Wilson Tapping Tool www.sm
Contents
1. Uu ua iuasisasasiqawawhaqas 16 4 3 Programming parameters for tapping in flat sheets 16 4 4 Programming parameters for tapping in extrusions 18 5 Maintenance 20 5 1 Lubrication unit tapping 20 5 2 Tapping tool drive 25 FENG ren 26 k N ae 1 Introduction The Wilson Tapping Tool represents a unique and innovative approach to sheet metal fabrication bringing more efficiency to sheet metal manufacturing through the forming of threaded holes on your Trumpf or Pullmax punch press The technology of thread tapping produces no chips since material is displaced pushed out of the way and not cut The teeth on the tap are pressed into the pre punched core hole The material pushed out in this process is pressed into the free thread gaps on the tool thus forming the core diameter of the formed thread The thread gap is not completely filed but this has no effect on the thread function The material undergoes strain hardening in the course of the displacement process The gain flow with thread forming remains intact in comparison with thread cutting For this reason the tensile strength of the formed thread is higher than the strength of taps produced by thread cutting With a higher tensile strength the formed thread can then2. Ieuoneloz xe OD o Q To 3 l uidi paads wudu p d EMSJEUI XEN lt co 1M co co JE HSJEU XEN co t I O cO cO ww ssaUYoIU ww 1i9 uueip yound ww ss uyoiu ww J9JWEIPp ww ss uyoiu ww 19J uueip 2315 SSajUle S 19995 PIN Aope winiurwnyy UOIS suolmnioA 91 LoEt L 8 00 L G G5E E u uuip WINWIXe N suomnioA 1 JO JOQUINN OL 8LINJOSX ursezs vSZS MV N3 peoiy L S uUS JEJ J u Guidde 10 ssajawesed Bunwweibold S aqel 17 V Attention Determining working position offset Number of revolutions V Attention ww w WILSON TOOL 4 4 Programming parameters for tapping in extrusions The Wilson Tapping Tool can also be used to tap into extrusions This is particularly useful for producing taps in thinner materials Note The recommended maximum material thickness for extrusions is 3mm Please contact the Wilson Tool Sales Desk or your local Sales Engineer for more information about extrusions When determining the working position offset for tapping into extrusions the height of the formed area must be considered h extrusion height s material thickness Figure 11 The working position offset is shown in the diagram above shown as offset The number of revolutions must be determined for the full height of the extrusion from the bottom of the sheet Shown as h on the diagram above When tappi
3. cases e g over rotation of the tap and consequential activation of the override clutch the number of revolutions necessary for the thread former release not according to programmed Therefore is necessary to check position of the tap by an operator if it is outside or still inside the sheet If the tap is still inside the sheet then activate softkey IN SHEET until the softkey OUT OF SHEET can be actuated The error message REMOVE TOOL informs the user that the freeing cycle has ended It is necessary to check the tool after any program interruption The opening of the tool clamp deletes the error message 26
4. 3 Tool presetting Before loading presetting must be done as follows 1 Turn the tool to the home position by holding the tool by the gear wheel and rotating the punch body until there is a click Gear Wheel Punch Body Figure 8 2 Check the values of diameter printed on the tap They must correspond to those on the spindle nut and leadscrew 3 Push the tap into the leadscrew until it locks in place 12 k N Q Leadscrew Setting gauge Spindle nut Figure 9 Setting the length of the tapping module assembly 4 Setsize 15 5mm 0 1mm between the nut and gearwheel on the leadscrew using the setting gauge Cat No 26448 Double check The tip of the tap must be close to flush with the front face of the spindle nut Remove the setting gauge when presetting of the tapping module assembly is complete Attention 13 k N DER 5 Insert the tapping module assembly into the punch body Pull the securing pin back and then push the tapping module assembly into the punch body Ensure that the slot on the tapping module assembly lines up with the securing pin Ja Tapping Module Assembly Pin amp Slot 7 7 4 Securing Pin Figure 10 6 Release the securing pin Ensure that the following is true a The securing pin is engaged in the slot on the tapping module assembly b The securing pin has returned to its home position c The tapping module assembly is locked
