow fixation with the SSMC female connector a b c Figure 10 a Examples of female SSMB top and female bottom connectors b male SSMB connector and c male SSMC connector 1 Attach the power cable as shown below For SSMB type connections pressing the female connector of the high voltage ca
26. int approximately 100 mm 150 mm 4 6 from connection at TriboMAM and check for proper lengths to accommodate slide movements Operation setup e Feed rate override must not cause feed rate to be different than programmed CNC value e Verify proper selection of TriboMAM TriboMAM on MEC Controller e f power amplifier output does not turn ON then check programmed conditions e Verify that the programmed value of RPM at the MEC controller matches the spindle RPM in the CNC code RPM must be an increment of 60 RPM e Do not turn TriboMAM On Off during actual drilling e g if TriboMAM is off do not turn on mid cycle etc TriboMAM Drilling System User Manual Version 02 20 14 Page 26 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge mA4sciences com 6 Specifications 6 1 TriboMAM micro Drilling diameter 0 2 mm to 2 0 mm Feed rate up to 0 015 mm rev flute Maximum spindle speed 9 960 rom Maximum coolant pressure 1 250 psi 86 bar 8 6 MPa 5 000 psi 345 bar 34 5 Mpa available as option Standard Dimensions not to scale OPTIONAL ELECTRICAL CONNECTION ELECTRICAL CONNECTIO A OPTIONAL HIGH PRESSURI a KEN COOLANT FITTING P MAX 86BAR 1250PS _ A gt p QL qi 67 23 2 65 24 60 0 97 GO g 19 05 0 75 mo is 20 00 0 79 i AN ger F 2 2 000 87 39 98 1 57 69 95 2 75 KS ele
27. lly decrease the number of peck cycles and test drill several parts at each new peck cycle condition verify that the CNC program conditions match the MEC PA08082 controller conditions Continue to incrementally decrease the number of peck cycles until 1 the quality requirements are exceeded and or 2 an acceptable level of drilling cycle time and drill wear rate is achieved Drill breakage can occur as the quantity of peck cycles decreases If drill tool failure occurs then increase the number of peck cycles to a condition that achieves acceptable production rate and or drill tool life 4 Twist flute drilling with flood coolant with peck cycles The TriboMAM can be used in peck drilling applications with flood coolant In these cases it is often important that the tip of the drill is lubricated at some time interval to prevent premature drill failure or unacceptable drill tool wear rate The number of peck cycles required depends on the process and the requirements of the user Follow the drill tool manufacturer s recommended conditions for pilot hole drilling After proper installation of the TriboMAM drilling system install a new twist flute drill for process testing For twist flute drilling with flood coolant and peck cycles the TriboMAM may be used to reduce the number of peck cycles The TriboMAM may also be able to achieve increased feed rate and or rotational speeds Incrementally decrease the number of peck cycles and test dr
28. n procedure If you believe the TriboMAM tool is not functioning properly this test should be completed prior to contacting M4 Sciences Note The function test requires a test indicator with 0 002 mm 0 0001 inch increments Do not attempt to perform this test with improper gage instruments Bench testing Place the test indicator with 0 002 mm increments against the front shoulder of the TriboMAM drilling system ER collet nose as shown to the right Establish a zero reference on the dial indicator using normal gage practices Using the MEC PAO8082 Controller go to the System Setting and select Function Test When this test is selected the MEC PAO8082 controller is outputting a low frequency voltage oscillation at maximum Figure 15 TriboMAM functional test amplitude for verify the TriboMAM operation using test indicator TriboMAM Drilling System User Manual Version 02 20 14 Page 23 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge m4sciences com The screen on the MEC controller will display a message that Function Test is running The test can be halted at any time by any button The total range of the displacement read as the difference between maximum and minimum on the test indicator should meet the specifications below If the total displacement measured using the test indicator does not meet this specification then contact M4 Sciences TriboM
29. ng production rates Large increases in drilling feed rate and or surface speed can be tested using the TriboMAM system While premature tool failure is expected during exploratory testing regardless of whether either a standard drill holder or the TriboMAM is used the user can quickly establish the potential performance envelope of the TriboMAM drilling system for a particular application TriboMAM users unable to incur costs of interrupted production and or drill tool replenishment for process development should perform more incrementally based changes to the drilling process along with some monitoring of the performance of the new process over some appropriate period of time The information provided in this section is a summary of useful practices for developing an improved drilling process using a TriboMAM drilling system The general engineering methods and practices employed to develop production drilling processes are unchanged with the use of the TriboMAM system Review all installation and operation instructions for the TriboMAM drilling system and the MEC PA08082 controller prior to beginning any drilling process development Follow ALL safety requirements and warnings provided by the machine tool manufacturer the drill manufacturer collet or collet nut manufacturer and the safety requirements described in the TriboMAM drilling system and MEC PA08082 controller installation guides M4 Sciences is not responsible for the improper use of eq
