CLOSE TO OUR CUSTOMERS. Parts and More Compact Quick-change toolholder system HT22

Transcription

1 CLOSE TO OUR CUSTOMERS Parts and More Compact Quick-change toolholder system HT22

2 CONTENTS 2

3 A WIRTGEN GROUP COMPANY ADVANTAGES 4 Original WIRTGEN quick-change toolholder systems 4 FACTS 10 HT22 in detail 10 Upper parts 10 Lengthwise wear 11 Servicing intervals 12 Contact area 14 Shaft cross-section 15 APPLICATION 16 Maintenance and replacement of toolholders 16 Specifications 22 3

4 ORIGINAL WIRTGEN QUICK-CHANGE TOOLHOLDER SYSTEMS PHILOSOPHY OF THE WIRTGEN QUICK-CHANGE TOOLHOLDER SYSTEM Based on the idea of replacing worn or defective toolholder upper parts as quickly as possible directly on-site, and thereby substantially reducing machine downtimes, WIRTGEN has been developing quick-change toolholder systems since They primarily consist of two parts: a housing (bottom part of toolholder), welded to the milling drum tube, and a toolholder (upper part), connected to the housing by a quick-release bolt connection. DEVELOPMENT OF THE WIRTGEN QUICK-CHANGE TOOLHOLDER SYSTEM The development of quick-change toolholder systems is a continuous process. Continuous further development has produced subsequent generations of different toolholders. Although these have been optimised, they still retain their unique zigzag shape. 4

5 ADVANTAGES I FACTS I APPLICATION In order to always meet the market s high demands on quality, the most recent investigation methods and computer simulations are employed early in the development and design phase. The finite element method (FEM) allows the physical properties of virtual prototypes to be examined on the computer. Component behaviour can be determined and optimised even at this early stage of the simulation. Long and extensive tests are performed in parallel under maximum loads and in extreme situations. PARTS AND MORE COMPACT QUICK-CHANGE TOOLHOLDER SYSTEM HT22 This brochure introduces you to the WIRTGEN quickchange toolholder systems and shows you the importance of handling them correctly during job site operations. 5

6 ORIGINAL WIRTGEN QUICK-CHANGE TOOLHOLDER SYSTEMS > Raw material billet 2 > Blank stage 1 3 > Blank stage 2 FORGING AND MACHINING PRODUCTION PROCESS High-quality hardened and tempered steels are worked in the forging process. Their wear resistance, the special heat treatment and years of production expertise form the basis for the excellent toolholder quality and guarantee a long service life and fracture resistance. In order to produce component dimensions as accurately as possible, extremely tight tolerances are adhered to during the machining process. 6

7 ADVANTAGES I FACTS I APPLICATION > Detailed mould 5 > Forging blank after deburring 6 > Waste trimmings HEAT TREATING AND HARDENING PRODUCTION PROCESS Final toolholder heat treating and hardening is particularly important, because both the great hardness and the necessary ductility represent important properties with regard to low wear. Using the most up-to-date production and testing methods, WIRTGEN continuously produces toolholders in a constant quality and thus guarantees optimum service lifetimes for the quick-change toolholder systems. 7

8 ORIGINAL WIRTGEN QUICK-CHANGE TOOLHOLDER SYSTEMS

9 ADVANTAGES I FACTS I APPLICATION 1 > Wear markings with 5 mm spacing 2 > 100 % increased maximum wear path compared to HT11 3 > Increased wear volume in the head 4 > Wear-resistant head design 5 > Optimised shaft angle for increased component strength 6 > Around 6 % greater shaft cross section for considerably greater resistance to breakage 7 > Protective plug for screw drive prevents the ingress of dirt 8 > Optimised screw geometry for simple and safe mating up 9 > Optimised welded joints with increased strength, yet at the same time with enough flexibility for optimum pick rotation 10 > Improved protection of the bottom part thanks to complete coverage of the upper part 11 > Contact surface of upper part to bottom part increased by 67 % for longer bottom part service life 12 > Seal between upper and bottom parts for easy and quick installation and removal of the upper part 9

