Walker Magnetics TURBOMILL 40B User Manual

OPERATOR'S MANUAL

AND

SAFETY INSTRUCTIONS

WITH INSPECTION AND MAINTENANCE INSTRUCTIONS

TURBOMILL 40B MAGNETIC MACHINING CHUCK SERIES

ELECTROPERM CHUCKS

O.S. WALKER

Rockdale Street, Worcester, MA 01606 (508)-853-3232 FAX (508)-852-8649

3508 Glenridge Drive, Chino Hills, CA 91709 (909)-597-4785 FAX (909)-597-0581

901 Arvin Avenue, Stoney Creek, Ontario, L8E5N9 Canada (905)-643-3338

In Canada: 1-800-267-4678 FAX (905)-643-6111

www.walkermagnet.com

Email: info@walkermagnet.com

Never attempt to operate this chuck until you have read and understand this OPERATOR’S MANUAL

O.S. WALKER Co. Inc., Turbomill Electroperm Chucks

DD15508M.doc Rev. ~, September 17, 2002

TABLE OF CONTENTS

1 INTRODUCTION...............................................................................................................................................................1-1

2 SAFETY INSTRUCTIONS................................................................................................................................................2-1

2.1 G

ENERAL SAFETY RULES

2.2 R

ECOGNIZE SAFETY INFORMATION

.............................................................................................................................................2-1

...............................................................................................................................2-2

2.2.1 Ways to Avoid a Reduction of Holding Capacity................................................................................................2-2

2.2.2 Additional Warnings ...........................................................................................................................................2-3

2.3 D

ESIGNATED PERSON

2.4 E

LECTRICAL GROUND

..................................................................................................................................................2-3

..................................................................................................................................................2-4

3 INSTALLATION INSTRUCTIONS FOR MOUNTING THE CHUCK................................................................................3-1

3.1 G

RINDING THE MOUNTING SURFACES OF RECTANGULAR CHUCKS

..................................................................................3-1

3.1.1 Connecting the Chuck........................................................................................................................................3-2

4 OPERATING INSTRUCTIONS.........................................................................................................................................4-1

4.1 S

YSTEM OPERATION

4.2 I

MPORTANT FACTS ABOUT MAGNETIC HOLDING

4.3 S

URFACE CONDITIONS

....................................................................................................................................................4-1

.............................................................................................................4-1

.................................................................................................................................................4-1

4.3.1 Magnetic Chuck Surface Condition....................................................................................................................4-1

4.3.2 Workpiece Surface Condition.............................................................................................................................4-2

4.3.3 Workpiece Thickness .........................................................................................................................................4-2

4.3.4 Portion of the Chuck Surface In Contact With the Workpiece ...........................................................................4-2

4.3.5 Workpiece Material.............................................................................................................................................4-2

4.4 G

UIDELINES FOR THE REDUCTION OF RATED HOLDING CAPACITY

4.5 T

HE BASICS OF MAGNETIC ATTRACTION

........................................................................................................................4-3

...................................................................................4-3

4.5.1 Principles of Magnetic Work Holding..................................................................................................................4-4

4.6 F

ORCES GENERATED BY MILLING

.................................................................................................................................4-5

4.6.1 Conventional Milling ...........................................................................................................................................4-5

4.6.2 Climb Milling.......................................................................................................................................................4-6

4.6.3 Face Milling ........................................................................................................................................................4-7

4.6.4 Edge Milling........................................................................................................................................................4-8

4.7 W

ORKPIECE BLOCKING

4.8 M

ILD STEEL POLE RISER

.................................................................................................................................................4-9

............................................................................................................................................4-12

4.8.1 How to Use Riser Blocks..................................................................................................................................4-13

5 INSPECTION AND MAINTENANCE INSTRUCTIONS ...................................................................................................5-1

5.1 D

AILY INSPECTION

5.2 R

EPLACEMENT PARTS LIST

.......................................................................................................................................................5-1

...........................................................................................................................................5-1

6 RETURN AND REPAIR INSTRUCTIONS........................................................................................................................6-1

O.S. WALKER Co. Inc., Turbomill Electroperm Chucks

DD15508M.doc Rev. ~, September 17, 2002

IGURE

4-1 B

ASIC MAGNETICS

4-2 M

AGNETIC ATTRACTION

4-3 C

ONVENTIONAL MILLING

4-4 C

LIMB MILLING

4-5 F

ACE MILLING

4-6 E

DGE MILLING

4-7 B

LOCKING

4-8 B

LOCKING

4-9 B

LOCKING

4-10 F

IXED RISER

4-11 F

IXED RISER

4-12 A

DJUSTABLE RISER

4-13 S

LIDING

4-14 R

ISER ORIENTATION

............................................................................................................................................................4-9

..........................................................................................................................................................4-10

..........................................................................................................................................................4-11

& F

TABLE OF FIGURES

...............................................................................................................................................4-3

.......................................................................................................................................4-4

.......................................................................................................................................4-5

.....................................................................................................................................................4-6

......................................................................................................................................................4-7

.....................................................................................................................................................4-8

....................................................................................................................................................4-12

..........................................................................................................................................4-12

IXED POLE RISERS

........................................................................................................................................4-13

.........................................................................................................................4-13

O.S. WALKER Co. Inc., Turbomill Electroperm Chucks

DD15508M.doc Rev. ~, September 17, 2002

1 INTRODUCTION

Thank you for purchasing this O. S. Walker, Inc. Chuck. If used and maintained properly, it should serve you for many years. However, if installed and used improperly it can be rendered inefficient and unsafe. Therefore, it is absolutely essential that anyone who uses this chuck and is responsible for its application be trained on how to use it correctly.

