Pullmax X91 bevelling milling machine

Pullmax X91 bevelling milling machine 

INSTRUCTION MANUAL

Technical data

Capacity
Bevelling angle
Depth of beve
Root face

Width of bevel Tensile strength of plate, kp mm 2
Maximum bevelling speed
Width of bevel
Smallest root face at a bevelling angle of mm
Ditto at a bevelling angle of 55 width of bevel 106 mm
If sіnaller root faces dre required at a bevelling angle of 450 to 550 a special Supporting Roller is required
Motor power at 50 cycles 5,5 HP
Weight without accessories 810 kilos
The machine is designed to work in the following alternative positions
Movable workpiece
Machine in normal vertical position. The plate horizontal.
Machine in horizontal position. The plate suspended vertically. The machine should be fitted with an extra supporting roller.
Stationary workpiece
A special suspension yoke will be needed. Can be delivered as an extra attachment. Machine in movable normal positon. Bevelling on top side of the plate.
Machine in movable up sidedown position. Bevelling underneath the plate.

Fitting of suspension Attachment
Remove the screws 199 which connect the bearing sleeves of the gear box with the frame. Fit the eccentric pivots 1 and 2 onto the flanges of the bearing sleeves by means of the extended screws 10 x 30. Check that the center of the pivots is positioned 20 mm behind and 5 mm above the center of the flange. Remove the two bearing caps 4 and place the yoke onto the eccentric pivots.
Refasten the bearing caps 4. Match the two locking plates 5 and 6 to the locking plug Plate 5, which is the thickest one, is to be placed at the top of the frame. Check that in its locked positions the yoke is parallel to the vertical line of the machine. Mark, drill and tap necessary M10 fitting holes in the frame. Fasten the locking plates by means of the screws included in the delivery.

With the machine suspended movable in relation to the workpiece a supplementary attachment as per the figure above is to be used.
Cross head
Travelling crab for beam INP 160                                  Suspension bar flat 20 x 60 mm, the length to be adapted to suit the local conditions
Suspension spring
Adjusting nut for height position totally 50 mm
Levelling lever movement 30 mm. To be used at working start. Stop against turning. By the special characteristics of the spring the suspended machine will follow the edge of the plate very carefully even if smaller waviness should occur.

Remove the control panel 1 on the left hand side of the machine. The incoming cable 2 is put through the fitting at the back of the machine and connected directly to the motor protector switch. The motor starter protects the machine only against overload. Fuses must therefore be connected before the machine. See table below. Please observe the direction of rotation of the motor. At ordinary running, the cutting wheel must rotate anti clockwise when seen from the front. Assemble the control panel.

Operating Controls
Height adjustment of hold down
Height adjustment of supporting rollers
Locking screws for supporting rollers
Adjustment of guiding device
Adjustment of back stop
Scale for adjusting guiding device
Locking of guiding device
Reading of adjusted bevel dimensions
Locking of runner
Adjustment of bevelling angle
Scale for adjusting bevelling angle
Locking nut for securing selected bevelling angle
Operating push buttons

Selection of Cutter
Generally a fine toothed cutter gives the smoothest cut. Difficulties, however, could arise with feeding, when bevelling harder or tougher materials, especially if the bevel is deep. In such cases a coarsetoothed cutter has to be used. Cutters with three different serrations
can be supplied with the machine. Compare A, B and C on the picture below.

Coarse serration
Medium serration
Fine serration
This cutter is recommended when performing maximum dimensions of bevels on large and heavy work pieces.
Suitable for large bevels on small work pieces.
Advantageous for all materials when the width of bevel is below 15 mm and when the weight of the work piece is below 50 kg.
Instruction for Grinding

The cutter should be ground only on its performed on a surface grinding machine if preferred.
Recommendations
Grinding wheel
Depth of grinding
Feeding
Cooling medium front face. The grinding can be or in a
2 mm per working stroke
supplied in abundance
Hone the cutting edge after grinding. Normally a cutting wheel can be reground three or four times. Total maximum 2 mm each regrind.

Medium or coarse serrated cutter is recommended when bevelling workpieces heavier than 50 kg.

Bevelling angle
Width of bevel
Depth of bevel
Root face
Plate thickness
The nomographic diagram below illustrates the relationship between these quantities.

Example A bevelling depth of 15 mm аnd a bevelling angle of 450 in 25 mm
Ρlate thickness give a bevelling width of 1 mm and a root face of 10 mm.

The angular position of the cutter is changed by varying the inclination of the gear box. Please observe that when increasing the bevelling angle the position of the cutter is lowered. The angle should on no account be adjusted while the machine is running.
Loosen the screw and lower the supporting device to its bottom position by turning the screws anti clockwise.
Loosen the nut. Adjust the desired bevelling angle by means of screw. The scale shows the angle to which the machine is set. Lock the setting in position by the nut. Guiding device. Loosen the locking screw. Set the guiding device to its outermost postion by turning the screw anti clockwise.
Loosen the screw and move the wedge so its index line coincides with desired bevelling angle on the scale. Lock. Move the guiding device inwards by turning the screw clockwise until rests against. Lock by means of the screw.