5. Insert the strainer basket Pour in oil Push in the container and lock the quick release coupling into place Bleed it if necessary 10 Close the front hood 23 NN E Replace hose seal Every 500 operating hours and whenever the nozzle is removed The hose seal is a wearing part and must be replaced at the specified intervals and each time the nozzle is replaced e D N Switch off the machine switch off the MAIN SWITCH lock it and remove the key Undo the screw 1 and remove the basic nozzle body Unscrew the nozzle 2 from the basic nozzle body Pull the hose seal off the basic nozzle body The new hose seal must be pushed up to the collar on the basic nozzle body and must close flush with the nozzle at the front The hose seal may have to be shortened Screw on the nozzle 24 SN 5 2 Tapping tool drive N Lubricate the drive every 40 operating hours Attention gt The tapping tool planetary gearbox must be lubricated with grease every 40 hours using the grease nipples on the back of the punch body 25 NA w WILSON TOOL 6 Freeing cycle The freeing cycle is necessary if the programme was interrupted by an external interference e g EMERGENCY STOP because a mechanical connection between the material and tool occurs during tapping The tapping tool is released from the sheet by the C axis rotation Equal quantity of revolutions is required as have been programmed In some
6. L TC 240R TC 260R Figure 4 Wilson Tapping Tools are designed for use in specific machine groups Group I tools and Group H tools are not interchangeable Attention k N DER 2 1 Tapping tool construction Figure 5 A tapping tool consist of 1 Punch body Two types available Type 1 M2 5 M5 thread range Type 2 M6 M10 thread range 2 Leadscrew 3 Tap 4 Spindle nut 5 Die NN e 2 2 Part numbers overview Group I Model Group I machines TruPunch 1000 TC 1000R TC 2000 R TruPunch 2020 TC 2020 R TruPunch 3000 TC 3000 R TruPunch 5000 TC 5000 R TruMatic 3000 TC 3000 L TruMatic 6000 TC 6000 L Type 1 Tapping Sizes from M2 5 to M5 M2 5 x 0 45 M3 x 0 5 M4 x 0 7 M5 x 0 8 Tapping module assembly consist of Tap Leadscrew amp Spindle nut Type 2 Tapping Sizes from M6 to M10 M6 x 1 0 M8 x 1 25 M10 x 1 5 Tapping module assembly consist of Tap Leadscrew amp Spindle nut Using a Wilson Tapping Tool with M10 tap without gear lubrication can cause damage to the tool All Wilson Tapping Tools are designed with grease nipples to top up the gear lubrication Please refill with grease when using an M10 tap Attention k N ae Group H Model Group H machines TC 190 R TC 200 R TC 500 R TC 600 L Type 1 Tapping Sizes from M2 5 to M5 M2 5 x 0 45 M3 x 0 5 M4 x 0 7 M5 x 0 8 Tapping module assembly cons
7. TM NG visen Wilson Tool International Ltd User manual Wilson Tapping Tool SM Tech www sm tech ro 01 09 NA w WILSON TOOL All brand and product names are trademarks or registered trademarks of the owner concerned 1st published 2009 edition date 01 09 Wilson Tool International Europe Ltd SN3 4TQ Swindon All rights reserved including those of the translation No part of this manual may be reproduced in any form printed photocopy microfilm or any other process or processed duplicated or distributed by means of electronic systems without written permission of Wilson Tool Ltd Swindon We reserve right to make technical changes and to amend errors omissions Subject to alteration without notice SN Contents T IRUFOdIICUQIK LI cicero eeunee ayes a 4 2 Tool Information 6 2 1 Tapping tool construction T 2 2 Part numbers overview 8 2 3 DI VE EEE EE 10 2 4 Lubrication of the tap 10 2 5 Safety devices 11 3 Toolpresetting 12 4 Tool programming parameters 15 4 1 945 102 16 JE uu Saku E aS 15 4 2 Pre DUHChIng