Read this manual carefully to learn how to operate and maintain your chuck. Failure to do so could result in serious injury, or even death, to yourself and others in the area.

This manual should be considered a permanent part of your chuck and should always be available to all operators and remain with the chuck if it is re-sold.

NOTE: Before using chuck, record this data from the *nameplate for future use in obtaining service.

MODEL NO._____________, PART NO._____________, SERIAL NO. __________

* information located on the terminal box end of the chuck body.

To request additional copies of this manual, call 1-800-962-4638 in the USA;

In Canada: 905-643-3338; In Europe: 31-4973-83835

O.S. WALKER Co. Inc., Turbomill Electroperm Chucks

1-1

DD15508M.doc Rev. ~, September 17, 2002

2 SAFETY INSTRUCTIONS

2.1 General Safety Rules

Danger always exists when using industrial holding equipment, especially if the equipment is not being used properly or is poorly maintained. Because accidents and sever bodily injury or death can result, special safety precautions apply to the installation, operation, inspection, and maintenance of all holding equipment.

Following these simple rules can help to avoid accidents:

• Never attempt to operate your magnetic chuck until you read and understand this operator's manual.

• Never disconnect a magnetic chuck from the control's DC power source while it is energized! Electrical arcing will occur and may cause serious injury or death.

• Only qualified personnel shall make adjustments within the control while it is energized!

• Never operate the chuck until it has been verified that a proper electrical ground for the control and Chuck has been established.

• Never operate damaged or malfunctioning controls or magnetic chucks.

Remember, proper holding knowledge and techniques in the use of this equipment are the responsibility of the operator. Be sure to read and understand the instructions and safety warnings contained in this manual before using your chuck control and magnetic chuck.

If you do not understand everything in this manual contact O.S. Walker for assistance before using the equipment.

CALL 1-800-W-MAGNET

(In Canada call 905-643-3338; In Europe 31-4973-83835)

O.S. WALKER Co. Inc., Turbomill Electroperm Chucks

IN THE USA

2-1

DD15508M.doc Rev. ~, September 17, 2002

2.2 Recognize Safety Information

This is the safety alert symbol. When you see this symbol on your chuck or in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe operating practices at all times.

This indicates a situation in which a hazard is imminent and will result in a high probability of serious injury or death.

Red Background, White Letters

This indicates a potentially hazardous situation, which could result in some probability of serious injury or death.

Orange Background, Black Letters

This indicates a potentially hazardous situation, which could result in minor injury or moderate injury.

Yellow Background, Black Letters

2.2.1 Ways to Avoid a Reduction of Holding Capacity

These are Hazard Seriousness Signal Words

To avoid any reduction of holding capacity:

• The holding surface of the chuck and the contact area of the workpiece where it will contact the chuck must be clean, smooth, flat, and free of nicks and burrs

• The surface of the workpiece must contact equal areas of the chuck's opposite polarity, major magnetic poles.

• The workpiece must be low carbon steel such as AISI 1020.

• The chuck control must provide "FULL" power to the chuck, that is, maximum output

voltage.

• The workpiece thickness must be at least equal or greater than the width of the chuck's major magnetic poles.

• The temperature inside the chuck control enclosure must not be greater than 104º Fahrenheit (40º Celsius), nor the temperature of the chuck must not be greater than 110º F (43º C).

• Repair of this chuck control should only be done by the O. S. Walker Co.*

• If you have any difficulty holding a work piece, DON'T attempt to machine it! Call the O.S.

Walker Co. for advice at 1-800-962-4638.

O.S. WALKER Co. Inc., Turbomill Electroperm Chucks

2-2

DD15508M.doc Rev. ~, September 17, 2002

2.2.2 Additional Warnings

• Never operate damaged or malfunctioning chuck.

• Never remove or damage Operating and Warning labels.

• Persons using pacemakers or any other medical devices should not use this magnet until they have consulted with their physician.

• The electrically conductive body of this chuck must be connected to a proper electrical ground.

2.3 Designated Person

*Walker replacement parts may be installed by a **Designated Person. ** Designated Person - A person selected or assigned by the employer as being competent

to replace specific replacement parts listed in this manual and is able to verify the proper functioning of the specific replacement parts and the entire product after the completion of the installation.

• Disassembly or repair of this chuck control can result in reduced holding power and/or cause an unsafe condition. Therefore, any time the control is disassembled or repaired it should be thoroughly inspected and re-tested for proper electrical grounding and power output.

• Modification of any operating circuits and electrical safety grounding can reduce the chuck control's effectiveness and/or cause an unsafe condition.

• Repair or modification of this chuck should only be done by O.S. Walker*.

O.S. WALKER Co. Inc., Turbomill Electroperm Chucks

2-3

DD15508M.doc Rev. ~, September 17, 2002

+ 18 hidden pages

Walker Magnetics TURBOMILL 40B User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual