OPTIMUM L685 Instruction Manual

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OPTIMUM

MASCHINEN - GERMANY

Operating manual

Version 1.0.3

Lathe

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OPTIMUM

MASCHINEN - GERMANY

1 Safety

1.1 Safety instructions (warning notes)...........................................................................................................7

1.1.1 Classification of hazards............................. ..............................................................................................7

1.1.2 Other pictograms......................................................................................................................................8

1.2 Intended use.............................................................................................................................................8

1.3 Reasonably foreseeable misuses.............................................................................................................9

1.3.1 Avoiding misuses................................................................................................ ......................................9

1.4 Possible dangers caused by the machine ................................................................................................9

1.5 Qualification of personnel.................................................................................................. .....................10

1.5.1 Target group...........................................................................................................................................10

1.5.2 Authorized personnel..............................................................................................................................11

1.5.3 Obligations of the operating company....................................................................................................11

1.5.4 Obligations of the operator .....................................................................................................................11

1.5.5 Additional requirements regarding the qualification................................................................................11

1.6 Operators positions.................................................................................................................................12

1.7 Safety measures during operation..........................................................................................................12

1.8 Safety devices ........................................................................................................................................12

1.9 EMERGENCY-STOP button............................................................................ ... ........................ ............13

1.9.1 Protective cover with safety switch.........................................................................................................13

1.9.2 Lathe chuck protection with position switch............................................................................................13

1.9.3 Lathe chuck key......................................................................................................................................13

1.10 Safety check...........................................................................................................................................14

1.11 Personnel protective equipment .............................................................................................................14

1.12 For your own safety during operation.....................................................................................................14

1.13 Disconnecting and securing the lathe.....................................................................................................15

1.14 Mechanical maintenance work ...............................................................................................................15

2 Technical data

2.1 Emissions ...............................................................................................................................................17

2.2 Dimensions, installation plan..................................................................................................................18

3 Unpacking and connecting

3.1 Scope of delivery....................................................................................................................................19

3.2 Storage...................................................................................................................................................19

3.3 Installation and assembly .......................................................................................................................20

3.3.1 Requirements regarding the installation site...........................................................................................20

3.3.2 Assembling.............................................................................................................................................20

3.4 First commissioning................................................................................................................................20

3.4.1 Warming up the machine........................................................................................................................21

3.4.2 Cleaning and lubricating.........................................................................................................................21

3.4.3 Functional test ........................................................................................................................................21

3.4.4 Functional check.....................................................................................................................................21

4 Assembly and function

4.1 Construction features..............................................................................................................................22

4.2 Spindle stock with feed gear...................................................................................................................22

4.2.1 Gear........................................................................................................................................................23

4.2.2 Feed gear ............................................................................................. ..................................................23

4.3 Lathe saddle...........................................................................................................................................23

4.4 Top slide.................................................................................................................................................23

4.5 Cross slide..............................................................................................................................................24

4.6 Tailstock..................................................................................................................................................24

5Handling

5.1 Safety......................................................................................................................................................25

5.2 Control and indicating elements .............................................................................................................25

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5.2.1 Switching elements .......................................................... ... ..................................... ..............................26

5.2.2 Switching on the machine ......................................................................................................................26

5.2.3 Switching off the machine ......................................................................................................................27

5.3 Clamping a tool ......................................................................................................................................27

5.3.1 Tool height..............................................................................................................................................27

5.4 Speed adjustment ..................................................................................................................................28

5.4.1 Changing the speed range.....................................................................................................................28

5.5 Straight turning.......................................................................................................................................29

5.5.1 Manually.................................................................................................................................................29

5.5.2 About self-acting feed.............................................................................................................................29

5.6 Turning short tapers with the top slide ...................................................................................................29

5.7 Clamping a workpiece into the three jaw chuck .....................................................................................30

5.7.1 Replacing the clamping jaws on the lathe chuck....................................................................................30

5.8 Adjusting feeds and thread pitches ........................................................................................................31

5.9 Feed table / Table for thread cutting ......................................................................................................31

5.10 Changing the change gears ...................................................................................................................32

5.10.1 Switching on the feed.............................................................................................................................32

5.11 General working advice - coolant...........................................................................................................32

6 Appendix turning

6.1 ISO-designation system for tool holder, inside machining .....................................................................34

6.2 ISO-designation system for tool holder, outside machining ...................................................................35

6.3 Cutter with hard metal reversible carbide tip soldered on ......................................................... .............36

6.4 Cut the first chips.............................................. ......................................................................................36

6.5 Outside machining, longitudinal turning and facing................................................................................37

6.6 Inside machining, drilling and longitudinal turning..................................................................................38

6.7 Tapping of external and internal threads................................................................................................38

6.7.1 Thread types ..........................................................................................................................................39

6.8 Metric threads (60° flank angle) .............................................................................................................41

6.8.1 British thread (55° flank angle)...............................................................................................................42

6.8.2 Indexable inserts....................................................................................................................................44

6.8.3 Examples for thread cutting....................................................................................................................45

6.9 Recessing, cutting off and turning off.....................................................................................................47

6.10 Turning of cones with high precision......................................................................................................48

6.11 Cutting materials ....................................................................................................................................51

6.12 Standard values for cutting data when turning .......................................................................................52

6.13 Cutting speed table ................................................................................................................................53

6.14 Grinding or regrinding of cutting edge geometries of turning tools.........................................................53

6.14.1 Terms for the rotating tool.............................................................................................. ........................54

6.14.2 Cutting edge geometry for turning tools.................................................................................................55

6.14.3 Types of cutting form levels....................................................................................................................55

6.15 Lifetime and wear characteristics...........................................................................................................57

7 Maintenance

7.1 Safety.....................................................................................................................................................58

7.2 Inspection and maintenance ..................................................................................................................58

7.3 Repair.....................................................................................................................................................59

8 Ersatzteile - Spare parts

8.1 Ersatzteilzeichnung Antrieb - Drawing spare parts actuation.................................................................61

8.2 Ersatzteilzeichnung Spindelstock - Drawing spare parts headstock ................................................. ... ..62

8.3 Ersatzteilzeichnung Abdeckungen - Drawing spare parts covers..........................................................63

8.3.1 Ersatzteilliste Antrieb, Spindestock - Spare parts list actuation, headstock ...........................................64

8.4 Ersatzteilzeichnung Planschlitten, Oberschlitten- Drawing spare parts cross slide, top slide................65

8.4.1 Ersatzteile Planschlitten, Oberschlitten - Spare parts list cross slide, top slide .....................................66

8.5 Ersatzteilzeichnung Maschinenbett - Drawing spare parts machine bed...............................................67

8.5.1 Ersatzteile Maschinenbett - Spare parts list machine bed .....................................................................68

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8.6 Ersatzteilzeichnung Reitstock - Drawing spare parts tailstock ..............................................................69

8.6.1 Ersatzteile Reitstock - Spare parts tailstock ..........................................................................................70

8.7 Ersatzteilzeichnung Wechselradgetriebe - Drawing spare parts change gear .......................................71

8.7.1 Ersatzteile Wechselradgetriebe - Spare parts change gear ...................................................................72

8.8 Maschinenschilder - Machine labels.......................................................................................................73

8.8.1 Maschinenschilder - Machine labels.......................................................................................................73

8.9 Schaltplan - Wiring diagram....................................................................................................................74

8.9.1 Ersatzteile elektrische Bauteile - Spare parts electrical components ....................................................75

9 Malfunctions

9.1 Malfunctions on the lathe........................................................................................................................76

10 Appendix

10.1 Copyright ................................................................................................................................................77

10.2 Terminology/Glossary.............................................................................................................................77

10.3 Change information operating manual....................................................................................................77

10.4 Liability claims for defects / warranty......................................................................................................78

10.5 Note regarding disposal / options to reuse: ............................................................................................78

10.5.1 Decommissioning ...................................................................................................................................79

10.5.2 Disposal of the packaging of new devices..............................................................................................79

10.5.3 Disposing of the old device.....................................................................................................................79

10.5.4 Disposal of electrical and electronic components...................................................................................79

10.6 Disposal via municipal collection............................................................................................................80

10.7 RoHS, 2002/95/EC............................... ..................................... .................................... .........................80

10.8 Product follow-up....................................................................................................................................80

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Preface

Dear customer, Thank you very much for purchasing a product made by OPTIMUM. OPTIMUM metal working machines o ffer a maximum of quality, technically optimum solutions and convince

by an outstanding price performance ratio. Continuous enhancements and product innovations guarantee state-of-the-art products and safety at any time.

Before commissioning the machine please thoroughly read these operating instructions and get familiar with the machine. Please also make sure that all persons operating the machine have read and understood the operating instructions beforehand. Keep these operating instructions in a safe place nearby the machine.

Information

The operating instructions include indications for safety-relevant and proper installation, operation and maintenance of the machine. The continuous observance of all notes included in this manual guarantee the safety of persons and of the machine.

The manual determines the intended use of the machine and includes all necessary information for its economic operation as well as its long service life.

In the paragraph "Maintenance" all maintenance works and functional tests are described which the operator must perform in regular intervals.

The illustration and information included in the present manual can possibly deviate from the current state of construction of your machine. Be ing the manufacturer we are continuously seeking for improv ements and renewal of the products. Therefore, changes might be performed without prior notice. The illustrations of the machine may be different from the illustrations in these instructions with regard to a few details. However, this does not have any influence on the operability of the machine. Therefore, no claims may be derived from the indications and descr i ptions. Changes and er rors ar e re served !

Your suggestion with regard to these operating instructions are an important contribution to optimising our work which we offer to our customers. For any questions or suggestions for improvement, please do not hesitate to contact our service department.

If you have any further questions after reading these operating instructions and you are not able to solve your problem with a help of these operating instructions, please contact your specialised dealer or directly the company OPTIMUM.

Optimum Maschinen Germany GmbH Dr.- Robert - Pfleger - Str. 26 D-96103 Hallstadt Mail: info@optimum-maschinen.de Internet: www.optimum-maschinen.com

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1 Safety

Glossary of symbols





 enumerations

This part of the operating instructions

 explains the meaning and use of the warning notices included in these operating instruc-

 defines the intended use of the lathe,  points out the dangers that might arise for you or others if these instru ctions are not

 informs you about how to avoid dangers.

In addition to these operation instructions, please observe

 the applicable laws and regulations,  the legal regulations for accident prevention,  the prohibition, warnin g and mandatory signs as well as the warning notes on the lathe .

European standards must be kept during installation, operation, maintenance and repair of the lathe.

If European standards are not applied at the national legislation of the country of destination, the specific applicable regulations of each country are to be observed.

If necessary, the required m easures must be taken to comply with the specific regu lations of each country before the lathe is used for the first time.

Always keep this documentation close to the lathe.

gives further advice calls on you to act

tions,

observed,

INFORMATION

If you are unable to solve a problem using these operating instructions, please contact us for advice:

Optimum Maschinen Germany GmbH Dr. Robert-Pfleger-Str. 26

D- 96103 Hallstadt Email: info@optimum-maschinen.de

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1.1 Safety instructions (warning notes)

1.1.1 Classification of hazards

We classify the safety warnings into various levels. The table below gives an overview of the classification of symbols (ideogram) and the warning signs for each specific danger and its (possible) consequences.

Ideogram Warning alert Definition / consequence

DANGER!

WARNING!

CAUTION!

ATTENTION!

INFORMATION

In case of specific dangers, we replace the pictogram by

Threatening danger that will cause serious injury or death to people. A danger that might cause severe injury to the personnel or can lead to

death. Danger or unsafe procedure that might cause injury to people or dam-

age to property.

Situation that could cause damage to the machine and product and other types of damage.

No risk of injury to people.

Application tips and other important or useful information and notes. No dangerous or harmful consequences for people or objects.

general danger by a warning of injury of hands, hazardous electri-

cal voltage,

rotating parts.

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1.1.2 Other pictograms

Warning danger of

slipping!

Switching on

forbidden!

Use protective boots! Use protective suit! Protect the

Caution, danger of

explosive substances!

Pull the main plug! Use safety glasses!

Warning of automatic

start-up!

protection

environment!

Warning hot surface! Warning biological

Use ear protection! Use protective

Contact address

1.2 Intended use

WARNING! In the event of improper use, the lathe

 will endanger personnel,  the machine and other material property of the operating company will be endan-

gered,

 the correct function of the machine may be affected.

The machine is designed and manufactured to be used in environments where there is no potential danger of explosion.

The lathe is designed and manufactured for straight turning and facing round and regular formed three-, six- or twelve-square workpieces in cold metal, castings and plastics or similar materials that do not constitute a health hazard or do not create dust, such as wood, Teflon®. The lathe must only be installed and operated in a dry and ventilated place. The clamping workpieces in the feed may only be effected with the supplied the special key for chucks.

If the lathe is used in any way other than described above, modified without authorization of Optimum Maschinen Germany GmbH, then the lathe is being used improperly.

We will not be held liable for any damages resulting from any operation which is not in accordance with the intended use.

We expressly point out that the guarantee or CE conformity will expire due to any constructive technical or procedural changes which had not been performed by the company Optimum Maschinen Germany GmbH.

It is also part of intended use that you

 the operating manual is constantly observed,  the inspection and maintenance instructions are observed.  observe the limits of the lathe.

 "Technical data“ on page 16

hazard!

gloves!

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In order to achieve optimum cutting performance, it is essential to choose the right turning tool, feed, tool pressure, cutting speed and coolant.

 "Appendix turning“ on page 33

WARNING! Heaviest injuries through improper use.

It is forbidden to make any modifications or alternations to the operation values of the lathe. They could endanger the staff and cause damage to the lathe.

INFORMATION

The lathe TU1503V is built according to the standard DIN EN 55011 class B.

WARNING! The class B (machine tools) is intended to be used in residential facilities, where the

power is supplied via a public low voltage supply system.

