Operation and Maintenance Manual

Titespot® Coolant Driven Angle Heads

Eltool Corporation

Major Components

Figure l

Basic Operation: High pressure coolant enters the Titespot® Angle Head and drives an
integral positive displacement ball piston motor (A). The motor is coupled to a drive
shaft (B) which in turn drives the spindle(C). Exhausted coolant (D) is directed at the
cutter.

Note: For machines not equipped with through spindle coolant delivery, Din B, coolant
induced toolholders or other options are available. Please consult factory.

Before Installing Your Titespot® Angle Head

Titespot® High Pressure Coolant Driven Angle Heads are powered hydraulically by a
positive displacement ball piston motor. With proper attention to coolant cleanliness and
angle head conditioning prior to storage, they require minimum maintenance.
1. Coolant Filtration: It is essential that coolant delivered to the angle head be free of
contaminant. We recommend a 50 micron pre-filter then 10 micron filtration or less,
preferably on the pressure side of the delivery system.

2. Coolant Type: Any high quality coolant is acceptable for use, provided it contains a
rust preventative and lubricating agents.

Important! After Using Your Titespot® Angle Head

If the angle head is to be taken out of service in excess of 48 hours it is essential to flush
and condition the tool as described below. Failure to follow this procedure may result
in residual coolant coagulation rendering the tool inoperable.

A. Blow high pressure filtered air through the retention knob, until all residual
coolant is flushed from the tool.

B. Squirt an oil (WD-40, or automatic transmission fluid or similar) into the tool
through the retention knob.

C. Blow air through the retention knob until oil is observed exiting the tool around
the spindle bearing.
.
D. As with any tool holder, coat the external surface with oil and store in a clean,
dry place.

Maintenance Notes:

Most failures are not due to wear or use.

Most failures are the result of:

Improper storage of an unused tool

When a tool is not going to be used for an extended period of time or is being returned
for repair it is important that coolant is not left inside the tool to dry up, harden or even
corrode the tool. The instructions above give the procedure to prevent this mode of
failure.
This is the most common maintenance issue we observe.

Insufficiently clean coolant

This can be due to improper filtration or coolant changes being too infrequent.
We recommend a 50 micron followed by a 10 micron filter on the pressure side of the
coolant pump.
Often materials such as cast iron and even aluminum can collect in even a well filtered
sump. These particles must be occasionally removed by draining, cleaning and refilling
the sump. While our tools are not overly sensitive to this, cleanliness will prolong the life
of the bearings and motor. New tools tend to be more prone to “lock up” if the coolant
contains particles than do tools with some working hours on them.

How to Maximize Motor Life

The reaction ring tends to be the first part to wear. It is inside the shank surrounding the
motor and is the inner race of the large needle bearing. The ball pistons in the motor’s
rotor push against this ring as it slowly rotates. The ring is mounted in such a way that the
balls do not ride on it symmetrically. You can extend the life of the motor by tracking
hours and flipping the ring after approximately 250 hours of use. Some applications may
benefit from more or less hours depending on such factors as coolant cleanliness and
severity of the application. If hours are tracked this frequency can be adjusted for
maximum motor life. The procedure can be performed in about 15 minutes.

Orienting the Angle Head for Single Position Machining

Initial Orientation: Because the tool changer typically loads the tool against the same side
of the keyway each cycle, it is important that the angle head be loaded by the tool
changer, not by hand, prior to final adjustment.

Final Adjustment: The head (E) is attached to the shank (F) by means of a clamp collar
(G). By loosening the four clamp collar screws (H) the head can be rotated 360 degrees
to the desired orientation. See Figure l.

Orienting the Angle Head for Multi-position Machining

On machines with a C Axis: The C Axis can be used to orient the machine spindle to any
position required.

On machines without a C Axis:

On machining centers equipped with a servo and encoder (as used in rigid
tapping) it is usually possible to re-orient the spindle to the desired machining
angle(s) by altering the parameter for the M-19 tool change position. The
following procedure and G code applies to machines with Fanuc controls. A
similar approach will work on most machine tools however the exact coding and
parameter numbers may vary depending on the machine or control.

This is the exact code and procedure with additional explanation to follow.

1. Find and record the value of parameter N4077.

2. Add these lines to your part program for each desired angle:

M19 (Orient Spindle)

G10 L50 (Access L50 parameter page)
N4077 P1 R(xxx) (Parameter No., Bit No., New Value(xxx) )
G11 (Turn off G-10)
M19 (Reorient to new position)

3. Prior to tool change repeat procedure to return Parameter N4077 to its

original value. Note: “R” value will be in encoder pulses. You may have
to experiment to determine “pulses per degree”.

On Fanuc controls the spindle encoder typically has 4096 pulses per
revolution. This means you would add 11.3778 pulses per desired degree of
spindle rotation. ( 4096/360 ) Other machines may have encoders with
different counts. You can call your machine tool builder and ask for this
information. However some experimentation with different values is usually
faster.