30. o and SVIMOOIS rer vejer Ave ene NA 5 2 ANTKOO OCTION sanien torn Ace a dare aaah eho 6 2 1 Primary System COMPONENTS aars bol aner eneret engel ede agenter 6 2 2 SVEM DESID O AE corse usunscea ere titanate A Er serende 7 2 3 Receiving Inspections nena E re ennen reed 7 2 4 Hardware IMStall a lO Mics ststtss ced iuias induce A aa 7 ZAM COMMONCT SetU enen entire a eo ea as 7 2 4 2 TribOMAM Installation and S tup ccc ccecccesecceecceesccceeseseeseeecseeeees 8 2 4 3 Coolant line setup if using through tool coolant c cece eeeecsceeeeeeeeeees 9 244A TADONIAN DOWER Call Cisiiient ordens bios E ADR GENE 13 24 5 J DPIMMSTAN AUION Motes thabraiastosenan E EEA 15 DAG MAION Ehe ER me eee trdeee huni na ioe E tesa EE 16 3 0 2 1 Pere eae me rence ET Fe OTe ar EAT SOT IR Pe Pre ay ee 17 3 1 MIT AN Z AU Oes A taunt coaubes Aa 17 3 2 Generi ODE aOR sete test eee oat oan 17 3 3 Process CO DEMMMIZAUI ON i or reen Eee Een ER een 18 A TribOMAM FunctonakTeESs ta ae see EEEE T 23 D gt WASTalatION C NECKS Ceir are A A E lakerede 25 6 SpeciicatiO A Saeni a a hannen been 27 6 1 PID OIVIA MAIC LO eraa aaa A Ea 21 6 2 BABOOM AM Ee 0a a fie ser smn Sr Rc rR a 28 6 3 TRIDOWIAW MES iorden heels esse teens anus 29 6 4 TrIDOMANESTIN ARE saae renee EN NR 30 6 5 NW 1 00 V PV V s 4 0 See 31 6 6 TriboMAM mega cc cccecceesesssssccccccecessssssccsccecccessssssscesescecseessstsseeeeseeeeens 32 L SS PANS ae E E E
31. ol slide verify that no interference occurs with the sub spindle pick off motions 5 Tighten screws in tool post to secure TriboMAM in tool post Caution tighten screws only to hand tight Do not over tighten TriboMAM Drilling System User Manual Version 02 20 14 Page 8 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge m4sciences com 2 4 3 Coolant line setup if using through tool coolant Warning Failure to follow these procedures could result in damage to equipment 1 Set high pressure system to less than 1 250 psi 86 bar 8 6 MPa 2 One end of the coolant line provided with the TriboMAM already has a swaged fitting for attaching the line to the Tribo MAM compression fitting coolant port The opposing end does not have a swaged fitting attached so as to allow the user to determine the length of coolant line needed 3 Follow these directions to re install the existing fitting for the TriboMAM port Fix the pre swage tool TPSS 18 1 in a vise and prepare the flexible tubing and stainless steel ferrules as shown in Figure 4 The pre swage tool will be used to pre swage the stainless steel ferrules The cone shaped ferrule is denoted here as the front ferrule and the rear ferrule is more disk shaped Only use coolant lines provided approved by M4 Sciences 3 8 inch open wrench c Compression fitting Rear ferrule Front ferrule Figur
32. quipment e These symbols may appear on the instrument CAT CAT Il Danger h Warning risk of electric shock Caution refer to Operator s Manual Installation category overvoltage category Classification for the operation of a unit using voltage systems or circuits with required standardized limits for transient voltages Category pertains to voltages supplied at the peripheral level with smaller tolerances for transient voltages as specified by the Low Voltage Safety standard EN 61010 1 Installation category Il overvoltage category Classification for the operation of a unit using voltage systems or circuits with required standardized limits for transient voltages Category II pertains to using voltage supplied on the local level example local wall outlets with smaller tolerances for transient voltages as specified by the Low Voltage Safety standard EN 61010 1 High voltage generating equipment including the MEC PAO8082 amplifier and related supplies are not designed rated or qualified to be operated in an environment or atmosphere which contains combustible or explosive materials or gases which may be ignited by electrical discharges TriboMAM Drilling System User Manual Version 02 20 14 Page 5 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge m4sciences com 2 Introduction 2 1 Primary System Components The TriboMAM
33. rer s recommended conditions for pilot hole drilling After proper installation of the TriboMAM drilling system install a new drill for process testing Incrementally increase the feed rate by 10 increments and test drill several parts at each feed rate increment verify that the CNC program conditions match the MEC PA08082 controller conditions for each test Continue to incrementally increase feed rate until 1 the quality requirements are exceeded and or 2 an acceptable level of drilling cycle time and drill wear rate is TriboMAM Drilling System User Manual Version 02 20 14 Page 19 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge mA4sciences com achieved Drill breakage can occur as feed rate is incrementally increased If drill tool failure occurs then reduce the feed rate to a condition that achieves acceptable production rate and or drill tool life 3 Twist flute drilling with high pressure through tool coolant with peck cycles Follow the drill tool manufacturer s recommended conditions for pilot hole drilling After proper installation of the TriboMAM drilling system install a new drill for process testing For twist flute drilling with high pressure through tool coolant and peck cycles the TriboMAM may be used to reduce the number of peck cycles The TriboMAM may also be able to achieve increased feed rate and or rotational speeds Incrementa