ATTENTION! If the lathe is not used as intended or if the safety directives or the operating in struct ions

are ignored the liability of the manufacturer for any damages to persons or objects resulting hereof is excluded and the claim under guarantee is becoming null and void!

1.3 Reasonably foreseeable misuses

Any other use as the one determined under the "Intended use" or any use beyond the described use shall be deemed as not in conformity and is forbidden.

Any other use has to be discussed with the manufacturer. It is only allowed to process metal, cold and non-inflammable materials with the lathe. In order to avoid misuse, it is necessary to read and understand the operating instructions

before the first commissioning. The operators must be qualified.

1.3.1 Avoiding misuses

 Use of suitable cutting tools.  Adapting the speed adjustment and feed to the material and workpiece.  Clamp workpieces firmly and vibration-free.

1.4 Possible dangers caused by the machine

The lathe has undergone a safety inspection (analysis of danger with assessment of risks). It has been designed and built on the basis of this analysis using the latest technological advances.

Nonetheless, there remains a residual risk, since the machine operates with

 high revolutions,  rotating parts,  with el ectrical voltages and currents.

We have used construction resources and safety techniques to minimize the health risk to personnel resulting from these hazards.

If the lathe is used and maintained by the staff who are not duly qualified, there may be a risk resulting from incorrect or unsuitable maintenance of the lathe.

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INFORMATION

Everyone involved in the assembly, commiss ion ing , op e ra tio n an d main te na nc e mu st

 be duly qualified,  strictly follow these operating instructions.

In the event of improper use

 there may be a risk to the personnel,  there may be a risk to the machine and other material values,  the correct function of the lathe may be affected.

Always disconnect the lathe if cleaning or maintenance work is being carried out, or is no longer in use.

WARNING! The lathe may only be used with the safety devices activated.

Disconnect the lathe immediately whenever you detect a failure in the safety devices or when they are not mounted!

All additional installatio ns carried out by the operator must incorpo rate the prescribed safety devices.

This is your responsibility being the operating company!

 "Safety measures during operation“ on page 12

1.5 Qualification of personnel

1.5.1 Target group

This manual is addressed to

 the operating companies,  the operators,  the personnel for maintenance works.

Therefore, the warning notes refer to both operation and maintenance of the machine . Always disconnect the machine plug from the mains. This will prevent it from being used by un-

authorized persons. The qualifications of the personnel for the different tasks are mentioned below:

Operator

The operator is instructed by the operating company about the assigned tasks and possible risks in case of improper behaviour. Any tasks which need to be performed beyond the operation in the standard mode must only be performed by the operator if it is indicated in these instructions and if the operating company expressively commissioned the operator.

Electrical specialist

Due to his professional training, knowledge and experience as well as his knowledge of respective standards and regulations the electrical specialist is able to perform works on the electrical system and to recognise and avoid any possible dangers himself.

The electrical specialist is specially trained for the working environment in which he is working and knows the relevant standards and regulations.

Qualified personnel

Due to their professional training, knowledge and experience as well as their knowledge of relevant regulations the qualified personnel is able to perform the assigned tasks and to recognise and avoid any possible dangers themselves.

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Instructed person

Instructed personnel were instru cted by the operating company about the assigned tasks and any possible risks in case of improper behaviour.

INFORMATION

Everyone involved in the assembly, commissioning, operation and maintenance must

 be duly qualifie d,  strictly follow these operating instructions.

In the event of improper use

 there may be a risk to the personnel,  there may be a risk to the machine and other material values,  the correct function of the lathe may be affected.

1.5.2 Authorized personnel

WARNING! Inappropriate operation and maintenance of the machine constitutes a danger for the

staff, objects and the environment. Only authorized personnel may operate the machine!

Persons authorized to operate and maintain should be trained technical personnel and instructed by the ones who are working for the operating com p an y an d fo r the ma nu fa ctu re r .

1.5.3 Obligations of the operating company

The operator must instruct the staff at least once per year regarding

 all safety standards that apply to the machine.  the operation,  accredited technical guidelines.

The operator must also

 check personnel‘s state of knowledge,  document the trainings/instructions,  require personnel to confirm participation in training/instructions by means of a signature,  check whether the personnel is working safety- and risk-conscious and observe the operat-

ing instructions.

1.5.4 Obligations of the operator

The operator must

 have read and understood the operating manual,  be familiar with all safety devices and regulations,  be able to operate the machine.

1.5.5 Additional requirements regarding the qualification

For work on electrical components or equipment, there are additional requirements:

 Must only be performed by a qualified electrician or person working under the ins tru ct io n s

and supervision of a qualifiedelectrician.

 Before carrying out work on electrical components or operating units, the following meas-

ures must be taken, in the order given.

 disconnect all poles.  Secure against switching on.  Check if the machine is zero potential.

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1.6 Operators positions

The operator’s position is in front of the machine.

1.7 Safety measures during operation

CAUTION! Risk due to inhaling of health hazardous dusts and mist.

Dependent on the material which need to be processed and the used auxiliaries dusts and mist may be caused which might impair you health.

Make sure that the generated health hazardous dusts and mist are safely sucked off at the point of origin and is dissipated or filtered from the working area. To do so, use a suitable extraction unit.

CAUTION! Risk of fire and explosion by using flammable materials or cooling lubricants.

Before processing inflammable materials (e.g. aluminium, magnesium) or using inflammable auxiliary materials (e.g. spirit) it is necessary to take additional preventive measures in order to safely avoid health risks.

CAUTION! Risk of winding-up or cutting damages when using hand tools.

The machine is not designed for the use of hand tools (e.g. emery cloth or files). It is forbidden to use any hand tools on this machine.

1.8 Safety devices

Use the lathe only with properly functioning safety devices. Stop the lathe immediately if there is a failure on the safety device or if it is not functioning for

any reason. It is your responsibility! If a safety device has been activated or has failed, the lathe must only be used if you

 the cause of the failure has been removed,  you have made sure th at there is no existing danger for personnel or objects.

WARNING! If you bypass, remove or override a safety device in any other way, you are endangering

yourself and other persons working on the machine. The possible consequences are

 injuries may occur due to workpiece or parts of workpieces flying off,  contact with rotating parts,  fatal electrocution.

WARNING! The separating protective equipment which is made available and delivered together

with the machine is designed to reduce the risk of workpieces or fractions of them which being expelled, but not to remove them completely. Always work carefully and observe the limits of their machining process.

The lathe includes the following safety devices:

 a EMERGENCY STOP button  a protective cover on the headstock,  a special key for the lathe chuck,  a lathe chuck pro tection with position switch.

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1.9 EMERGENCY-STOP button

EMERGENCY-

STOP button

Protective cover

Lathe chuck pro-

tection

Safety lathe chuck

key

Lathe chuck key

The EMERGENCY-STOP button switches the lathe off.

Knocking on the emergency stop device triggers an emergency stop.

After actuating the switch, turn it to the right, in order to restart the lathe.

1.9.1 Protective cover with safety switch

The spindle head of the lathe is equipped with a fixed, separating protective cover.

The locked position is monitored by means of an electrical limit switch.

INFORMATION

It is not possible to start the machine until the protective cover is closed.

OPTIMUM

MASCHINEN - GERMANY

Img.1-1: EMERGENCY-STOP button

1.9.2 Lathe chuck protection with position switch

The lathe is provided with a lathe chuck protection. The lathe can only be switched on if the lathe chuck protection is closed.

1.9.3 Lathe chuck key

The lathe is equipped with a special key for chucks. Once the lathe chuck key has been released, it is pushed out of the lathe chuck by a spring.

CAUTION!

Img.1-2: for the protective cover of the headstock

Img.1-3: lathe chuck protection

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Only operate the lathe using this key.

Img.1-4: Lathe chuck key

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1.10 Safety check

Check the lathe regularly. Check all safety devices

 before starting work,  once a week,  after every maintenance and repair work.

General check Equipment Check OK

Protective covers, lathe chuck protection

Signs, Markings

Functional check Equipment Check OK

EMERGENCY-STOP button

Lathe chuck key Once the chuck key has been released, it should be automati-

Lathe chuck protection / protective cover headstock

Mounted, firmly bolted and not damaged

Installed and legible

When the EMERGENCY STOP push button is activated, the lathe must switch off.

cally pressed out of the lathe chuck. The lathe shall only run with the lathe chuck protection / protec-

tive cover headstock closed.

1.11 Personnel protective equipment

For certain work personal protective equipment is required. Protect your face and your eyes: Wear a safety helmet with facial protection when performing

works where your face and eyes are exposed to hazards.

Use protective gloves when handling pieces with sharp edges. During operation of the lathe, the we aring of gloves is pr ohibited because o f the risk of winding

up. Use safety shoes when you assemble, disassemble or transport heavy components.

Use ear protection if the noise level (emission) in the workplace exceeds 80 dB (A). Before starting work, make sure that the prescribed personal protective equipment is available

at the workplace.

CAUTION! Dirty or contaminated personnel protective equipment can cause diseases. Clean it each

time after use and at least once a week.

1.12 For your own safety during operation

We specially point out the specific dangers when working with and on the lathe.

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WARNING! Before switching on the lathe make sure that there are no

 no dangers generated for persons,  not cause damage to equipment.

Avoid any risky working practices:

 Make sure that nobody is endangered by your work.  Clamp the work piece tightly before activating the lathe.  For clamping workpieces, only use the special chuck key supplied.  Mind the maximum chuck opening.  Wear safety goggles.  Do not rem ove the turning chips by hand. Use a chip hook and / or a hand brush to remove

turning chips.

 Clamp the turning tool at the correct height and with the least possible overhang.  Turn off the lathe before measuring the workpiece.  The instructions mentioned in these operating instructions have to be strictly observed dur-

ing assembly, operation, maintenance and repair.

 Do not work on the lathe, if your concentration is reduced, for example, because you are

taking medication.

 Observe the accident prevention regulations issued by your Employers Liability Insurance

Association or other competent supervisory authority, responsible for your company.

 Stay at the lathe until all movements have come to a complete standstill.  Use the prescribed personnel protective equipment. Make sure to wear a well-fitting work

suit and, if necessary, a hairnet.

We specially point out the specific dangers when working with and on the machine.

1.13 Disconnecting and securing the lathe

 Pull the mains plug before beginning any maintenance or repair work or or switch off the

supply voltage to the lathe. All machine components and hazardous voltages and movements are disconnected.

 Attach a warnin g sign on the machine.

1.14 Mechanical maintenance work

Remove or install protection safety devices before starting any maintenance work and re-install them once the work has been completed.This includes:

 Covers,  Safety indi cations and warning signs,  earth (ground) connections.

If you remove protection or safety devices, refit them immediately after completing the work. Check if they are working properly!

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2 Technical data

The following information are the dimensions and indications of weight and the manufacturer‘s approved machine data..

Electrical connection

Total connection rate 230V ; 450 W ~ 50Hz Degree of protection IP 54

Machine data

Height of centres [mm] 70

Max. swing [mm] 140

Max. swing over

Cross slide [mm]

Distance between centres [mm] 250

-1

Spindle speeds [min

Spindle taper MT1

Spindle hole, rod opening [mm] 11

Bed width [mm] 70

Travel of top slide [mm] 40

Travel of cross slide [mm] 55

Tailstock cone MT1 shortened

Tailstock sleeve travel [mm] 30

Longitudinal feed [mm/revolution] 0.05 - 0.1

Pitch - Metric 0.5 - 1.5

Quadruple tool holder seat height [mm] 12

Level difference between bearing surface quadruple seat

and turning centre [mm]

] 120 - 3000

7.85 + 0 / - 0.3

Dimensions

Height / Length / Width [mm] 290 / 560 / 320

Total weight [kg] 22

Operating material

Slideways, lubrication nipples e.g. machines oil (Mobil Oil, Fina, ...)

Environmental conditions

Temperature 5 - 35 °C

TU1503VGB

We recommend the use of weapon oil, weapon oil is acid-

, stain- and resin-free.

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MASCHINEN - GERMANY

Environmental conditions

Humidity 25 - 80 %

2.1 Emissions

The generation of noise emitted by the lathe is less than 70 dB(A). If the lathe is installed in an area where various machines are in operation, the noise exposure (immission) on the operator of the at the working place may exceed 80dB(A).

INFORMATION

This numerical value was measured on a new machine under proper operating conditions. Depending on the age respectively on the wear of the machine it is possible that the noise behaviour of the machine changes.

Furthermore, the factor of the noise emission is also depending on manufacturing influencing factors, e.g. speed, material and clamping conditions.

INFORMATION

The mentioned numerical value is the emission level and not necessarily a safe working level. Though there is a dependency between the degree of the noise emission and the degree of the

noise disturbance it is not possible to use it reliably to determine if further precaution meas ures are required or not.

The following factors influence the actual degree of the noise exposure of the operator:

 Characteristics of the working area, e.g. size or damping behaviour,  Other noise sources, e.g. the number of machines,  Other processes taking place in the proximity and the period of time during which the oper-

ator is exposed to the noise.

Furthermore, it is possible that the admissible exposure level might be different from country to country due to national regulations. This information about the noise emission shall allow the operator of the machine to more easily evaluate the endangering and risks.

CAUTION! Depending on the overall noise exposure and the basic limit values the machine

operators must wear an appropriate hearing protection. We generally recommend to use a noise protection and a hearing protection.

TU1503V GB

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MASCHINEN - GERMANY

2.2 Dimensions, installation plan

Img.2-1: Dimensions, installation plan

TU1503VGB

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MASCHINEN - GERMANY

3 Unpacking and connecting

INFORMATION

The lathe is delivered pre-asse mbled. When the lathe is delivered, check immediatel y before and after unpacking hat the lathe has not been damaged during shipping and that all components are included. Also check that no fastening screws have come loose.

3.1 Scope of delivery

Compare the scope of delivery with the packing list.

3.2 Storage

ATTENTION! In case of wrong and improper storage electrical and mechanical machine components

might get damaged and destroyed. Store packed and unpacked parts only under the intended environmenta l conditions. Follow the instructions and information on the transport case.

 Fragile goods

(Goods require careful handling)

 Protect against moisture and humid environment

 "Environmental conditions“ on page 16

 Prescribed position of the packing case

(Marking of the top surface - arrows pointin g to th e top)

 Maximum stacking height

Example:not stackable - do not stack a second pac k ing case on top of the first packaging case

Consult Optimum Maschinen Germany GmbH if the machine and accessories are stored for more than three months or are stored under different environmental conditions than those given here .

 "Information“ on page 6

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3.3 Installation and assembly

3.3.1 Requirements regarding the installation site

INFORMATION

In order to attain good functionality and a high processing accuracy as well as a long durability of the machine the installation site should fulfil certain criteria.

Please observe the following points:

 The device must only be installed and operated in a dry and well-ventilated place.  Avoid places nearby machines generating chips or dust.  The installation site mu st be free from vibrations also at a distance of presses, planing

machines, etc.

 The substructure must be suitable for turning. Also make sure that the floor has sufficient

load bearing capacity and is level.

 The substructure must be prepared in a way that possibly used coolant cannot penetrate

into the floor.

 Any parts sticking out such as stops, handles, etc. have to be secured by measures taken

by the customer if necessary in order to avoid endangerment of persons.

 Provide sufficient space for the staff preparing and operating the machine and transporting

the material.

 Also consider that the machine is accessible for setting and maintenance works.  The mains plug and the main switch of the lathe has to be freely accessible.  Provide for sufficient illumination (Minimum value: 300 lux).

In case of little intensity of illumination provide for additional illumination i.e. by a separate workplace illumination.

INFORMATION

The mains plug of the lathe must be freely acces sib le .

3.3.2 Assembling

ATTENTION! The lathe can slip slowly during operation on the ground. Attach the machine to the

ground.

 Attach the lathe to the provided through holes (2 pieces) along with the chip pan and the

intended base.

 "Dimensions, installation plan“ on page 18

ATTENTION! Tighten the setscrews on the lathe only until it is firmly secured and can neither move

during operation nor be turned over. If the fixing screws are too tight in particular in connection with an uneven substructure it may result in a broken stand of the machine bed.

3.4 First commissioning

ATTENTION! Before commissioning the machine check all screws, fixtures resp. safety devices and

tighten up the screws if necessary! WARNING!

Risk by using improper tool holders or by operating them at inadmissible speeds.

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Only use the tool holders (e.g. drill chuck) which were delivered with the machine or which are offered as optional equipment by OPTIMUM.

Only use tool holders in the intended admissible speed range. Tool holders may only be modified in compliance with the recommendation of OPTIMUM

or of the manufacturer of the clamping devices. WARNING!

When first commissioning the lathe by inexperienced staff you endanger people and the machine.

We do not take any liability for damages caused by incorrectly performed commissioning.

3.4.1 Warming up the machine

ATTENTION! If the lathe and in particular the lathe spindle is immediately operated at maximum load

when it is cold it may result in damages.

If the machine is cold such as e. g. directly after having transportation, t he machine should be warmed up for the first 30 minutes at a spindle sp ee d of only 500 1/min.

3.4.2 Cleaning and lubricating

 Remove the anti-corrosive agents on the lathe which had been applied for transportation

and storage. Therefore, we recommend you to use paraffin.

ATTENTION! Do not use any solvents, cellulose thinner or any other cleaning agents which might

affect the coating of the lathe when cleaning the lathe. Observe the indications and notes of the manufacturer for cleaning agents.

 Oil all blank machine parts using an acid-free lubricating oil.  Lubricate the machine.  "Inspection and maintenance“ on page 58

3.4.3 Functional test

 Check if all spindles are running smoothly.  Check the state of the lathe chuck and the turning jaws.

3.4.4 Functional check

 Clamp a workpiece into the lathe chuck of the machine or close the jaws of the lathe chuck

fully before turning on the machine.

WARNING!

 Mind the maximum chuck opening.  Do not stand in front of the lathe chuck when turning on the machine for the first

time.

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Engaging switch

MASCHINEN - GERMANY

4 Assembly and function

The machine is a centre lathe. It has been designed and manufactured for straight turning and facing round or regularly-formed square workpieces in metal, plastics or similar materials for model making.

The hollow work spindle enables you to clamp longer workpieces with a diameter of up to 10 mm.

The speed is changed progressively in the predefined speed range of the corresponding V-belt pulley.

The leadscrew enables longitudinal feed and thread-cutting. When turning between centres, the tailstock is used to hold the centre and, when drilling, coun-

tersinking or reaming, to hold the tool with a drill chuck.

4.1 Construction features

 Electronic continuous speed regulation with dynamically readjusting control,  Powerful DC motor with high capacity from 120 rpm upwards  Spindle-bearing arrangement with precision ball bearings,  Prismatic bed made from ground grey cast iron,  High concentricity precision of the work spindle < 0.015 mm,  Left- and right-hand motor rotation controlled by a switch,  Turning graduated collars,  Leadscrew for thread-cutting or feed for straight turning with change gear set  Tailstock sle eve and handwheel with adjustable precision scaling.

-1

4.2 Spindle stock with feed gear

The spindle stock houses the feed gear for adjusting the feed speeds and the reducing gear for adjusting the speed range.

The automatic feed is activated by switching the engaging switch on the spindle stock.

Img.4-1: Engaging switch

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V-belt

Crank handle Lathe saddle

Tool holder

MASCHINEN - GERMANY

4.2.1 Gear

By changing the position of the V-belt on the pulleys you can select two speed ranges. The potentiometer is used to change the speed within the correspond ing speed range.

Img.4-2: V-belt

4.2.2 Feed gear

The feed gear is used to obtain the feeds for straight turning and threading by changing the change gears.

The travel of the lathe saddle for each revolution of the spindle, and depending on the change gears installed is shown in the table.

 "Feed table / Table for thread cutting“ on page 31

4.3 Lathe saddle

The lathe saddle (saddle slide) glides along the prismatic slideways of the lathe bed. It allows feed movement parallel to the workpiece axis. Feed motion is carried out using the crank or automatically via the feed gear through the leadscrew.

Img. 4-3: Crank of lathe saddle

4.4 Top slide

The tools (cutting tools) are fitted to the toolholder of the top slide.

The top slide glides on a rotating swivel piece which runs on bearings on the top of the cross slide. The swivel piece is clamped with a screw.

 "Turning short tapers with the top slide“

on page 29

Img.4-4: Tool holder

TU1503V GB

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Tailstock

MASCHINEN - GERMANY

4.5 Cross slide

The cross slide is connected to the lathe saddle (saddle slide) with the help of a dovetail slideway. Movement is at right angles to the workpiece axis by means of the cross slide.

4.6 Tailstock

The tailstock consists of a guide plate with gripping yoke and upper part. It is readjusted manually and clamped on the slideways of the lathe bed with the help of the clamping screw and the gripping yoke. The upper part houses the spindle sleeve. It has a small inside cone MT1 in shortened version. The spindle sleeve may be adjusted longitudinally via a threaded spindle. Clamping is by means of a clamping screw.

Img.4-5: Tailstock

TU1503VGB

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5 Handling

5.1 Safety

Use the lathe only under the following conditions:

 The lathe is in proper working order.  The lathe is used as prescribed.  The oper ating manual is followed.  All safety devices are installed and activated.

All failures should be eliminated immediately. Stop the immediately in the event of any abnormality in operation and make sure it cannot be started-up accidentally or without authorisation.

 "For your own safety during operation“ on page 14

5.2 Control and indicating elements

Pos. Designation Pos. Designation

1 EMERGENCY-STOP button 2 ON / Off - Switch 3 Speed adjustment 4 for the protective cover of the headstock 5 Rotation direction switch 6 Lathe ch uck pr otection 7 Change wheel and feed table 8 Shift lever automatic feed 9 Handwheel cross slide 10 Tailstock 11 Steady rest (example) 12 Follow rest (example) 13 Tool holder 14 Lathe chuck 15 Handwheel top slide 16 Clamping screw tailstock sleeve 17 Clamping screw tailstock 18 Handwheel lathe saddle

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5.2.1 Switching elements

Push button ON

The “hand actuated auxiliary switch ON” switches the rotation of the lathe on.

Hand actuated auxiliary switch OFF

The “hand actuated auxiliary switch OFF”

Speed adjustment

It is possible to set the required speed using the speed adjustment.

Rotation direction switch

The direction of rotation of the lathe can be switched by actuating the change-over switch. It is possible to select a speed for each direction of rotation.

 The labelling “R” means right-handed rotation.  The labelling “L” means left-handed rotation.

ATTENTION! Wait until the rotation of the spindle has come to complete standstill before changing

the direction of rotation by actuating the change-over switch. A change over of the rotation direction during operation may result in a destruction of

the motor and of the rotation direction switch.

switches the rotation of the lathe off.

5.2.2 Switching on the machine

 Perform basic setting on the lathe (speed stage, feed, etc.).  Check if the protective cover of the lathe chuck and the protective cover are closed – close

the protective covers if necessary.

 Select the direction of rotation.

 Actuate the push button „ON“.

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Tool holder

Tool adjusted to center height

Tool adjusted above adjusted to center height

Tool adjusted below adjusted to center height

MASCHINEN - GERMANY

5.2.3 Switching off the machine

 Actuate the push button "OFF".

If the machine stands still for a longer period of time, disconnect the machine from the electrical power supply.

WARNING! Risk by using improper workpiece clamping materials or by operating the machine with

inadmissible speed. Only use the tool holders (e.g. drill chuck) which were delivered with the machine or

which are offered as optional equipment by OPTIMUM. Only use tool holders in the intended admissible speed range. Tool holders may only be modified in compliance with the recommendation of OPTI-

MUM or of the manufacturer of the clamping devices.

5.3 Clamping a tool

Clamp the lathe tool into the tool holder. The lathe tool needs to be clamped as short

and tight as possible when turning in order to be able to absorb the cutting force well and reliably during the chip formation.

Adjust the height of the tool. Use the tailstock with the center point in order to determine the required height. If necessary, put the steel washers beneath the tool to achieve the required height.

Img.5-1: Tool holder

5.3.1 Tool height

For the facing process, the cutting edge of the tool must be exactly aligned with the height of the lathe centre to obtain a shoulder-free face. The facing process is a turning operation in which the turning tool feeds perpendicular to the axis of rotation of the workpiece in order to produce a flat surface. Here it is distinguished between cross-facing, cross-slicing and longitudinal facing.

Img.5-2: Height of tool

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V-belt

Tension pulley

Position of the front V- belt; Speed range: 120 - 1500 min

-1

Position of the rear V-belt; Speed range: 320 - 3000 min

-1

MASCHINEN - GERMANY

5.4 Speed adjustment

Adjust the speed with the potentiometer. In order to use another speed range, you must change the position of the V-belt on the pulleys.

WARNING! Unplug the shockproof plug of the lathe before opening the protective cover of the

spindle stock.

5.4.1 Changing the speed range

 Unplug the shockproof plug from the mains.  Open the protective cover of the spindle sto c k .  Loosen the Allen screw of the tensioning pulley.  Lift the V-belt to the relevant position.

 Turn the pulley by hand in order to facilitate positioning on the other pulley diameter. Make

sure that the synchronous belt does not twist.

 Handle the V-belt with care. It must not be damaged or overstretched.

 Push the tensioning pulley upwards to tension the V-belt.  Fit the tensioning pulley.

 The correct tension of the V-belt has been reached, when you can still bend it approxi-

mately 3mm with your index finger.

ATTENTION! Make sure the tension of the V-belt is correct. Excessive or insufficient tension may

cause damage.

Img.5-3: V- belt positions and speed ranges

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5.5 Straight turning

Feed

Engaging

switch

Position

automatic

feed "OFF"

Position

automatic

Clamping

screw

6 Appendix turning

Turning is a cutting manufacturing process with certain geometrically positive or negative cutting edge geometries.

For the machining on the outside tool holder with quadrate shaft and for the machining on the inside boring bars with rounded or oblated shafts are used (refer to ISO-code for tool holders and boring bars).

To determine the machining direction, we distinguish between right, left and neutral tools. On this type of lathes you generally work with right tools, as the tools are used before the center

of turning.

Machining direction for

tool holders

Img.6-1: right holder Img.6-2: right boring bar

Img.6-3: left holder Img.6-4: left boring bar

Machining direction for

boring bars

Img.6-5: neutral holder

For the machining of a workpiece on the outer or inner diameter tools with different forms are required for longitudinal turning, facing, contour turning or thread cutting as well as for grooving, cutting off and cutting.