An explanation of the M19 cycle is helpful to understand how we are using

this code to index your spindle. When your control sees an M19 request it
slowly rotates the machine tool spindle “looking” for the marker pulse on
the encoder. (encoders have one discrete pulse marking “zero”. This is called
the marker pulse). When it sees the marker pulse it will count out however
many pulses are stored in the orient parameter (N4077 on Fanuc). In that
position it will lock up the spindle.

Example: You find parameter N4077 had a value of 500 and you have
determined that you have a 4096 count encoder. You have aligned the head
using the procedure described above so at spindle orient the tool is pointed
to zero degrees. To index the spindle to a 30 degree angle we would change
parameter N4077 to 841 (4096/360 = 11.377778 X 30 + 500 = 841.333)
Yes, you will be 1/3 of a pulse off but remember one degree is 11+ pulses. It
can be important however not to let this error accumulate. Consider
recalculating from the marker pulse each time instead of adding to your
current position. If your second hole is an additional 30 degrees change the
parameter to 1183 (4096/360 = 11.377778 X 60 + 500 = 1182.666)
To be clear these numbers are typical for the Fanuc control. Your formula
may be different. Actual numbers are determined as follows:

(your spindle encoder count/360 = pulses per degree of rotation X desired

index in degrees + initial parameter count = new parameter value)

Occasionally a machine will have radial “play” in the orient position. The
amount of play the servo will tolerate is also determined by a parameter.
This play can almost always be tightened up to an acceptable level by
adjusting this parameter. In the rare cases where it can not be or in
applications where the radial load on the spindle exceeds the servos capacity
Eltool has optional spindle clamps and brakes available. This should be
your last resort however as this issue can almost always be resolved via a
parameter adjustment.

Selecting the Proper Spindle: If space restrictions are not a consideration,

it is generally recommended that a standard, commercially available spindle
(ER-ll or ER-16) be selected. For confined space applications, Eltool
offers proprietary spindles designed to minimize the profile of the angle
head.

Taperlock Spindles (Size l Heads): Like a morse taper, the shank of the
cutting tool is held in place by the binding action of the tapered spindle.
Special geometry is required on the tool shank when using this spindle,
as shown below.
 Taper-lock tool shank and spindle geometry

Draw Type (Eltool) Collet (Size 2, 2M, 3 Heads): The spindle accepts a
tapered, internally threaded draw collet. The collet is drawn tightly into the
spindle by a 6/32 draw screw (5/16 hex head) located on the back face of the
angle head. A spanner wrench (supplied with the angle head) holds the
spindle in place during the tightening process.

Draw type (Eltool) Collet Assembly and Exploded View

Controlling Angle Head RPM: Cutter RPM is directly proportional to
coolant flow rate through the positive displacement ball piston motor. At
70% volumetric efficiency the .18 cu. in/rev motor will rotate at
approximately 900 rpm per gpm coolant flow. If a lower rpm is desired,
this can be accomplished in several ways.

If the High Pressure Coolant System is a Variable Flow Type, rpm

can be controlled by adjusting the output flow of the HPCS.

If the High Pressure Coolant System is a Fixed Flow Type

l. Flow can be controlled by threading a ¼ NPT pipe plug into the

retention knob, drilled with an orifice sized to deliver the desired flow at the
system pressure specification. The chart below specifies orifice sizes for
various output flows at a l000 psi system pressure. For pressures other than
l000 psi, consult factory. Note: The plug should be drilled prior to
assembly to avoid chip contamination of the angle head.
Example: A high pressure coolant system delivering 8 gpm flow rate will
produce a cutter speed of approximately 7200 rpm ( 8 gpm x 900 rpm/gpm =
7200 rpm) for a l000 psi system. To reduce flow, and rpm, by
approximately 50%, a .060 orifice is required.

2. Fine Adjustment (Size 3 and 3M only): Coolant flow can be “fine

tuned” by means of a metering screw located on the front face of the angle
head.

3.Gear reducer/Torque Multiplier: When lower speed and higher torque is

required, we recommend the use of our Model 521 Torque Multiplier. The
Model 521 incorporates a planetary gear with a 5 to l gear ratio and is
capable of developing up to l00 inch lbs. of torque. The Model 521 is
available as original equipment or as a retrofit.

Modular Design: Titespot® Angle Heads are modular, allowing l00%

interchangeability between heads and shanks, a potential cost savings
where multiple applications for different sized heads or shank styles are
contemplated. Consult factory for pricing of heads or shanks only.

Customer Support: Please call or email us with any questions concerning

our product or your application.

Website: www.eltool.com
Phone #: 1-877-435-8665 (toll free in U.S.)
1-513-723-1772
Email: [email protected]
Tech support contact: John Young