Parts and More Compact Quick-change toolholder

CLOSE TO OUR CUSTOMERS
Parts and More Compact
Quick-change toolholder
system HT22
Contents
2
A Wirtgen Group Company
Advantages4
Original Wirtgen quick-change toolholder systems
4
Facts10
HT22 in detail
10
Upper parts
10
Lengthwise wear
11
Servicing intervals 12
Contact area
14
Shaft cross-section
15
Application16
Maintenance and replacement of toolholders 16
Specifications22
3
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
1990.
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
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
ORIGINAL WIRTGEN
QUICK-CHANGE
TOOLHOLDER SYSTEMS
1
2
3
1 > 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
ADVANTAGES
4
I
FACTS
5
I
APPLICATION
6
4 > 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
ORIGINAL WIRTGEN
QUICK-CHANGE
TOOLHOLDER SYSTEMS
1
2
3
4
5
7
6
8
12
10
11
9
8
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
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
10
> HT22
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
1500
1400
HT22 Higher lengthwise wear
HT22 Moderate lengthwise wear
HT22 Lower lengthwise wear
1300
1200
1100
1000
Operating hours
900
800
700
600
500
400
300
200
HT11 Higher lengthwise wear
HT11 Moderate lengthwise wear
HT11 Lower lengthwise wear
100
0
0
5
10
15
20
25
30
11
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
Advantages I Facts I Application
13
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
required on the bottom part of the toolholder.
+ 67 %
> HT11 = 2372 mm2
14
> HT22 = 3969 mm2
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
> HT22
+ 6%
> HT11 = 924 mm2
> HT22 = 984 mm2
15
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
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!
1
2
3
17
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.
4
6
18
5
Advantages I Facts I Application
>> Fig. 06: The toolholder shaft is then coated with a tem­
perature-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.
7
8
19
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
Advantages I Facts I Application
9
10
11
12
21
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.: 2198001
2 > Toolholder HT22 D22
Part No.: 2198002
3 > Toolholder HT22 D25
Part No.: 2198003
4 > Dummy upper part HT22
Part No.: 2198005
5 > Retaining screw M30x2 for HT22
Part No.: 158501
6 > Plug HT22
Part No. individual: 2197999
Part No. 100 pieces: 2197988
7 > Bottom part seal
Part No. individual: 2198006
Part No. 100 pieces: 2197989
Further information on ordering quick-change toolholder
systems HT22 can be found in the Parts and More catalogue,
on the DVD and online under www.partsandmore.net.
22
ADVANTAGES
1
4
I
FACTS
I
APPLICATION
HT3
HT11
HT22
1.76 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
3
2
5
6
7
23
WIRTGEN GmbH
Reinhard-Wirtgen-Str. 2
53578 Windhagen
Germany
T: +49 26 45 / 131 0
F: +49 26 45 / 131 397
[email protected]
HAMM AG
Hammstr. 1
95643 Tirschenreuth
Germany
T: +49 96 31 / 80 0
F: +49 96 31 / 80 120
[email protected]
> www.wirtgen.de
> www.hamm.eu
JOSEPH VÖGELE AG
Joseph-Vögele-Str. 1
67075 Ludwigshafen
Germany
T: +49 621 / 81 05 0
F: +49 621 / 81 05 463
[email protected]
KLEEMANN GmbH
Manfred-Wörner-Str. 160
73037 Göppingen
Germany
T: +49 71 61 / 206 0
F: +49 71 61 / 206 100
[email protected]
> www.voegele.info
> www.kleemann.info
Illustrations and texts are non-binding. Subject to technical changes.
Performance data depend on operational conditions.
No. 2316937 EN-01/16 · © by WIRTGEN GROUP Holding GmbH 2016 · Printed in Germany