Img.6-6: tool holder for grooving, cutting

off and cutting

Version 1.0.3 dated 2014-5-14 Page 33Original operating instructions

Img.6-7: boring bar for grooving

Page 34

OPTIMUM

clamped from above

clamped from above clamped the hole

above the hole clamping

screwed through the hole

Ty p e of fixtureMaterial of the body Shank diameter Tool length

08 10 12 16 20 25 32 40 50

Identification letters for the length

A B C D E F G H J K L M N P Q R S T U V W X Y

32 mm 40 mm 50 mm 60 mm 70 mm 80 mm 90 mm 100 mm 110 mm 125 mm 140 mm 150 mm 160 mm 170 mm 180 mm 200 mm 250 mm 300 mm 350 mm 400 mm 450 mm special length 500 mm

Identification of letterMaterial of the bodyConstruction features

S Steel cutter none A with inner coolant

feeding

Bwith vibration

damping

Dwith vibration

damping and inner coolant feeding

hard metal none

with inner coolant feeding

with vibration damping

with vibration damping and inner coolant feeding

cutter with steel head

C E

heavy metal none

with inner coolant feeding

H J

MASCHINEN - GERMANY

Img.6-8: tool holder for thread cutting

6.1 ISO-designation system for tool holder, inside machining

Img.6-9: boring bar for thread cutting

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Page 35

6.2 ISO-designation system for tool holder, outside machining

clamped at the top

clamped at the top above the hole

clamped above the hole

screwed through the hole

free angles where special indications are required

Type of fixture Form of the indexable insertsForm of the tool holder

Free angle of the indexa

OPTIMUM

MASCHINEN - GERMANY

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MASCHINEN - GERMANY

6.3 Cutter with hard metal reversible carbide tip soldered on

Img.6-10: straight cutter DIN 4971

ISO 1

Img.6-12: inside tool DIN 4973

ISO 8

Img.6-14: tip of cutter DIN 4975 Img.6-15: cutter width DIN 4976

Img.6-16: offset face turning tool DIN 4977

ISO 5

Img.6-18: offset side turning tool DIN 4980

ISO 6

Img.6-11: bent cutter DIN 4972

ISO 2

Img.6-13: internal side turning tool for corner work

DIN 4974 ISO 9

ISO 4

Img.6-17: offset tool for corner work DIN 4978

ISO 3

Img.6-19: cut off tool DIN 4981

ISO 7

Lathe tools made of high-speed steel (HSS) and lathe tools with hard metal tips soldered on are solid tools. The cutting edge geometry is to be ground for the corresponding machining.



"Grinding or regrinding of cutting edge geometries of turning tools“ on page 53 For tool holders with indexable inserts the cutter geometry of the tool holder and of the corre-

sponding indexable insert is given. For this type of tools there are four types of fixture for the indexable inserts.

 "ISO-designation system for tool holder, outside machining“ on page 35

6.4 Cut the first chips

In order to cut the first chips, a tool holder for the outside machining and a cutter bar for the inside machining are required. Furthermore, some twist drills (HSS) are required to centrically drill the part to be turned.

For the "do-it-yourselfer" it is recommended to use lathe tools with indexable inserts and screwed clamping. The lathe tool does not require grinding and the indexable insert have a positive cutting form level.

Before you can set the tools you have to determin e the shank he ight and width resp ectively the shank diameter.

The indicated height of centres is the measure from the cutting point to the lathe bed. As there is no tool holder yet, the difference in height is to be determined from the bearing surface of the tool holder in the quadr uple holder to the rotation axis. For some m achines, the difference in height to the rotation axis is indicated in the technical data.

For tools according to ISO or DIN, the shank height is equal to the height of the cutting point. After clamping the tool holder, the height of the cutting point is to be checked. For drill rods ac-

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OPTIMUM

c 1000

d314

------------------------ -

80 1000 30 3 14

----------------------- -

849min

1–

===

Feed direction

Advance of depth of cut

MASCHINEN - GERMANY

cording to ISO, the height of the cutting po int is half the shank diameter and for flattened drill rods half the flattened height. For inside tools according to DIN the height of the cutting point corresponds to 0,8 x shank diameter respectively shank height.

ATTENTION!

If due to a variation in tolerance there is a slug or cone on the plane face, the exact height of centers is to be found by facing trials (put the tool holder higher for slugs and lower for cones).

The height of centres is to be checked each time when the turning tools are changed! For example, a shaft with a diameter of 30mm is to be machined of C45. The outside diameter

is to be turned and faced 20mm and a hole of 16mm is to be drilled.

Selecting the tools

 tool holder for turning and facing with 95° tool cutting edge angle  indexable insert with a point angle of 80°  we select a coa ted hard metal HC M15/K10 as cutting material With this tool about 75% of

all lathe work on the outside diameter may be performed.

Selecting the cutting data

 A hard metal with the designation HC M15/K10 is selected as cutting material, cutting-

speed



= 80 m/min

 ap = 0,4mm for outside machining; ap = 0,2 mm for inside machining  f = 0,05 mm/U (value for automatic feed)

The speed which is to be set is calculated with the formula

6.5 Outside machining, longitudinal turning and facing

For longitudinal turning, the tool holder is moved parallel to the rotation axis. The feed is performed by turning the handwheel of the top slide (therefore the bedslide is to be fixed with the clamping screw). Furthermore you have to pay attention that the angular scale of the top slide is set to zero so that no tapers are being produced .

The feed may also be performed automatically over the leading spindle by shifting the engaging lever of the leadscrew nut. Pay attention that the feed is not automatically switched off.

The feed switching off is to be done manually! Pay also attention to the correct toothed pairing of change gear! The infeed of the depth of cut is performed over the handwheel of the cross slide in direction to

the rotation axis.

Img.6-20: Straight turning

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Advance of depth of cut

Feed direction

MASCHINEN - GERMANY

For facing the bedslide is to be fixed with the clamping screw. The feed is performed by turning the handwheel of the cross slide. The infeed of the depth of cut is performed with the handwheel of the top slide.

Img.6-21: Facing operation

6.6 Inside machining, drilling and longitudinal turning

Selecting the tools

 drill chuck with morse cone seat.  twist drill with center drill.  drill rod with 95° tool cutting edge angle. This drill rod has a shank diameter of 8,0mm, e.g.

a cutting point height of 4,0mm. For a drill rod shank with a flattening at the top, a support may be put beneath the tool in order to achieve the require height of centres. If the drill rod has got a straight shank, a prison or a special straight shank seat is required.

 For drill rods please take into account that there is a predetermined minimum turning diam-

eter in this example of 11mm.

 The advantage in selecting these tools is that you may use the same indexable inserts as

for the outside machining.

 With this tool about 75% of all lathe work on the outside diameter may be performed.  In order to machine centric holes on the lathe, twist drills (HSS) are required. Furthermore a

drill chuck with a chucking capacity of 1 to 13mm or 3-16mm with a more cone seat (example morse cone seat of the size 2) is required. The drill chuck with the morse cone seat is held by the tailstock sleeve and the twist drills are clamped into the drill chuck. The feed for drilling is performed after clamping the tailstock to its position with the handwheel on the tailstock sleeve.

 To make sure that the twist drill will not run off center when spot-drilling, the workpiece is to

be centered with a center drill. For holes from 6,0mm onward you should predrill with a smaller drill. The drill diameter must be as large as the core diameter of the drill of the hole diameter which is to be drilled! For drilling comes a 4.0 mm and 11.5 mm drill bit are used.

 With the drill rod only the predetermined diameter is followed. The feed is performed by

turning the handwheel of the top slide parallel to the rotation axis (please also follow theindications for longitudinal turning. The infeed of the depth of cut is performed over the handwheel of the cross slide in direction to the rotation axis.

 Please make sure that the drill rods are clamped as short as possible (to avoid oscilla-

tions).. You may assure a projection length from the drill rod seat of 4 x drill hole diameter as an empirical formula.

6.7 Tapping of external and internal threads

Threads with smaller diameters and standard thread pitches should be tapped manually on the lathe with screw-taps or dies by turning the clamping chuck as this is more simple to produce.

CAUTION! Pull off the mains plug of the lathe if you want to tap a thread as described above.

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Nut

Bolt

Nut

Bolt

MASCHINEN - GERMANY

Img.6-22: die Img. 6 -23: screw tap

Bolts and nuts with large thread diameters, deviating thread pitches or special types of thread,right-handed and left-handed threads may be produced by threading. For this manufacturing there are as well tool holders and drill rods with exchangeable indexable inserts (oneedged or multiple-edged).

Img.6-24: Tap external

thread

Img.6-25: Tap internal

thread

6.7.1 Thread types

Designation Profile Code

ISO-thread M

UNJ UNJ 1/4" - 20UNJ

letter

UNC

UNF

UNEF

UNS

Short term (e. g.) Application

M4x12

1/4" - 20UNC - 2A

0,250 - UNC - 2A

and general

Machine tools

mechanical engineering

and

Aircraft

aerospace industry

Version 1.0.3 dated 2014-5-14 Page 39Original operating instructions

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OPTIMUM

Nut

Bolt

Nut

Bolt

Nut

Bolt

Nut

Bolt

Cone

MASCHINEN - GERMANY

Whitworth B.S.W.W1/4" in. -20 B.S.W.

for thread

Pipe threads,

Cylindrical threads,

or conical pipe threads

connections which seal

ISO-trapezoid

thread

(one- and multi-

ple- threaded)

Round thread RD RD DIN 405

NPT NPT 1“ – 11 ½“ NPT

TR Tr 40 x 7

Tr 40 x 14 P7

Motion thread,

Leading spindle and transport spindle

Fittings and for

purposes of the fire brigade

tube joints

Fittings and

Version 1.0.3 dated 2014-5-14Page 40 Original operating instructions

Page 41

6.8 Metric threads (60° flank angle)

Nut

Bolt

Metric coarse-pitch thread

Sizes in mm: preferably use the threads in column 1

OPTIMUM

MASCHINEN - GERMANY

pitch P depth of thread of the bolt h2=0,6134 x P depth of thread of the nut H1 = 0,5413 x P rounding r = 0,1443 x P flank diameter d2 = D2 =d - 0,6493 core removing hole drill = d - P flank angle = 60°

Thread

denomination

d = D

Column 1 Column 2 Bolt

pitch P

M 1 0.25 0.838 0.693 0.729 0.153 0.135 0.036 0.75

M 1.1 0.25 0.938 0.793 0.829 0.153 0.135 0.036 0.85

M 1.2 0.25 1.038 0.893 0.929 0.153 0.135 0.036 0.95

M 1.4 0.3 1.205 1.032 1.075 0.184 0.162 0.043 1.1

M 1.6 0.35 1.373 1.171 1.221 0.215 0.189 0.051 1.3

M 1.8 0.35 1.573 1.371 1.421 0.215 0.189 0.051 1.5

M 2 0.4 1 .740 1.509 1.567 0.245 0.217 0.058 1.6

M 2.2 0.45 1.908 1.648 1.713 0.276 0.244 0.065 1.8

M 2.5 0.45 2.208 1.948 2.013 0.276 0.244 0.065 2.1

M 3 0.5 2 .675 2.387 2.459 0.307 0.271 0.072 2.5

M 3.5 0.6 3.1 10 2.764 2.850 0.368 0.325 0.087 2.9

Flank

d2 = D2

diameter

Core

diameter

Nut

Depth of thread

Bolt

Nut

Rounding r

Core removing hole driill

M 4 0.7 3 .545 3.141 3.242 0.429 0.379 0.101 3.3 M 5 0.8 4.480 4.019 4.134 0.491 0.433 0.115 4.2 M 6 1 5.350 4.773 4.917 0.613 0.541 0.144 5.0

M 8 1.25 7.188 6.466 6.647 0.767 0.677 0.180 6.8 M 10 1.5 9.026 8.160 8.376 0.920 0.812 0.217 8.5 M 12 1.75 10.863 9.853 10.106 1.074 0.947 0.253 10.2

M14 2 12.701 11.546 11.835 1.227 1.083 0.289 12

M 16 2 14.701 13.546 13.835 1.227 1.083 0.289 14

M18 2.5 16.376 14.933 15.294 1.534 1.353 0.361 15.5

M 20 2.5 18.376 16.933 17.294 1.534 1.353 0.361 17.5

M 22 2.5 20.376 18.933 19.294 1.534 1.353 0.361 19.5

M 24 3 22.051 20.319 20.752 1.840 1.624 0.433 21

Version 1.0.3 dated 2014-5-14 Page 41Original operating instructions

M 27 3 25.051 23.319 23.752 1.840 1.624 0.433 24

Page 42

OPTIMUM

MASCHINEN - GERMANY

M 30 3.5 27.727 25.706 26.211 2.147 1.894 0.505 26.5 M 36 4 33.402 31.093 31.670 2.454 2.165 0.577 32 M 42 4.5 39.077 36.479 37.129 2.760 2.436 0.650 37.5 M 48 5.5 44.752 41.866 41.866 3.067 2.706 0.722 43 M 56 5.5 52.428 49.252 49.252 3.374 2.977 0.794 50.5 M 64 6 60.103 56.639 56.639 3.681 3.248 0.866 58

Metric fine-pitch thread

Denomination of

thread

d x P

M2 x 0,2 1.870 1.755 1.783 M16 x

Flank

diameter

d2 = D2

Core

diameter

Bolt Nut Bolt Nut

Denomination of

thread

d x P

1,5

Flank

diame-

ter

d2 = D2

15.026 14.160 14.376

Core

diameter

M2.5 x

0.25

M3 x 0,35 2.773 2.571 2.621 M20 x

M4 x 0,5 3.675 3.387 3.459 M24 x

M5 x 0,5 4.675 4.387 4.459 M24 x 2 22.701 21.546 21.835

M6 x 0,75 5.513 5.080 5.188 M30 x

M8 x 0,75 7.513 7.080 7.188 M30 x 2 28.701 27.546 27.835

M8 x 1 7.350 6.773 6.917 M36 x

M10 x

0,75

M10 x 1 9.350 8.773 8.917 M42 x

M12 x 1 11.350 10.773 10.917 M42 x 2 40.701 39.546 39.835

M12 x

1.25

M16 x 1 15.350 14.773 14.917 M48 x 2 46.701 45.546 45.835

2.338 2.193 2.229 M20 x 1 19.350 18.773 18.917

19.026 18.160 18.376

1.5

23.026 22.160 22.376

1,5

29.026 28.160 28.376

1,5

35.026 34.160 34.376

1,5

9.513 9.080 9.188 M36 x 2 34.701 33.546 33.835

41.026 40.160 40.376

1,5

11.188 10.466 10.647 M46 x 1,5

47.026 46.160 46.376

6.8.1 British thread (55° flank angle)

BSW (Ww.): British Standard Withworth Coarse Thread Series is the most common coarse thread in Great Britain and corresponds in its usage category to the metric coarse-pitch thread. The designation of a hexagon head screw 1/4" - 20 BSW x 3/4" , is here: . 1/4" is the nominal diameter of the screw and 20 is the number of threads in 1" of length.