10 ORIGINAL WIRTGEN HT22 IN DETAIL LARGER AND MORE ROBUST UPPER PARTS The upper parts have all been reinforced using considerably more wear volume in all wear-relevant areas. The maximum life is additionally ensured by robust securing in the bottom part of the quick-change toolholder and by increased fracture strength. A comparison to the precursor system HT11 makes this clear. > HT11 > HT22 10

11 ADVANTAGES I FACTS I APPLICATION LENGTHWISE WEAR Thanks to the 100 % increase in the maximum wear path, the service life of the toolholder can be as much as 1000 hours under optimum conditions Lengthwise wear in mm HT22 Higher lengthwise wear HT22 Moderate lengthwise wear HT22 Lower lengthwise wear Operating hours HT11 Higher lengthwise wear HT11 Moderate lengthwise wear HT11 Lower lengthwise wear

12 ORIGINAL WIRTGEN HT22 IN DETAIL REDUCED SERVICING REQUIREMENTS THANKS TO INCREASED SERVICING INTERVALS The dynamically impacting loads imposed during the milling process can reduce the high pretension of the thrust screw over the long service period. The thrust screw pretension can be reduced due to material deformation in the quick-change toolholder system as a result of extreme loads, e.g. by accidental milling in large steel components. It is therefore advisable to check the specified torque of 500 Nm (corresponds to 370 lbf ft) at regular intervals and thus the system s pretension. On the HT22 quick-change toolholder system these ser vicing intervals are now substantially increased thanks to the system s particularly robust design. After an initial inspection following first use (approx. 10 operating hours) the specified intervals for the HT22 quick-change toolholder system have now increased from 250 h to 500 h compared to the HT11 precursor system. The next inspections then follow at 1000 h, 1500 h and 2000 h. 12

13 ADVANTAGES I FACTS I APPLICATION 13

14 ORIGINAL WIRTGEN HT22 IN DETAIL LARGE, SELF-CENTRING CONTACT AREAS Thanks to the prismatic arrangement of the contact area between the upper and the bottom part, increased by nearly 70 % compared to the HT11 quick-change toolholder system, particularly high cutting forces can be reliably transferred to the bottom part of the toolholder. Complete covering of the bottom part by the upper part prevents burr formation on the bottom part. This guarantees simple changing of the upper part without work being re quired on the bottom part of the toolholder % > HT11 = 2372 mm 2 > HT22 = 3969 mm 2 14

15 ADVANTAGES I FACTS I APPLICATION HIGHEST FRACTURE STRENGTH THANKS TO LARGE SHAFT CROSS-SECTION WIRTGEN road milling machines deliver increasing milling performance. This substantially increases the demands on the quick-change toolholder system s strength parameters. The strengthened and shape-optimised shaft of the HT22 quick-change toolholder system is extremely resistant to fracture and offers increased resistance to undesirable deformation. > HT11 > HT % > HT11 = 924 mm 2 > HT22 = 984 mm 2 15

16 ORIGINAL WIRTGEN MAINTENANCE AND REPLACEMENT OF TOOLHOLDERS Damaged or worn toolholders should be replaced to minimise operating costs. Please replace carefully and always follow the instructions below. Only use the correct tools and adhere to the inspection intervals. Given adequate maintenance it is possible to correctly replace the upper part of a toolholder within a few minutes. The toolholders must be continuously kept in excellent condition. Inspection for wear is therefore recommended several times a day. Using the milling drum turning device, the milling drum is positioned such that the picks and toolholders are easily accessible. MAINTENANCE AND REPLACEMENT OF TOOLHOLDERS > Fig. 01: First clean the retainer screw s access bore of asphalt residues. Then remove the plug with the aid of a screwdriver. The plugs offered by WIRTGEN substantially reduce cleaning effort, thus allowing faster replacement. > Fig. 02: The retainer screw is now carefully cleaned, loosened by hand using an Allen key and removed completely. The threads and the screw head may deform as a result of the high loads imposed during the cutting process. To prevent damage to the threads in the bottom part of the toolholder, the screw should therefore not be reused. 16

17 ADVANTAGES I FACTS I APPLICATION > Fig. 03: Once the retainer screw has been removed, the toolholder can be pulled out of the bottom part. The tool should reach to the full depth to prevent damage to the screw during removal. Do not use worn tools!