34. sciences com 2 4 6 Installation check 1 Re verify that the TriboMAM is secure in the tool block 2 Check clearance of the TriboMAM drilling system front and back on all slides tools and tool blocks as well as proper electrical cable and coolant line routing anchoring by testing the maximum range of motion of the machine axes 3 Verify that the drill is installed properly and the ER collet is secure 4 Verify that all program positions and tool positions are correct 5 Continuously run coolant for a minimum of 10 minutes to verify no leaks are present Warning Failure to follow these installation checks could result in damage or failure of the TriboMAM drilling system TriboMAM Drilling System User Manual Version 02 20 14 Page 16 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge mA4sciences com 3 Operation 3 1 Initialization 1 Ensure that the TriboMAM controller output is off 2 Set TriboMAM tool offsets according to the standard instructions from the machine manufacturer 3 If a high pressure coolant line is used verify that the high pressure coolant setting is adjusted to lt 1 250 psi 86 bar 8 6 MPa 4 Dry cycle program to verify clearance of the TriboMAM drilling system drill tool and electrical coolant cabling on any slide sub slide motions 5 Input the process parameters drill diameter number of flutes rotational sp
35. set Figure 6 Provided compression fittings for coolant manifold TriboMAM Drilling System User Manual Version 02 20 14 Page 10 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge m4sciences com While the coolant fitting is shipped pre assembled it is possible that this pre assembly may be disturbed prior to installation The front and rear stainless steel ferrules must be in the order shown in the Figure 7 Pre assemble the coolant fitting following the order of assembly as shown in Figure 7 and lightly tighten the hex nut to the compression fitting Remove the coolant line from the pre assembly as the line will not be swaged to until the last step of this process Attach the appropriate either right angle or straight style pre assembled coolant fitting to the coolant manifold and tighten secure as shown in Figure 7 Figure 7 Pre assembly order of fittings for coolant manifold left and middle Final pre assembled fitting on coolant manifold and with coolant line removed right As shown in Figure 8 route the coolant line from TriboMAM connection point to the machine coolant manifold and cut the line to an appropriate length with sufficient slack for anchoring and strain relief if necessary Figure 8 Shortening of coolant line to an appropriate length for routing to coolant manifold left and final length right TriboMAM Drilling System User Manual
36. uipment or the use of drilling conditions that may cause damage to machines tools or possible injury to personnel Baseline drilling process already established The TriboMAM is designed to improve drilling processes that are already optimized or established in production by the user In this case the CNC drilling conditions e g drill type drill feed rate spindle speed and tool wear rate are already known by the user For installations where the baseline drilling conditions have already been established these conditions may be used as a reference for test drilling with the Tribo MAM system The TriboMAM drilling system may allow increases in drilling speed e g spindle RPM and or feed rate while testing a new drilling process TriboMAM Drilling System User Manual Version 02 20 14 Page 18 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge mA4sciences com In general if a baseline drilling process is already established then increased drilling productivity can be accomplished by increasing drill feed rate In some cases especially in high length to diameter ratio drilling in high strength materials increases in drilling feed rate may increase thrust forces in drilling These increased forces can exceed the buckling stability load of a particular drill tool In these cases increased drilling productivity may be achieved by increasing drilling spindle speed
37. y that Tribo MAM shank or nose will clear all slides and tools on other blocks If TriboMAM is installed on sub spindle verify no interference at pick off by sub spindle e Check set screws hold down on TriboMAM tool e Verify proper torque procedure of TriboMAM tool collet nose e Verify high pressure coolant is less than 1 250 psi 86 bar 8 6 MPa e Check positioning of external coaxial cable and coolant lines ensure proper strain relief to TriboMAM Check cables or coolant lines allow all slide movements e Test high pressure coolant line for minimum of 10 minutes prior to actual testing to check for any leaks Controller installation e Refer to MEC PA08082 Controller Manual for installation details e Place the controller on the machine or other surface e g on top of bar feeder high pressure coolant tank Ensure that the external heat sink fins are not obstructed e Check incoming power supply line to amplifier for proper ground and voltage If ground cannot be verified then bond ground post at back of amplifier to machine or external ground e Verify that the controller is not in E Stop prior to power on e Verify SSMB or SSMC cable connection at TriboMAM TriboMAM Drilling System User Manual Version 02 20 14 Page 25 of 39 M4 Sciences 1201 Cumberland Avenue Suite A West Lafayette IN 47906 USA P 765 479 6215 F 765 807 3066 knowledge mA4sciences com e Provide strain relief to power cable and zip tie to rigid po
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