BSF: British Standard Fine Thread Series. British Standard Fine Thread Series. BSW- and BSF are the thread selection for the common screws. This fine thread is very common in the British machine tool industry, but it is replaced by the American UNF thread.

BSP (R): British Standard Pipe Thread. Cylindric pipe thread; designation in Germany: R 1/4" (nominal width of the tube in inch). Tube threads are larger in their diameter as "BSW". Designation 1/8" - 28 BSP

Version 1.0.3 dated 2014-5-14Page 42 Original operating instructions

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OPTIMUM

MASCHINEN - GERMANY

BSPT: BSPT: British Standard Pipe - Taper Thread. Conic tube thread, cone 1:16; designation: 1/4" - 19 BSPT

BA: BA: British Association Standard Thread (47 1/2° flank angle). Common with instruments and watches, is being replaced by the metric ISO thread and by the ISO miniature thread. It consists of numeric designations from 25 to 0=6,0mm max diameter.

Table of the British threads

Nominal diameter of

the thread

[Inch] mm (R) D. [mm] No. D

1/16 1.588 60 - - 16 134 0.79 3/32 2.382 48 - - 15 121 0.9

1/8 3.175 40 - 28 9.73 14 110 1.0 5/32 3.970 32 - - - 13 102 1.2 3/16 4.763 24 32 - - 12 90.9 1.3 7/32 5.556 24 28 - - 11 87.9 1.5

1/4 6.350 20 26 19 13.16 10 72.6 1.7 9/32 7.142 20 26 - - 9 65.1 1.9 5/16 7.938 18 22 - - 8 59.1 2.2

3/8 9.525 16 20 19 16.66 7 52.9 2.5 7/16 11.113 14 18 - - 6 47.9 2.8

1/2 12.700 12 16 14 20.96 5 43.0 3.2 9/16 14.288 12 16 - - 4 38.5 3.6

5/8 15.875 11 14 14 22.91 3 34.8 4.1

BSW BSF: BSP/BSPT BA-threads

Threads in 1" Threads in 1"

55° Flank angle 47 1/2° Flank angle

[mm]

11 /16 17.463 11 14 - - 2 31.4 4.7

3/4 19.051 10 12 14 26.44 1 28.2 5.3

13/16 20.638 10 12 - - 0 25.3 6.0

7/8 22.226 9 11 14 30.20

15/16 23.813 9 11 - -

1 25.401 8 10 11 33.25 1 1/8 28.576 7 9 - 1 1/4 31.751 7 9 11 41.91 1 3/8 34.926 6 8 - 1 1/2 38.101 6 8 11 47.80 1 5/8 41.277 5 8 - 1 3/4 44.452 5 7 11 53.75 1 7/8 47.627 4 1/2 7 - -

2 50.802 4 1/2 7 11 59.62

Version 1.0.3 dated 2014-5-14 Page 43Original operating instructions

Page 44

OPTIMUM

Feed direction

Core diameter

Flank diameter

Thread diameter



tan



---------------- -

MASCHINEN - GERMANY

6.8.2 Indexable inserts

For indexable inserts there are partial profile and full profile indexable inserts. The partial profile indexable inserts are designed for a certain pitch range (e.g. 0.5 - 3mm).

 The partial profile indexable insert is optimally appropriate for the single-piece production.  The full profile indexable insert is only designed for a certain pitch.

Img.6-26: partial profile

indexable insert

Img.6-27: full profile indexa-

ble insert

Determining the machining method of right-handed and left-handed threads:

Right-handed tool holders or drill rods are used. In order to top right-handed threads the feed direction towards the clamping chuck is selected and the machine spindle turns to the right (the turning direction of the machine spindle is determined when you look into the spindle from the rear side). If a left-handed thread is to be tapped, the feed direction is selected away from the clamping chuck in direction to the tailstock and the machine spindle turns to the right.

Img.6-28: right-handed

thread with the machine spindle turning to the right

Img.6-29: left-handed

thread with the machine spindle turning to the right

As for thread cutting there are other conditions as for longitudinal turning, the forward cutter must show a larger clearance as the pitch angle of the thread.

Pitch angle Pitch P

Img.6-30: Pitch angle

Version 1.0.3 dated 2014-5-14Page 44 Original operating instructions

Page 45

OPTIMUM

1 2 3 4 5 6 7

8 9 10 11 12 13 14

MASCHINEN - GERMANY

6.8.3 Examples for thread cutting

As an example, a metric external thread M30 x 1,0 mm made of brass is being machined.

Selecting the tool holder

For lathe TU1503V and TU1804V , TU2004V, turning tool No.6 and for lathe TU2404 , TU2404V, TU2506 , TU2506V, TU2807 , TU2807V turning tool No.13.

Pointing turning tools are also appropriate Img.6-14: “tip of cutter DIN 4975“ on page 36with hard metal plates soldered on of the complete set for the lathe TU1503V and TU1804V , TU2004V, 8mm, 11-pieces, item no. 344 1008 and for lathe TU2404 , TU2404V, TU2506 , TU2506V, TU2807 , TU2807V, 8mm, 11-pieces, item no. 344 1108 .

The above mentioned thread turning tools have a point angle of 60°.

Set of turning tools HM 9mm 344 1011 7-pieces with HM indexable inserts TiN-coated in a wooden case ISO designation tool holder Turning tool 1: SWGCR/L0810D05 Turning tool 2: SCLCR/L0810D06 Turning tool 3: SDJCR/L0810D07 Turning tool 4: SDNCN/L0810D07 Turning tool 5: SCLCL0810D06 Turning tool 6: LW0810R/L 04 Turning tool 7: QA0812R/L03

Set of turning tools HM 10mm 344 1111 7-pieces with HM indexable inserts TiN-coated in a wooden case ISO designation tool holder Turning tool 8: SWGCR/L1010E05 Turning tool 9: SCLCR1010E06 Turning tool 10: SDJCR/L1010E07 Turning tool 11: SDNCN/L1010E07 Turning tool 12: SCLCR/L1010E06 Turning tool 13: LW1010R/L04 Turning tool 14: QA1012R/L03

 Steel sheets are to be laid under the complete tool holder or turning tool to achieve exactly

the turning center.

 The lowest spindle speed is set so that the lathe will not coast too long !  Mount gear pairing for pitch 1,0mm in the change gear !

The outer diameter had been turned to 30,0mm and the tool holder is clamped in the quadruple holder for threading aligned angular to the rotation axis. The height of centres is checked (as described).

Img.6-31: Thread cutting

Version 1.0.3 dated 2014-5-14 Page 45Original operating instructions

Page 46

OPTIMUM

MASCHINEN - GERMANY

Img.6-32: radial infeed

Img.6-33: Alternate infeed

The depth of thread is manufactured in various passes. The infeed is to be reduced after each pass.

The first pass takes place with an infeed of

0.1 - 0.15 mm For the last pass the infeed shall not be

below 0,04mm. For pitches up to 1,5mm the infeed may

be radial. For our example 5 to 7 passes are being

determined.

For larger pitches the alternate flank infeed is selected. The top slide is from the 2nd passage in each case 0.05 - 0.10 mm adjusted alternately to the left and right. The last two passes are performed without lateral offset. When the depth of thread is achieved, two passes are performed without infeed.

To machine internal threads, about 2 passes shall be selected additionally for the infeed (drill rods are more instable).

The cutting point is slit slightly by turning the handwheel of the cross slide the scale is turned to zero. This is the point of departure for the infeed of the depth of thread.

The scale of the top slide is also set to zero (this is important for the lateral offset whenturning threads with larger pitches).

The cutting point is set just in front of the starting point of the start of the thread by actua ting thehandwheel of the bedslide.

The cutting point is set just in front of the starting point of the start of the thread by actua ting thehandwheel of the bedslide. With this connection, the adjusted thread pitch is transferred to the bedslide and to the tool holder.

ATTENTION! This connection must not be disconnected until the thread is finished!

Version 1.0.3 dated 2014-5-14Page 46 Original operating instructions

Page 47

OPTIMUM

MASCHINEN - GERMANY

Starting the threading:

 Radial infeed over the handwheel of the cross slide.  Turn the chan ge-over, switch to the right  Start the machine and have the first cutting process run.

ATTENTION! Always have the thumb ready on the OFF-switch in order to prevent a collision with the

workpiece or with the clamping chuck !

 Immediately turn off the machine at the run out of the thread and cam the cutter out by turn-

ing the handwheel of the cross slide.

 Turn the change-over, switch to the left.  Turn the machine on and return the bedslide to the starting point and switch the machine

off.

 Radial infeed over the handwheel of the cross slide.  Turn the chan ge-over, switch to the right  Switch the machine on and have the second cutting process run.  Repeat this procedure as often as necessary until the depth of thread is achieved.  To check the thre ad you may use a thread gauge or a workpiece with an internal thread

M30 x 1.0

 If the thread is having the exact size, the thread cutting process may be terminated. Now

you may again shift the operating lever of the lead-screw nut in standstill. In this way, the connection between the lead spindle and the bedslide is interrup ted.

 Now the toothed wheels for the longitudinal feed are to be mounted again!

6.9 Recessing, cutting off and turning off

When recessing, grooves at the outer or inner diameter are manufactured e.g. for o-rings and locking rings. There is also the possibility to manufacture recesses on the plane face.

When cutting off the finished workpiece is separated from the feed stock. The turning off is a combination of recessing and longitudinal turning. For each of these machining methods there are indexables inserts with sintered cutting form

levels available.

Img.6-34: outside recessing Img.6-35: recessing on

plane faces

Img.6-36: cutting off, turn-

ing off

Version 1.0.3 dated 2014-5-14 Page 47Original operating instructions

Img.6-37: inside recessing

Page 48

OPTIMUM



 2



 2

MASCHINEN - GERMANY

Img.6-38: recessing 1 Img.6-39: recessing 2

On a shaft made of brass, an undercut for a thread M30 is to be machined. Groove with 5,0mm with a depth of 2,5mm.

Selecting the tool holder For lathe TU1503V and TU1804V , TU2004V, turning tool No.7 and for lathe TU2404 , TU2404V, TU2506 , TU2506V, TU2807 , TU2807V turning tool No.14.

For small lathes the cutting speed for this machining compared to the cutting speed for longitudinalturning is reduced by about 60% in order to prevent oscillations.

Cutting speed Vc = 40 m/min, the speed to be set would be 425min The tool holder is clamped into the quadruple holder, aligned angular to the rotation axis and

the height of centres is checked. The tool is positioned and fixed wi th the bedslide. The ex act position is set with the handwheel

of the top slide. With the indexable insert the outer diameter is slit slightly (by turning the handwheel of the cross slide). Set the scale to zero and the first recess of 3,0mm width may be machined. Apply some machine oil on the cutter to grease it! Another recess of 2,0mm is required to achieve a groove width of 5,0mm.

-1

6.10 Turning of cones with high precision

D = large diameter [mm] d = small diameter [mm] L = cone length [mm] Lw = workpiece length [mm]

= cone angle

= setting angle Kv = cone proportion Vr = tailstock offset

Img.6-40: Designation on the cone

There are different possibilities to machine a cone on a common small lathe:

1. By twisting the top slide by setting the setting-angle with the angular scale. But there the graduation of the scale is too inaccurate. For chamfers and conic passings the graduation of the angular scale is sufficient.

2. By a simple calculation, a stop measure of 100mm length (of your own production) and a gauge with stand.

Vd = measure change [mm] Vo = twist measure of top slide [mm]

Version 1.0.3 dated 2014-5-14Page 48 Original operating instructions

Page 49

OPTIMUM

Dd–

------------ -

100mm

------------------ -

-------

100mm D d–

2L

-------------------------------------------

100mm 30mm 24mm–

222mm

------------------------------------------------------------------- -

100mm 6mm

44mm

------------------------------------- -

13=63mm==

Gauge

Stop measure 100mm

Limit stop

Measuring direction

Advance of depth of cut

MASCHINEN - GERMANY

Calculation

of the offset of the top slide relating to the stop measure with a length of 100mm.

Step by step

by one calculation step (summary)

Example: D = 30.0 mm ; d = 24.0 mm ; L = 22.0 mm

The stop measure (100mm) is to be put between a fixed unit stop and the bedslide. Put the gauge with stand on the lathe bed and horizontally align the test prod with the test prod with thetop slide (90° to the top slide). The twisting measure is calculated with the above mentioned formula. The top slide is twisted by this value (then set the gauge to zero). After removing the stop measure, the bedslide will be aligned to the limit stop. The gauge must indicate the calculated value "Vo" Then the workpiece and the tool are clamped and positioned (the bedslide is fixed). The infeed is performed with the handwheel of th e top slide. The depth of cut is advanced with the handwheel of the cross slide.

Img.6-41: Cone setting with stop measure

Version 1.0.3 dated 2014-5-14 Page 49Original operating instructions

Page 50

OPTIMUM

Gauge

Advance of depth of cut

2Kv

----------------

Dd– 2L

------------ -

Lw=

max

------- -

MASCHINEN - GERMANY

3. By measuring an existing cone with gauge and stand.

The stand is put on the top slide. The gauge is aligned horizontally and 90° to the top slide. The top slide is approximately adjusted to the cone angle and the test prodbrought in contact with the cone surface (fix the bedslide). Now the top slide is twisted in a way that the gauge does not indicate any travel of the pointer over the whole length of the cone (offset over the handwheel of the top slide).

Then you may start reaming the lathe as described under point 2. The workpiece might be a flange for lathe chucks or a face plate.

Img.6-42: Cone setting with stop measure

4. By offsetting the tailstock as the cone length is larger than the adjustable stroke of the top slide.

The workpiece is clamped be tween two po ints, theref ore center holes are re quired on the face. They are to be drilled before removing the lathe chuck. The slaving of the workpiece is performed by a pulling pin and a lathe carrier.

The calculated value "Vr" is the offset meas ure of the tailstock. The offset is monitored with the gauge (also the return travel).