18 ORIGINAL WIRTGEN MAINTENANCE AND REPLACEMENT OF TOOLHOLDERS > Fig. 04: The threaded bore and the cylindrical guide of the bottom part of the toolholder welded onto the milling drum must then be carefully cleaned and inspected for damage. Cleaning ensures that no milled material is located in the bottom part and the contact areas between the upper and bottom part fit tightly together after assembly without any gaps. There is a danger of fracture if the surface of the bottom part of the toolholder is not even and undamaged. > Fig. 05: Once a perfect contact area has been produced, push the bottom part seal over the shaft of the new toolholder

19 ADVANTAGES I FACTS I APPLICATION > Fig. 06: The toolholder shaft is then coated with a temperature-resistant grease (up to 100 C respectively 212 F) and placed in the bottom part of the toolholder. The grease assumes a sealing function, protects the toolholder against corrosion and allows easier removal when necessary. > Fig. 07: The new retainer screw is also coated with a temperature-resistant grease and screwed in approx. three turns by hand. If the retainer screw can only be screwed in using great effort, the thread in the bottom part must be recut using a thread cutter. Never use used retainer screws! > Fig. 08: The retainer screw is now tightened to a torque of 500 Nm (corresponds to 370 lbf ft) using a torque wrench. Only use a hand-operated torque wrench to tighten the hexagon socket screws

20 ORIGINAL WIRTGEN MAINTENANCE AND REPLACEMENT OF TOOLHOLDERS > Fig. 09: A ring test should be performed after tightening the retainer screw. Applying a hammer blow to the upper part of the toolholder s contact area, check whether it settles further. Use a 1 kg copper hammer to do this. > Fig. 10: After this, the torque 500 Nm (corresponds to 370 lbf ft) on the retainer screw must be checked again. > Fig. 11: The plug is now fitted in the retainer screw. > Fig. 12: Finally, the new pick is fitted. Use a copper hammer to do this. Following first use (approx. 10 operating hours) the hexagon socket screws must be retightened to a torque of 500 Nm (corresponds to 370 lbf ft); then at regular 500 operating hour intervals (500 h, 1000 h, 1500 h). If conspicuous rotation is noted, the bottom part of the toolholder must be inspected. 20

21 ADVANTAGES I FACTS I APPLICATION

22 ORIGINAL WIRTGEN SPECIFICATIONS Specifications Weight of upper part D20 Tightening torque First servicing interval, check torque Second servicing interval, check torque Third servicing interval, check torque Fourth servicing interval, check torque Additional servicing intervals, check torque 1 > Toolholder HT22 D20 Part No.: > Toolholder HT22 D22 Part No.: > Toolholder HT22 D25 Part No.: > Dummy upper part HT22 Part No.: > Retaining screw M30x2 for HT22 Part No.: > Plug HT22 Part No. individual: Part No. 100 pieces: > Bottom part seal Part No. individual: Part No. 100 pieces: Further information on ordering quick-change toolholder systems HT22 can be found in the Parts and More catalogue, on the DVD and online under 22

23 ADVANTAGES I FACTS I APPLICATION HT3 HT11 HT kg 1.70 kg 2.30 kg 500 Nm (corresponds to 370 lbf ft) 500 Nm (corresponds to 370 lbf ft) 500 Nm (corresponds to 370 lbf ft) 10 hours 10 hours 10 hours 250 hours 250 hours 500 hours 500 hours 500 hours 1000 hours 750 hours 750 hours 1500 hours Every 250 hours Every 250 hours Every 500 hours

24 WIRTGEN GmbH Reinhard-Wirtgen-Str Windhagen Germany T: F: customersupport@wirtgen.de > HAMM AG Hammstr Tirschenreuth Germany T: F: customersupport@hamm.eu > JOSEPH VÖGELE AG oseph-v gele-str Ludwigshafen Germany T: F: customersupport@voegele.info > KLEEMANN GmbH Manfred-W rner-str G ppingen Germany T: F: customersupport@kleemann.info > Illustrations and texts are non-binding. Subject to technical changes. Performance data depend on operational conditions. No EN-01/16 by WIRTGEN GROUP Holding GmbH 2016 Printed in Germany