8. apping unit mild steel stainless X Cel Tap Lubricant Al 55268 aluminium and aluminium alloys Tapping tool X Drive grease 100ml 55269 drive 5 1 Lubrication unit tapping There is a high risk of injury when carrying out maintenance on A N a live machine Consider the following actions gt Complete a risk assessment before starting any maintenance Attention task Place a sign on the machine informing other staff that maintenance work is being carried out Appoint a supervisor Ensure no one is within the danger zone before starting the machine The quantity of oil in the lubricant reservoir is sufficient for about 20 000 strokes Check oil stream Every 40 operating hours The oil must hit the tap in a sharp straight jet After several oil pulses the oil must drip from the tap If this is not the case air has entered the system and oil cannot be transported reliably Possible causes The oil reservoir is empty e The hose seal in the nozzle is defective e The nozzle is blocked by contamination 20 NA w WILSON TOOL Check oil level Every 40 operating hours gt To ensure air does not enter the system ensure the lubricant reservoir is never allowed to run completely empty 1 Switch off the machine switch off the MAIN SWITCH lock it and remove the key 2 Open the front hood 3 Check the filling volume of the reservoir Bleeding The oil reservoir must be bled if it has be
9. be used to replace weld nuts which are in many cases unsuitable due to heat related distortion of the sheet In summary thread forming technology saves your production costs and machining time dar FE a nh tH et of ae I 4 te Photomicrographs show grain structures of cut Fig 1 and formed Fig 2 threads Displacement of metal during the forming process results in threads that are generally stronger and have a smooth burnished surface finish This manual is intended to explain the use and limitations of the Wilson Tapping Tool Please read all instructions carefully before operating this tool Writing conventions 7 No w WILSON TOOL Symbols used in this manual have the following meanings P gt indicates actions to be taken Attention Warns of a hazardous situation that could result in damage to the product or components Caution Warns of the possibility of serious damage and injury Indicates interesting tips and additional information DN GEER 2 Tool Information Wilson Tapping Tools are available in two models designed for Group and Group H machines Group I Model Group I machines newer group TruPunch 1000 TC 1000R TC 2000R TruPunch 2020 TC 2020R TruPunch 3000 TC 3000R TruPunch 5000 TC 5000R TruMatic 3000 TC 3000L TruMatic 6000 TC 6000L and Pullmax 520 530 720 amp 730 Figure 3 Group H Model Group H machines older group TC 190R TC 200R TC 500R TC 600
10. en run empty by mistake or another one is used The machine is switched on during the following maintenance work There is a high risk of injury when carrying out maintenance on a live machine Consider the following actions gt Complete a risk assessment before starting any maintenance Attention task Place a sign on the machine informing other staff that maintenance work is being carried out Appoint a supervisor Ensure no one is within the danger zone before starting the machine 21 DN DER Figure 12 1 Open the hose fitting on the basic nozzle body 1 Do not remove the hose 2 Exit the danger zone and press the ACKNOWLEDGE LIGHT BARRIER foot switch Select Operation gt Set up gt Switch elements Select the General switch element Select the Lubricate tapping tool switch element approximately 10 times until no more bubbles are visible in the hose 6 Close the hose fitting Illustrations are from a Trumpf 1000 Design may vary depending on machine model 22 Refill with oil At less than of the filling volume 9 oT Oo oe oS hy k N ae F W fd 1 y 7 4 7 _ 7 4 j AR gt Figure 13 1 2 Switch off the machine switch off the MAIN SWITCH lock it and remove the key Open the front hood Undo the quick release coupling 2 and pull out the reservoir 1 Open the filling nozzle Remove and clean the strainer basket
11. into the punch body 14 Pre punch diameter Type of material Rotational speed Type of sheet NA w WILSON TOOL 4 Tool programming parameters The following section contains the parameters and data required to program the Wilson Tapping Tool Specific information regarding the machine controller is not included within this manual Please see your machine s Operator Manual for detailed information on programming the tapping tool on your machine 4 1 Parameters The quality and accuracy of a formed thread depends on the parameters listed below Pre punch diameter Type of Material Rotational speed Type of sheet The tolerance of the pre punched hole is critical to ensure a good quality formed thread The pre punch diameter can be reduced for soft material e g aluminium due to greater deformability The rotational speed of the C axis has to be optimised to suit the thread dimension and the type of material Threads can be formed into extrusions to allow tapping in thinner sheet materials 15 Pre punch diameter Rotational speed Number of revolutions 7 Attention Maximum number of revolutions NA w WILSON TOOL 4 2 Pre punching If the punch diameter is smaller than the material thickness s follow the instructions listed below s lt 4mm use stubby style tool s gt 4mm use active presser foot Table of ratios In normal punching conditions the ratios be