 "Designation on the cone“ on page 48

For this type of cone machining the lowest speed is used ! Annotation: In order to check the position of the tailstock axis to the rotation axis, a shaft with two centering-

sis clamped between the points. The stand with the gauge is put on the bedslide. The gauge is aligned 90° to the rotation axis and horizontally brought into contact with the shaft. The gauge will pass along the shaft with the bedslide. There must not be any travel of the pointer along the whole length of the shaft. If a deviation is being shown, the tailstock is to be corrected.

Calculation

The tailstock offset must not exceed the value tumbles!

"Vrmax"

as the workpiece

Version 1.0.3 dated 2014-5-14Page 50 Original operating instructions

Page 51

OPTIMUM

150

240

-------------- -

1 875mm==

max

150

-------- -

3mm==

MASCHINEN - GERMANY

Example: Kv = 1 : 40 ; Lw = 150 mm ; L = 100 mm

Img.6-43: Workpiece between points: Tailstock offset Vr

6.11 Cutting materials

The basic requirement for a cutting material is that it is harder than the material which is to be worked. The larger the difference is, the higher the wear resistance of the cutting material.

High-speed steel (HSS)

High-speed steel is a high-alloy tool steel with high tenacity. The cutting edges may be ground sharp-edged and the tools may be used with low cutting speed.

Hard metal (uncoated and coated)

Hard metal is a sintered material on the basis of tungsten carbide which may be applied for almost all materials which are to be chipped due to the different composition. There are some more wear-resistant types of hard metal and others with a higher tenacity.

The hard metals are divided into three main groups: P - for long-chipping materials (steel, meltable cast iron) M - for long- and short-chipping material (stainless steel, machining steel) K - for short-chipping materials (castiron, NE metals, hardened steel) An additional classification is performed with an annexed figure: The lower the figure (P10), the higher is the wear resistance (planing) The higher the figure (P40), the higher the tenacity (roughing). In order to make hard metals more wear resistant, they may be coated with mechanically resist-

ant materials. These layers may be applied as single or multiple-layer coatings. There are two procedures:

 PVD / Physical Vapor Deposition,  CVD / Chemikal Vapor Deposition.

The most common layers of mechanically resistant materials are:

 TiN / titanium nitride,  TiC / titanium carbide,  TiCN / titanium carbon nitride,  Al

as well as their combinations The PVD-coated indexable inserts have sharper cutting edges and thus lower cutting forces. Al-

so well appropriate for small lathes.

/ aluminium oxide,

2O3

Version 1.0.3 dated 2014-5-14 Page 51Original operating instructions

Page 52

OPTIMUM

Vc 1000

d314

-------------------------

MASCHINEN - GERMANY

Cermet (uncoated and coated)

Cermet (ceramic-metal) is a hard metal on the basis of titanium carbide. The cutting material has very good wear resistance and edge strength. Indexable inserts made of Cermet are used with high cutting speeds for planing.

Cutting ceramics

Cutting ceramics is composed of non-metalic anorganic material. Oxide ceramics on the basis of aluminium oxide and an addition of zircon. The main applica-

tion is the machining of cast iron. Mixed ceramics made of aluminium oxide an addition of titanium carbide has good a wear´r-

esistance on the edge strength. This cutting material is applied in the machining of chill casting. Non-oxide ceramics on the basis of silicon nitride is insensible against thermal shock (it may be

used with coolants). Non-alloy cast iron is chipped.

Cubic boron nitride (CBN)

Cubic boron nitride has a high tenacity and a good high temperature strength. It is appropriate for the planing of hardened materials.

Polycrystalline diamond (PKD)

Polycrystalline diamond has a good wear resistance. Good surface qualities with stable cutting conditions are being achieved. Fields of application are non ferrous and non-metallic materials in the finishing.

For other application references please refer to the documents of the tools’ manufacturer.

6.12 Standard values for cutting data when turning

The better the cutting data are selected, the better the turning result. Some standard values for cutting speeds of different materials are listed on the following pages.

 "Cutting speed table“ on page 53

Criteria of the cutting conditions:

Cutting speed: Vc (m/min) Depth of cut: ap (mm) Infeed: f (mm/rev)

Cutting speed:

In order to get the speed for the machine settings of the selected cutting speeds the following formula is to be applied:

Speed: n (1/min) Workpiece diameter: d (mm) For lathes without continuously adjustable drive (V-belt drive, speed gear) the nearest speed is

being selected.

Depth of cut:

In order to achieve a good chipping, the results of the depth of cut divided by the infeed shall result in a figure between 4 and 10.

Example: ap = 1.0mm; f = 0.14mm/U ; and this equals to in a value of 7.1 !

Version 1.0.3 dated 2014-5-14Page 52 Original operating instructions

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OPTIMUM

MASCHINEN - GERMANY

Infeed

The infeed for roughing/turning is to be selected in a way that it does not exceed buff the value of the corner radius.

Example: r = 0.4mm ; equals to fmax. = 0.2 mm/rev ! For planing/turning the infeed should be maximum 1/3 of the corner radius. Example: r = 0.4mm ; equals to fmax. = 0.12mm/rev !

6.13 Cutting speed table

Turning Drilling

Materials Cutting materials

P40HCK15

70 -

- 180

150 -

- 300

non-alloyed steel; steel casting;

C45; St37

HSS P10 P20 P40 K10

35 -

- 50

100 -

- 150

80 -

- 120

50 -

- 100

M15/

K10 90 -

- 180

HSS

30 -

- 40

low-alloy steel, steel casting;

42CrMo4; 100Cr6

high-alloyed steel; steel casting;

X38CrMoV51;

S10-4-3-10

rust-resistant steel

X5CrNi1810;

X10CrNiMoTi12

grey cast iron

GG10 ; GG40

cast iron with nodular graphite

GGG35 ; GGG70

copper, brass

aluminium alloys

Description of the coated hard metals: HC P40 = a PVD - coating TiAlN HC K15 = a CVD - coating TiN-Al

2O3

HC M15/K10 = CVD - coating TiAiN

20 -

- 35

10 -

- 20

15 -

- 40 10 -

- 25 40 -

- 90 40 -

- 100

80 -

- 120

70 -

- 110

- TiCN - TiN

60 -

- 100

50 -

- 90

40 -

- 80

30 -

- 80

40 -

- 190 25 -

- 120 60 -

- 180 80 -

- 200

70 -

- 160

60 -

- 130

120 -

- 250

80 -

- 220

90 -

- 200 80 -

- 180 90 -

- 300

100 -

- 400

80 -

- 160

70 -

- 140

50 -

- 140

70 -

- 150 60 -

- 130 60 -

- 150 80 -

- 200

20 -

- 30

8 -

- 15

10 -

- 15

20 -

- 30 15 -

- 25 30 -

- 80 40 -

- 80

6.14 Grinding or regrinding of cutting edge geometries of turning tools

This affects all cutters made of high-speed steel (HSS) and tools with carbide tipped tools soldered on according to DIN 4971 - 4977 and 4980 - 4981.

The soldering steels may be used with the delivered edge polished section. But this is not the optimum cutting edge geometry for all applications.

The HSS-square turned piece DIN 4964 type B are without a polished section, they are to be ground before they are first used.

Special fused alumina for HSS and silicone carbide or diamonds for hard metal may be used as grinding medium.

Version 1.0.3 dated 2014-5-14 Page 53Original operating instructions

Page 54

OPTIMUM

Tool

Workpiece

Cutting direction

Wedge

Clearance surface

Chip thickness Chip surface





Chip surface



Chip angle Positive





positive clearance angle

Clearance surface

Chip surface



Chip angle negative





positive clearance angle

Clearance surface

MASCHINEN - GERMANY

6.14.1 Terms for the rotating tool

Img.6-44: Geometrically

determined cutter for the separation process

Img.6-46: Cut A - A, posi-

tive cutter

Wedge angle 

Img.6-45: Cut and chip size

Img.6-47: Cut A - A, nega-

tive cutter

The following factors influence the

chip break when turning Chip angle  Setting angle  Clearance angle  Corner radius r Clearance angle minor cutting edge



Setting angle  Cutting speed:

Cutting edge geometry

In most cases the setting angle is depending on the work piece. A setting angle of 45° to 75° is suitable for roughing. setting angle of 90° to 95° (no tendency to chattering) is suitable for planing.

The corner angle serves as passing from the major cutting edge to the minor cutting edge. Together with the infeed it determines the surface quality. The corner radius must not be selected too large as this might result in vibrations.

Setting angle minor cutting edge  Point angle

Depth of cut: Infeed

ap (mm)

f (mm/U)

Depth of cut: ap

Infeed



Version 1.0.3 dated 2014-5-14Page 54 Original operating instructions

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6.14.2 Cutting edge geometry for turning tools





High-speed steel Hard metal

OPTIMUM

MASCHINEN - GERMANY

Clearance

angle

Steel +5° to +7° +5° to +6° +5° to +11° +5° to +7°

Cast non +5° to +7° +5° to +6° +5° to +11° +5° to +7°

non-ferrous metal +5° to +7° +6° to +12° +5° to +11° +5° to +12°

aluminium alloys +5° to +7° +6° to +24° +5° to +11° +5° to +24°

Chip angle

Clearance

angle

Chip angle

6.14.3 Types of cutting form levels

They are needed to influence the chip drain and the chip shape in order to achieve optimum chipping conditions.

Examples of types of cutting form levels

Img.6-48: Cutting form level Img.6-49: Cutting form level

with fillet

b = 1.0 mm to 2.2 mm

t = 0.4 mm to 0.5 mm For infeeds of 0.05 to 0.5mm/U and depths of cut of 0.2mm to 3.0mm. The different apex angles ( of the cutting form level need to conduct the chip.

Img.6-50: Positive apex

angle for planing

b = 2.2mm with fillet

Img.6-51: Neutral apex

angle for planing and roughing

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10°







2°

MASCHINEN - GERMANY

Img.6-52: Negative apex angle for roughing

The ready-ground major cutting edge must be slightly ground with a grindstone for the planing.

For the roughing, a small chamfer must be produced with the grindstone in order to stabilize the cutting edge against striking chips (b

= f x 0.8).

Img.6-53: Stabilize cutting edge

Polished section for recessing and cutting off

(for chip angle refer to table)

Img.6-54: Polished section recessing and cutting off

Polished section for threading

The point angle or the shape for chasing tools is depending on the type of thread. Also refer to:

  "Thread types“ on page 39   "Pitch angle“ on page 44

The measure X must be larger than the depth of thread. Make save that no chip angle is being ground as in this case there would be a strain of the profile.

Version 1.0.3 dated 2014-5-14Page 56 Original operating instructions

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

MASCHINEN - GERMANY

Img.6-55: Polished section for threading

6.15 Lifetime and wear characteristics

In the chipping shaping by lifetime we understand the time which the cutting edge survives (pure contact time).

The causes for the end of the lifetimes may be the following:

 dimensional deviation  too high cutting pressure  bad surface quality  high burr formation for tool exit

The wear of clearance surface V common type of tool wear. They are mainly formed by friction. The clearance surface wear has effects on the dimensional accuracy of the workpieces and on the cutting force (the cuttingforce increases by 10% for each 0,1mm V criteria.

Crackings on the cutting edge may be caused by casting crusts or forging skins. Another cause may be ridge cracks (cracks transversal to the edge). Which are caused by thermal and mechanical shock loads such as interrupted cuts or short contact times for very hard cutting materials.

The cutting edge crack may be caused by selecting a too rough cutting material or by wrong selection for cutting data.

If a thermal excessive strain of the cutting material is existing, there would be a plastic deformation on the cutter.

and the crater wear KT on the chipping surface is the most

). The clearance wear is generally used as lifetime

Img.6-56: Clearance sur-

face wear

Img.6-57: Crater wear

Version 1.0.3 dated 2014-5-14 Page 57Original operating instructions

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7 Maintenance

In this chapter you will find important information about

 Inspection  Maintenance  Repair

of the lathe.

ATTENTION ! Properly performed regular maintenance is an essential prerequisite for

 operational safety,  failure-free operation,  long durability of the lathe and  the quality of the products which you manufacture.

Installations and equipment from other manufacturers must also be in good order and condition.

7.1 Safety

WARNING! The consequences of incorrect maintenance and repair work may include:

 Very serious injury to personnel working on the lathe,  Damage to the lathe.

Only qualified personnel should carry out maintenance and repair work on the lathe.

7.2 Inspection and maintenance

The type and level of wear depends to a large extent on the individual usage and operating conditions. For this reason, all the intervals are only valid for the authorised conditions.

Interval Where? What? How?

 Lubricate all bright steel parts with non-corrosive

lubricating oil.

Lubricate

Machine bed

every week

 "Operating material“ on page 16

 Check that the fastening screws of the change

gears on the quadrant and the fastening screws of

Testing

Spindle stock

the V-belt pulleys are firmly tightened.

TU1503VGB

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Lubricating nipple

Readjusting gibs

MASCHINEN - GERMANY

Interval Where? What? How?

 Grease the leadscrew on the lubricating nipple.

Every month

every six months

as required

Lubricating

Spindle stock

Visual inspection

Readjusting

Lathe saddle

Img.7-1: Feed gear

 Control if the synchronous belts are porous or

worn.

 Readjust the slideway clearance of the cross and

8 Ersatzteile - Spare parts

8.1 Ersatzteilzeichnung Antrieb - Drawing spare parts actuation

TU1503V DE | GB

Abb.8-1: Antrieb - Actuation

MASCHINEN - GERMANY

OPTIMUM

Page 62

8.2 Ersatzteilzeichnung Spindelstock - Drawing spare parts headstock

TU1503VDE | GB

MASCHINEN - GERMANY

OPTIMUM

Version 1.0.3 2014-05-1462 Original operating instructions

Abb.8-2: Spindelstock - Headstock

Page 63

Version 1.0.3 2014-05-14 63Original operating instructions

8.3 Ersatzteilzeichnung Abdeckungen - Drawing spare parts covers

TU1503V DE | GB

Abb.8-3: Abdeckungen - Covers

MASCHINEN - GERMANY

OPTIMUM

Page 64

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8.3.1 Ersatzteilliste Antrieb, Spindestock - Spare parts list actuation, headstock

Menge Grösse Artikelnummer

Bezeichnung Designation

Pos.