The maximum depth of bevel can be seen from the above diagram. The maximum depth of bevel is for instance at 45 approximately 17,7 mm in mild steel and 10,6 mm in stainless steel.
Loosen the wing screw. Set the adjustable angular scale runner so that the index line coincides with desired bevelling angle. Turn the supporting screws see page 12 so that the index line comes straight in front
of desired root face on the scale. Lock the screws.
Very Important The smallest allowable root
ace is З mm. If the machine is set for smaller root faces, the cutter can be damaged by touching against the supporting wheel or running onto the plate. Check that the cutter is free cutting approximately 2 mm, i.e. that the edge of the cutter comes over the edge of the plate.

Hold down
Both the hold down rollers can be fitted in three different positions. These vary in direction and depth depending on the workpiece to be bevelled. As a general rule, the hold down rollers should be positioned as far as possible from the cutter. To change the position of the hold down rollers, unscrew the supporting spindle until it is possible to turn it into required position. Turn the hold down rollers to coincide with the feeding direction of the plate. The hold down rollers should be set so that they press lightly against the plate and hold it horizontal.

Marks from the hold down rollers can sometimes be seen when bevelling soft materials as alumimium and similar materials. This effect can be eliminated if the machine is equipped with the hold down bridge no as the bridge is equipped with 7 rollers the surface pressure against the
workpiece is considerably reduced. The hardened steel rollers are equipped with bushes, that do not need any lubrication. The bridge is mounted on the hold down arms of the machine, which are turned towards the interior of the machine. The adjustment is in principle made as for the ordinary hold down. Besides the above mentioned case, the hold down bridge is also very suitable if the workpiece is oblique angled or comparatively short. The extremely good guiding of the plate, given by the bridge, has also a good effect upon the life of the cutting wheel, especially when bevelling coarse and or high strength materials. The holdidown bridge, which is delivered as an extra, is not suitable for bevelling of circles.

Small work pieces can be bevelled by attaching a hold down plate, which prevents tilting. The hold down plate 1, which is manufactured in a case hardened steel, is mounted by connected spacing sleeves 2 in the hold down arms 3 of the machine. The arms have to be turned inwards against the machine. The setting should be made according to the instructions for ordinary holddowns. The hold down plate will be delivered as an extra attachment with order No.
Bevelling of discs
When bevelling discs the bevelling machine must be equipped with a special device for guiding of the work piece. The picture on the next page shows the attachment which has been developed for X91. This attachment consists of an extra guiding roller with adjusting device, which is screwed to the slide of the lower supporting roller on the outfeed side of the machine. The machine backstop serves as an in going guiding device. The guiding roller, mounted in needle bearings, is mounted on a fork shaped bar which can be moved axially in a holder. The adjusting position, which can be read on a scale, is locked by means of two clamping screws. The holder is fastened to the hold down bracket by means of a splined joint. A certain adjustment of angles is possible. The angle position is also indicated on scales. The relation between axial adjustment and position of angle at a certain circle diameter can be seen on the diagram at the bottom of page 17. If, for instance, a disc with the diameter 750 mm is to be bevelled, and axial adjustment 39 mm should be chosen.

The smallest disc diameter is limited to about 300 mm. The largest bevelling width which can be achieved when using this extra guiding attachment is about 20 mm.

Bevelling of narrow flat iron 18
When bevelling narrow flat steel bars and similar work pieces the bevel width may under certain circumstances show a tendency to increase during the final phase of the bevelling operation. In order to eliminate this, a special guiding attachment for work pieces with Darallel edges has been developed for X91. The attachment is shown on sketch below. The special guiding attachment is screwed to the base slide of the lower supporting roller on the outfeed side of the machine and is thus following the vertical adjustment of this roller. The guiding attachment consists of a bracket, on the upside of which a stationary shaft has been arranged between two journal bearings. On the shaft, which is thus not swivelling, a stop dog is running, which can
Be moved to any position and then be locked by the clamping screws. The stop dog carries the real guiding roller, which rotates round a vertical shaft. In addition to this, an extra supporting roller has been mounted on shaft. This guiding attachment is recommended for plate widths between.
Order No.

Support roller for bevelling with machine on its back
When the machine is working on its back, the dead weight of the working material causes a certain extra load on the cutter. In order to eliminate this load, and thus increase the life of the cutter, particularly when using heavy work pieces, an extra supporting roller is offered for mounting on the frame at the outfeed side of the machine. The broad supporting roller is mounted in plain bearings and is adjustable in height and must be set so that the bevelled plate edge rests on the roller without alteration to the feeding direction. This attachment does not prevent the scrap removal.
Order No.

Changing of feeding speed
The machine has two speeds high speed for mild steel and steels with a low carbon content, copper, aluminium and similar materials, and low speed for stainless steel and steel with a carbon content higher than 0,20%.
The speed is altered by changing the V belts and V pulley on the drive shaft of the motor. This is carried out as follows
Remove cover plate 2 on the right hand side of the machine and also the lower cover plate at the back.
Remove the locking screw 3 and also the washer from the motor drive shaft. Loosen the V belt tension adjusting screw 4 and remove the V belts 1. fRemove the V pulley and select the one required, i.e, the larger one for high speed and the smaller one for low speed. Re assemble using V belts for high speed and A45 V belts for low speed. Re tension V belts with adjusting screw 4 and replace cover plates.

Lubrication
The gear box must contain oil to a level visible in the oil glass B when the bevelling angle is set at 300 and the machine is standing in normal vertical position. Oil filler plug at A and drain plug at C.
Necessary oil quantity.
Recommended grades of oil.

The guiding and supporting rollers should be greased after each 50. hours of runninq at all necessary places with Recommended greases