12. ist of Tap Leadscrew amp Spindle nut Type 2 Tapping Sizes from M6 to M10 M6 x 1 0 M8 x 1 25 M10 x 1 5 Tapping module assembly consist of Tap Leadscrew amp Spindle nut Using a Wilson Tapping Tool with M10 tap without gear lubrication can cause damage to the tool All Wilson Tapping Tools are designed with grease nipples to top up the gear lubrication Please refill with grease when using an M10 tap Attention k N GEER 2 3 Drive Vertical movement of the tap into the sheet is achieved through rotation of the C axis and the gears within the tool No programmed vertical movement of the C axis is required to achieve vertical movement of the tap N Lubricate the drive every 40 operating hours See page 25 Attention 2 4 Lubrication of the tap Lubricant is applied automatically to the tap by the machine at the start of every tap cycle via bore holes in the tool body and stripper bore holes for lubricating the thread Figure 6 N Every 40 operating hours check the oil stream See page 20 Attention 10 NN e 2 5 Safety devices The die is fitted with a pneumatic sensor which activates the FEED HOLD on the machine if the tap plunges too deeply into the die caused by over rotation of the tap or if the leadscrew works itself free This feature provides an additional safe guard against tool breakage Pneumatic sensor Figure 7 11 k N ae
13. ng in material with sheet distortion i e not totally flat increase the working position offset and number of revolutions to compensate for the height of the distortion In addition to programming information for tapping in extrusions the following table also includes data on the extrusion pre punch required 18 y WILSON TOOL x 20118094 AJUO sue s s yzu ed UI s njea u Wu uBi u uolsnu1x e1340 U wudu OEE 0 p se uJoul SG UBD 1 0009 OL 0009 gt NEWNNIL H 000S OL 000S YDUNdNIL 104 tudi p ds jeuoHejos WNWIXEN ON ed yound xg uoisni N q 3 a ww 2 ap oJaId Hulme p uoisni x l wuwu yound ON Hed Hasu 91 d Buimel wudu p ds jeuonejog ww 19 uueiIp yound aid uid p ds jeuonejog yound aid ww 19 uueiIp wudu p ds jeuonejog yound aid ww 49 uueiIp ww ss uyoiu leae N SUOI NJOAD JO JOQUINN ww 19J uueip JOO 29 S SS 9JUILIS Lost L OL 8LINJOSX 19935 PIN 8 00 L UPSETS Aoyje wniulwnjy sese e YSLS MV NI UOIS u uuip pe J L SUOISNA X9 u Huldde 104 SJajaweJed BultuuieiDBoid 9 EL 19 N Oson c OL 5 Maintenance Table 7 Lubricants required for use with the Wilson Tapping Tool Lubrication Capacity Lubricant Quantity Cat Kinematic Point No Viscosity at 40 C Lubrication X Cel Tap Lubricant Fe 55267 22 t
14. tween punch diameter and material thickness are aluminium diameter at least equal to material thickness mild steel diameter at least 1 5 times material thickness stainless steel diameter at least 2 times material thickness Stubby style tooling must be used for any pre punch falling outside the criteria above Stubby style tooling is not covered by Wilson Tool s normal warranty 4 3 Programming parameters for tapping in flat sheets The following tables list the pre punch diameters to be used for tapping Pre punch diameters vary depending on the desired thread the type of material and the material thickness The maximum input value depends on the type of material The values in parentheses are only theoretical e g it is not possible to tap an M10 thread in a 1 mm sheet When tapping in material with sheet distortion i e not totally flat increase the working position offset and number of revolutions to compensate for the height of the distortion The leadscrew is secured against incorrect input of the number of revolutions by an override clutch The values are for orientation purposes only 16 W WILSON TOOL x Ie91J 1o u juo sue s s yzu ed UI s njea u ww ss uyspoiu euejeN s wudu OSE 0 p se ou SG ueo 1 0009 OL 0009 938Wnil 4 000S DOL 000S YOUNdNJ 104 tudi p ds Ieuoneloi WNUWIXEN 1d s jJeuolejyoy yound aid eb
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