3 Sicherungsring Retaining ring 2 DIN 471 - 8x0,8 4 Kugellager Ball bearing 2 698-2Z 040698.Z 5 Keilriemenscheibe V-belt pulley 1 0342025105

6 Feste Welle Fix shaft 1 14 Gewindestift Grub screw 1 GB 79-85 - M5 x 8 0342025107 15 Motorscheibe Motor pulley 1 0342025115 16 Spindel Spindle 1 0342025116 17 Kugellager Ball bearing 2 6003-2Z 0406003.2R 18 Spindelstock Head stock 1 0342025118 19 Innensechskantschraube Socket head screw 4 GB 70-85 - M5 x 40 23 Grundplatte Support plate 1 0342025123 24 Innensechskantschraube Socket head screw 4 GB 70-85 - M5 x 10 26 Kugellager Ball bearing 4 626-2Z 040626 27 Buchse Bushing 2 0342025127 28 Spannrolle Tension pulley 2 0342025128 29 Innensechskantschraube Socket head screw 1 GB 70-85 - M5 x 40 33 Sechskantmutter Hexagon nut 1 0342025133 34 Keilriemenscheibe V-belt pulley 1 0342025134 35 Abstandshülse Spacer 1 0342025135 37 Klemmmuter Klamping nut 2 0342025137 38 Keilriemen V-Belt 1 03912060 41 Sicherungsring Retaining ring 1 DIN 472 - 19 x 1 42 Buchse Bushing 1 0342025142 43 Scheibe Washer 1 DIN 125 - A 6,4 47 Buchse Bushing 1 0342025147 48 Schraube Screw 4 ISO 7046-M4 x 6 49 Scheibe Washer 4 DIN 125 - A 5,3 50 Sechskantmutter Hexagon nut 1 ISO 4032 - M6 53 Innensechskantschraube Socket head screw 4 GB 70-85 - M4 x 14 54 Sechskantmutter Hexagon nut 3 ISO 4032 - M6 55 Flansch Flange 1 0342025155 56 Gewindebolzen Thread bolt 3 57 Dreibackenfutter 3-jaw chuck 1 3440287 59 Keilriemen V-Belt 1 0342025159 60 Zahnrad Gear belt 1 Z=16 03420251519 61 Gewindestift Grub screw 1 DIN 4026/M4x4 62 Zahnriemen Gear belt 1 0391265 72 Sicherungsgehäuse Fuse housing 2 0342025172 76 Spänewanne Chip pan 1 0342025176

Quantity

Size Article no.

101 Steuerplatine Control card 1 03420260101 102 Not-Aus-Schalter Emer gehcy stip button 1 03420260102 103 Drehrichtungsschalter Change over switch 1 03420260103 104 Skala Scale 1 03420260104 105 Knopf Knob 1 03420260105 106 Gewindestift Grub pin 1 03420260106 107 Platte Plate 1 03420260107 108 Schutzglas Safety glass 1 03420260108 109 Drehfutterschutz Lathe chuck safety 1 03420260109

110 Welle Shaft 1 03420260110 111 Gehäuse Housing 1 03420260111 112 Sicherung Fuse 1 03420260112 113 Sicherheitsschalter Safety switch 1 03420260113 114 Netzfilter Line filter 1 03420260114 115 Abdeckung Cover 1 03420260115 116 Halter Holder 1 03420260116 117 Riemenabdeckung Belt cover 1 03420260117 118 Abdeckung Cover 1 03420260118

119 Wechselradtabelle Change wheel table 1 03420260119 120 Spritzwand Dash panel 1 03420260120 121 Motor Motor 1 03420260121 122 Maschinenlabel Machine label 1 03420260122

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8.4 Ersatzteilzeichnung Planschlitten, Oberschlitten- Drawing spare parts cross slide, top slide

TU1503V DE | GB

Abb.8-4: Planschlitten, Oberschlitten - Cross slide, top slide

MASCHINEN - GERMANY

OPTIMUM

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MASCHINEN - GERMANY

8.4.1 Ersatzteile Planschlitten, Oberschlitten - Spare parts list cross slide, top slide

Menge Grösse Artikelnummer

Bezeichnung Designation

Pos.

201 Werkzeughalter Tool rest 1 03420251201 202 Innensechskantschraube Socket head screw 3 GB 70-85 - M6 x 20 203 Sechskantmutter Hexagon nut 5 ISO 4032 - M3 204 Gewindestift Grub screw 2 GB 78-85 - M3 x 8 205 Innensechskantschraube Socket head screw 2 GB 70-85 - M3 x 10 206 Spindel Top lead screw 1 03420251206 207 Innensechskantschraube Socket head screw 1 GB 70-85 - M6 x 14 208 Oberschlitten Top slide 1 03420251208 209 Keilleiste Gib 1 03420251209 210 Skalenring Scale ring 1 03420251210

211 Handrad Handwheel 1 03420251211 212 Hutmutter Cap nut 2 GB 923-88 - M6 213 Spindelmutter Feeding nut 1 03420251213 214 Hülse Sleeve 1 03420251214 215 Schraube Screw 1 03420251215 216 Spindel Feeding lead screw 1 03420251216 218 Planschlitten Cross slide 1 03420251218 219 Klemmplate Clamping plate 1 03420251219 220 Gewindestift Grub screw 5 GB 80-85 - M5 x 8 222 Schraube Screw 1 03420251222 223 Hülse Sleeve 1 03420251223 225 Handrad Hand wheel 1 03420251225 226 Skalenring Scale ring 1 03420251226 227 Keilleiste Gib 1 03420251227 229 Abdeckung Cover 1 03420251229 230 Innensechskantschraube Socket head screw 1 GB 70-85 - M3 x 8 231 Vierkantmutter 4-side nut 1 03420251231 232 Innensechskantschraube Socket head screw 1 GB 70-85 - M4 x 8 233 Planschlitten Cross slide 1 03420251233 234 Gewindestift Grub screw 1 GB 78-85 - M5 x 10 236 Innensechskantschraube Socket head screw 3 GB 70-85 - M3 x 14 238 Skala Scale 1 03420251238 239 Niet Rivet 4 240 Halter Holder 1 03420251240 241 Innensechskantschraube Socket head screw 2 GB 70-85 - M4 x 12 242 Feder Spring 03420251242 243 Scala Scale 1 03420251243 244 Gewindestift Grub screw 1 GB 80-85 - M6 x 6 245 Buchse Bushing 1 03420251245 226 Skalenring Scale ring 1 03420251226 227 Keilleiste Gib 1 03420251227 229 Abdeckung Cover 1 03420251229 230 Innensechskantschraube Socket head screw 1 GB 70-85 - M3 x 8 231 Vierkantmutter 4-side nut 1 03420251231 232 Innensechskantschraube Socket head screw 1 GB 70-85 - M4 x 8 233 Planschlitten Cross slide 1 03420251233 234 Gewindestift Grub screw 1 GB 78-85 - M5 x 10 236 Innensechskantschraube Socket head screw 3 GB 70-85 - M3 x 14 238 Skala Scale 1 03420251238 239 Niet Rivet 4 240 Halter Holder 1 03420251240 241 Innensechskantschraube Socket head screw 2 GB 70-85 - M4 x 12 242 Feder Spring 03420251242 243 Scala Scale 1 03420251243 244 Gewindestift Grub screw 1 GB 80-85 - M6 x 6 245 Buchse Bushing 1 03420251245

Quantity

Size Article no.

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Version 1.0.3 2014-05-14 67Original operating instructions

8.5 Ersatzteilzeichnung Maschinenbett - Drawing spare parts machine bed

TU1503V DE | GB

Abb.8-5: Maschinenbett - Machine bed

MASCHINEN - GERMANY

OPTIMUM

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8.5.1 Ersatzteile Maschinenbett - Spare parts list machine bed

Menge Grösse Artikelnummer

Bezeichnung Designation

Pos.

301 Maschinenbett Machine bed 1 03420251301 302 Gewindestift Grub screw 3 GB 80-85 - M5 x 6 303 Buchse Bushing 1 03420251303 304 Skalenring Scale ring 1 03420251304 305 Handrad Handwheel 1 03420251305 306 Hülse Sleeve 1 03420251306 307 Schraube Screw 1 03420251307 308 Hutmuter Cap nut 1 GB 923-88 - M6 309 Leitspindel Lead spindle 1 03420251309 310 Zylinderstift Straight pin 1 GB 879-86 - 3 x 10

311 Kupplung Clutch 1 03420251311 312 Drehknopf Knob 1 03420251312 313 Gewindestift Grub screw 1 GB 80-85 - M4 x 6 314 Welle Shaft 1 03420251314 315 Zylinderstift Straight pin 1 GB 119-86 - 2 x 6 316 Innensechskantschraube Socket head screw 2 GB 70-85 - M5 x 25 317 Stahlkugel Steel ball 1 03420251317 318 Gewindestift Grub screw 1 GB 80-85 - M6 x 6 319 Feder Spring 1 03420251319 320 Gewindestift Grub screw 1 GB 79-85 - M5 x 6 321 Halter links Left support 1 03420251321 322 Verbindung Connector 1 03420251322 323 Gewindestift Grub screw 1 GB 80-85 - M5 x 6 324 Welle Shaft 1 03420251324 325 Schmiernippel Lubrication cup 1 03420251325 326 Flansch Flange 1 03420251531 327 Innensechskantschraube Socket head screw 1 GB 70-85 - M5 x 12 328 Gewindestift Grub screw 1 GB 80-85 - M4 x 6 329 Zahnrad Gear 1 Z=20 03420251505 329 Zahnrad Gear 1 Z=40 03420251506 330 Skala Scale 1 03420251331 331 Niet Rivet 2 03420251332

Quantity

Size Article no.

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8.6 Ersatzteilzeichnung Reitstock - Drawing spare parts tailstock

TU1503V DE | GB

Abb.8-6: Reitstock - Tailstock

MASCHINEN - GERMANY

OPTIMUM

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8.6.1 Ersatzteile Reitstock - Spare parts tailstock

Menge Grösse Artikelnummer

Bezeichnung Designation

Pos.

401 Zentrierspitze Dead center 1 03420251401 402 Pinole Pinole 1 03420251402 403 Innensechskantschraube Socket head screw 1 GB 70-85 - M6 x 35 404 Gewindestift Grub screw 1 GB 80-85 - M4 x 6 405 Innensechskantschraube Socket head screw 1 GB 70-85 - M6 x 14 406 Gewindestift Grub screw 1 ISO 4027 - M4 x 8 407 Spindel Spindle 1 03420251407 408 Buchse Bushing 1 03420251408 409 Skalenring Skale ring 1 03420251409 410 Handrad Handwheel 1 03420251410

411 Hülse Sleeve 1 03420251411 412 Schraube Screw 1 03420251412 413 Hutmutter Cap screw 1 GB 923-88 - M6 414 Feder Spring 1 03420251414 415 Klemmplate Clamping plate 1 03420251415 416 Gehäuse Reitstock Tailstock body 1 03420251416 417 Niet River 2 03420251417 418 Skala Scale 1 03420251418

Reitstock komplett Tailstock complete 03420251416CPL

Quantity

Size Article no.

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8.7 Ersatzteilzeichnung Wechselradgetriebe - Drawing spare parts change gear

TU1503V DE | GB

Abb.8-7: Wechselradgetriebe - Change gear

MASCHINEN - GERMANY

OPTIMUM

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8.7.1 Ersatzteile Wechselradgetriebe - Spare parts change gear

Menge Grösse Artikelnummer

Bezeichnung Designation

Pos.

503 Führungsplatte Support plate 1 03420251503 507 Sechskantschraube Socket head screw 3 GB 6170-86 - M5 508 Zahnrad Gear 1 Z=17 03420251508 509 Schraube Screw 1 03420251509 510 Scheibe Washer 1 03420251510

511 Innensechskantschraube Socket head screw 1 GB 70-85 - M5 x 35 512 Zahnrad Gear 1 Z=16/64 03420251512 513 Scheibe Washer 2 DIN 125 - A 5,3 520 Zahnrad Gear 1 Z=30 03420251520 521 Zahnrad Gear 1 Z=28 03420251521 522 Zahnrad Gear 1 Z=25 03420251522 523 Zahnrad Gear 1 Z=20 03420251523 524 Zahnrad Gear 1 Z=32 03420251524 525 Buchse Bushing 1 03420251525 528 Innensechskantschraube Socket head screw 1 GB 70-85 - M5 x 30 529 Schraube Screw 2 ISO 7046-M4 x 6 530 Zahnrad Gear 1 Z=30/16 03420251530 531 Buchse Bushing 1 03420251531

Zubehör komplett Accessory box cpl. 0341438

Quantity

Size Article no.

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8.8 Maschinenschilder - Machine labels

OPTIMUM

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Abb.8-8: Maschinenschilder - Machine labels

8.8.1 Maschinenschilder - Machine labels

Menge Grösse Artikelnummer

Pos.

1 Sicherheitsschild Safety label 1 03420251L01 2 Frontschild Front label 1 03420251L02 4 Sicherheitsschild Safety label 1 03420251L04 5 Sicherheitsschild Safety label 1 03420251L05 6 Hinweisschild Instruction label 1 03420251L06 7 Gewindeschneidtabelle Tapping table 1 03420251L07

Bezeichnung Designation

Quan-

tity

Size Article no.

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Page 74

8.9 Schaltplan - Wiring diagram

TU1503VDE | GB

MASCHINEN - GERMANY

OPTIMUM

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Abb.8-9: Schaltplan - Wiring diagram

Page 75

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MASCHINEN - GERMANY

8.9.1 Ersatzteile elektrische Bauteile - Spare parts electrical components

Menge Grösse Artikelnummer

Pos.

1F1 Sicherung Fuse 1 034202601F1 1S1 Ein-Aus-Schalter On-Off switch 1 034202601S1 1Z1 Netzfilter Line filter 1 034202601Z1 1A2 Steuerplatine Control board 1 034202601A2 1R4 Potentiometer Potentiometer 1 034202601R4 1S4 Drehrichtungsschalter Change over switch 1 034202601S4

1M4 Motor Motor 1 034202601M4

1S6 Not-Aus-Schalter Emergency stop button 1 034202601S6

1B6.2

1B6.1

Bezeichnung Designation

Sicherheitsschalter Riemenabdekkung

Sicherheitsschalter Drehfut-

terschutz

Belt cover safety switch 1 034202601B6.2

Drill chuck safety switch 1 034202601B6.1

Quan-

tity

Size Art icl e no .

Version 1.0.3 2014-05-14 75Original operating instructions

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9 Malfunctions

9.1 Malfunctions on the lathe

Malfunction

Surface of workpiece too rough

Workpiece becomes conical

Lathe is chattering

Center runs hot Tool has a short edge life

Flank wear too high

Cause/

possible effects

• Tool blunt

• Tool springs

• Feed too high

• Radius at the tool tip too small

• Top slide is not exactly set to zero (when turning with the top slide)

• Feed too high

• Main bearings have clearance

• Workpiece has expanded • Loosen tailstock center

• Hard casting skin

• Cutting speed to high

• Crossfeed to high

• Insufficient cooling

• Clearance angle too small (tool "pushes")

• Tool tip not adjusted to center height

• Resharpen tool

• Clamp tool with less overhang

• Reduce feed

• Increase radius

• Set top slide to exact zero position

• Reduce feed

• Have the main bearings readjusted

• First break casting skin

• Reduce cutting speed

• Lower crossfeed (smooth finish allowance not over 0,5 mm)

• More coolant

• Increase clearance angle

• Correct height adjustment of the tool

Solution

Cutting edge breaks off

Cut thread is wrong

• Wedge angle too small (heat buildup)

• Grinding cracks due to wrong cooling

• Excessive clearance in the spindle bearing arrangement (vibrations)

• Tool is clamped incorrectly or has been started grinding the wrong way

• Wrong pitch

• Wrong diameter

• Increase wedge angle

• Cool uniformly

• Have the clearance in the spindle bearing arrangement readjusted. If necessary, replace the tapered roller bearings.

• Adjust tool to the center

• Grind angle correctly

• Adjust right pitch

• Turn the workpiece to the correct diameter

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10 Appendix

10.1 Copyright

This document is copyright. All derived rights are also reserved, especially those of translation, re-printing, use of figu res, broadcast, reproduction by photo-mechanical or similar means and recording in data processing systems, neither partial nor total.

Subject to technical changes without notice.

10.2 Terminology/Glossary

Term Explanation

Spindle stock Housing for the feed gear and the synchronous belt pulleys. Lathe chuck Clamping tool for holding the workpiece. Drill chuck Drill bit chuck Lathe saddle Slide on the slideway of the machine bed which feeds parallel to the tool

axis. Cross slide Slide on the lathe saddle which moves transversely to the tool axis. Top slide Swivelling slide on the cross slide. Taper mandrel Taper of the bid, the drill chuck or the center. Tool Cutting tool, bit, etc. Workpiece Piece to be turned or machined. Tailstock Movable turning aid. Rest Follow or steady support for turning long workpieces. Lathe dog Device or clamping aid for driving pieces to be turned between centers.

10.3 Change information operating manual

Chapter Short note new version number

5.2 Control an d indicating elements 1.0.1 EC declaration changed standard 1.0.2

Version 1.0.3 dated 2014-05-14 Page 77Original operating instructions

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10.4 Liability claims for defects / warranty

Beside the legal liability claims for defects of the customer towards the seller the manufacturer of the product, OPTIMUM GmbH, Robert-Pfleger-Straße 26, D-96103 Hallstadt, does not grant any further warranties unless they are listed below or had been promised in the frame of a single contractual agreement.

 The processing of the liability claims or of the warranty is performed as chosen by

OPTIMUM GmbH either directly or through one of its dealers. Any defective products or components of such products will either be repaired or replaced by components which are free from defects. The property of replaced products or components passes on to OPTIMUM Maschinen Germany GmbH.

 The automatically generated original proof of purchase which shows the date of purchase,

the type of machine and the serial number, if applicable, is the precondition in order to assert liability or warranty claims. If the original proof of purchase is not presented, we are not able to perform any services.

 Defects resulting of the following circumstances are excluded from liability and warranty

claims:

- Using the product beyond the technical options and proper use, in particular due to overstraining of the machine.

- Any defects arising by one's own fault due to faulty operations or if the operating manual is disregarded.

- Inattentive or incorrect handling and use of improper equipment.

- Non-authorized modifications and repairs.

- Insufficient installation and safeguarding of the machine

- Disregarding the installation requirements and conditions of use.

- Atmospheric discharges, overvoltage and lightning strokes as well as chemical influences.

 The following items are as well not subject to the liability or warranty claims:

- Wearing parts and components which are subject to a standard wear as intended such as e.g. V-belts, ball bearings, illuminants, filters, sealings, etc.

- Non reproducible software errors

 Any services which OPTIMUM GmbH or one of its agents performs in order to fulfill in the

frame of an additional guarantee are neither an acceptance of the defects nor an acceptance of its obligation to compensate. Such services do neither delay nor interrupt the warranty period.

 Place of jurisdiction amo ng traders is Bamberg.  If one of the abo ve mentioned agreeme nts is totally or partially inefficient an d/or null, it is

considered as agreed what is closest to the will of the warrantor and which remains in the framework of the limits of liability and warranty which are predefined by this contract.

10.5 Note regarding disposal / options to reuse:

Please dispose of your device environmentally friendly by disposing of scrap in a professional way.

Please neither throw away the packaging nor the used machine later on, but dispose of them according to the guidelines established by your city council/municipality or by the corresponding waste management enterprise.

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10.5.1 Decommissioning

CAUTION! Used devices need to be decommissioned in a professional way in order to avoid later

misuses and endangerment of the environment or persons.

 Pull off the mains plug.  Cut the connection cable.  Remove all environmentally hazardous operating fluids from the used device.  If applicable remove batteries and accumulators.  Disassemble the machine if required into easy-to-handle and reusable assemblies

and component parts.

 Supply the machine components and operating fluids to the provided disposal

routes.

10.5.2 Disposal of the packaging of new devices

All used packaging materials and packaging aids of the machine are recyclable and generally need to be supplied to the material reuse.

The packaging wood can be supplied to the disposal or the reuse. Any packaging components made of cardboard box can be chopped up and supplied to the

waste paper collection. The films are made of polyethylene (PE) and the cu shion parts are made of polystyrene (PS).

These materials can be reused after reconditioning if they are forwarded to a collection station or to the appropriate waste management enterprise.

Only forward the packaging materials correctly sorted to allow a direct reuse.

10.5.3 Disposing of the old device

INFORMATION

Please take care in your interest and in the interest of the environment that all component parts of the machine are only disposed of in the intended and admitted way.

Please note that the electrical devices include lots of reusable materials as well as environmentally hazardous components. Account for separate and professional disposal of the component parts. In case of doubt, please contact your municipal waste management. If appropriate, call on the help of a specialist waste disposal company for the treatment of the material.

10.5.4 Disposal of electrical and electronic components

Please make sure that the electric al components are disposed of professionally and according to the legal regulations.

The device includes electric and electronic components and must not be disposed of with the rubbish. According to the European directive 2002/96/EG regarding electrical and electronic used devices and the execution of national rights used electrical tools and electrical machines need to be collected separately and be supplied to an environmen tally compatible reuse.

Being the machine operator you should obtain information regarding the authorized collection or disposal system which applies for your company.

Please make sure that the batteries and/or accumulators are disposed of in a professiona l way according to the legal regulations. Please only throw discharged batteries in the collection boxes in shops or at municipal waste management companies.

INFORMATION

Used coolant emulsions and oils should not be mixed up since it is only possible to reuse used oils which had not been mixed up without pre-treatment.

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The disposal notes for the used lubr icants are made available by the manufacturer of the lubricants. If necessary, request the product-specific data sheets.

10.6 Disposal via municipal collection

Disposal of used electrical and electro nic com pone n ts (Applicable in the countries of the European Union and other European countries with a separate collecting system for those devices).

The sign on the product or on its packing indicates that the product must not be handles as common household waist, but that is needs to be delivered to a central collection point for recycling. Your contribution to the correct disposal of this product will protect the environment and the health of your fellow men. The environment and the health are endangered by incorrect disposal. Recycling of material will help to reduce the consumption of raw materials. Your District Office, the municipal waste collectio n station or the shop where you have bought the product will inform you about the recycling of this product.

10.7 RoHS, 2002/95/EC

The sign on the product or on its packing indica te s tha t this pr od uc t c omp lies with the European guideline 2002/95/EC.

10.8 Product follow-up

We are required to perform a follow-up service for our products which extends beyond shipment.

We would be grateful if you could send us the following information:

 Modified settings  Any experiences with the lathe which might be important for other users  Recurring failures

Optimum Maschinen Germany GmbH Dr.-Robert-Pfleger-Str. 26

D-96103 Hallstadt Fax +49 (0) 951 - 96 555 - 888

Email: info@optimum-maschinen.de

TU1503VGB

Version 1.0.3 dated 2014-05-14Page 80 Original operating instructions

Page 81

EC - declaration of conformity

Hallstadt, 2014-05-12

Kilian Stürmer

(CEO, General manager)

Machinery Directive 2006/42/EC Annex II 1.A

OPTIMUM

MASCHINEN - GERMANY

The manufacturer / retailer:

hereby declares that the following product, Product designation: Lathe Designation of the machine: TU1503V Serial number: _ __ __ __ __ Year of manufacture: 20__

Manual geared drill for private persons as well as for craft and industrial plants which meets all the relevant provisions of the above mentioned Directive 2006/42/EC as well as the other directives applied (below) including their amendments in force at the time of declaration. The following other EU Directives have been applied: EMC Directive 2014/30/EC, Low Voltage Directive 2006/95/EC

The safety objective meet the requirement of EC Directive 2006/95/EC

The following harmonized standards were applied:

EN 1037:1995+A1:2008 Safety of machinery - Prevention of unexpected start-up EN 1088:1995+A2:2008 Safety of machinery - Interlocking devices associated with guards - Principles for

design and selection EN ISO 23125:2010 - Machine tools - Safety - Turning machines (ISO 23125:2010 + Amd. 1:2012) DIN EN 55011 2009/A1:2010 Industrial, scientific high frequency equipment - Radio-frequency disturbance

characteristics - Limits and methods of measurement EN 50581:2012 Technical documentation for the assessment of electrical and electronic products with

respect to the restriction of hazardous substances EN 60204-1:2006/AC: 2010 Safety of machinery - Electrical equipment of machines - Part 1: General

requirements (IEC 60204-1:2005 (modified)) EN ISO 12100:2010 Safety of machinery - General principles for design - Risk assessment and risk reduc-

tion (ISO 12100:2010) EN ISO 13857:2008 Safety of machinery - Safety distances to prevent hazard zones being reached by

upper and lower limbs

Optimum Maschinen Germany GmbH Dr.-Robert-Pfleger-Str. 26 D - 96103 Hallstadt

Responsible for documentation: Kilian Stürmer, phone: +49 (0) 951 96555 - 800 Address: Dr.-Robert-Pflege r-Str.26D - 96103 Hallstadt

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Index

Appendix turning .................................................. 33

Cone ..................................................................... 48

Control elements Cutting materials Cutting off Cutting speed

.................................................. 26

.................................................. 51

............................................................. 47

........................................................................ 52

Cutting speed table

.............................................. 53

Dimensions .......................................................... 16

Disposal

............................................................... 80

EC - declaration of conformity .............................. 81

Environmental conditions External threads

................................................... 38

..................................... 16

Facing and recessing ........................................... 29

Grinding of cutting edge geome trie s .................... 53

Hazards

Classification

..................................................... 7

Inch thread ........................................................... 42

Indexable inserts Internal threads

.................................................. 44

.................................................... 38

Lathe chuck key ............................................. 13, 14

Lathe chuck protection

......................................... 13

Machine data ........................................................ 16

Malfunctions Mechanical maintenance work Metric threads Misuse

......................................................... 76

............................. 15

...................................................... 41

.................................................................... 9

Obligations

of the operating company of the operator

Outside machining

................................................. 11

............................................... 37

............................... 11

Protective

equipment

Protective cover

of rotating chuck

....................................................... 14

................................................... 13

.............................................. 13

Qualification of the personnel

Safety

.............................................................. 10

Recessing ............................................................ 47

Safety

instructions

Scope of delivery

.........................................................7

..................................................19

Technical data

dimensions Emissions Environmental conditions

machine data Thread types Turning of cones Turning off Turning short tapers

.......................................................16

........................................................17

.................................16

...................................................16

.........................................................39

...................................................48

.............................................................47

..............................................29

Using lifting equipment .........................................15

Warming up the machine ......................................21

Warning notes

.........................................................7

TU1503VGB

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OPTIMUM L685 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of contents

1 Safety

2 Technical data

3 Unpacking and connecting

4 Assembly and function

5Handling

6 Appendix turning

7 Maintenance

8 Ersatzteile - Spare parts

9 Malfunctions

10 Appendix

Preface

1 Safety

2 Technical data

3 Unpacking and connecting

4 Assembly and function

5 Handling

6 Appendix turning

7 Maintenance

8 Ersatzteile - Spare parts

9 Malfunctions

10 Appendix

EC - declaration of conformity

Index