parts and more compact quick-change toolholder system ht22

Parts and More CompactQuick-change toolholder system HT22

CLOSE TO OUR CUSTOMERS

Contents

2

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

A Wirtgen group CompAny

3

ORIGINAL WIRTGEN

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 there-by 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.

QUICK-CHANGE TOOLHOLDER SYSTEMS

4

in order to always meet the market’s high demands on quality, the most recent investigation methods and computer simula-tions are employed early in the development and design phase.

the finite element method (FeM) allows the physical proper-ties 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 quick-change toolholder systems and shows you the importance of handling them correctly during job site operations.

AdvAntAges I Facts I applIcatIon

5

ORIGINAL WIRTGEN

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.


1 2 3

1 > Raw material “billet”

2 > Blank stage 1

3 > Blank stage 2

6

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 tool-holders in a constant quality and thus guarantees optimum service lifetimes for the quick-change toolholder systems.

4 5 6

4 > Detailed mould

5 > Forging blank after deburring

6 > Waste trimmings

ADVANTAGES I FACTS I APPLICATION

7

ORIGINAL WIRTGEN


1

2

3

45

6

7

8

9

10

11

12

8

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 opti-mum 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 in-creased 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

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.

HT22 IN DETAIL

> HT11 > HT22

10

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.

50 10 2015 25 30

1300

1200

1100

1000

900

800

700

600

500

400

300

200

100

0

1400

1500

Lengthwise wear in mm

Op

erat

ing

ho

urs

Ht22 Higher lengthwise wear Ht22 Moderate lengthwise wear Ht22 Lower lengthwise wear

Ht11 Higher lengthwise wear Ht11 Moderate lengthwise wear Ht11 Lower lengthwise wear

11

AdvAntAges I Facts I ApplIcAtIon

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 acci-dental milling in large steel components. It is therefore advis-able 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

ORIGINAL WIRTGEN

LARGE, SELF-CENTRING CONTACT AREAS

Thanks to the prismatic arrangement of the contact areabetween 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.

HT22 IN DETAIL

> HT11 = 2372 mm2 > HT22 = 3969 mm2

+ 67 %

14

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

> HT11 = 924 mm2 > HT22 = 984 mm2

+ 6 %

15


ORIGINAL WIRTGEN

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.

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.

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 tool-holders are easily accessible.

16

> 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

AdvAntAges I FActs I ApplicAtion

ORIGINAL WIRTGEN


> 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 locat-ed 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 sur-face 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 tool-holder.

4 5

6

18

> Fig. 08: the retainer screw is now tightened to a torque of 500 nm (corresponds to 370 lbf ft) using a torque wrench.

> 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 neces-sary.

> Fig. 07: the new retainer screw is also coated with a tem-perature-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.

Only use a hand-operated torque wrench to tighten the hexagon socket screws.

Never use used retainer screws!

7 8

19


ORIGINAL WIRTGEN


> 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

9

10 11

12

21


ORIGINAL WIRTGEN

SPECIFICATIONS

Specifications HT3 HT11 HT22

Weight of upper part D20 1.76 kg 1.70 kg 2.30 kg

Tightening torque500 Nm(corresponds to 370 lbf ft)

500 Nm(corresponds to 370 lbf ft)


First servicing interval, check torque 10 hours 10 hours 10 hours

Second servicing interval, check torque 250 hours 250 hours 500 hours

Third servicing interval, check torque 500 hours 500 hours 1000 hours

Fourth servicing interval, check torque 750 hours 750 hours 1500 hours

Additional servicing intervals, check torque Every 250 hours Every 250 hours Every 500 hours

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.

1 > Toolholder HT22 D20Part No.: 2198001

2 > Toolholder HT22 D22 Part No.: 2198002

3 > Toolholder HT22 D25 Part No.: 2198003

4 > Dummy upper part HT22Part 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 sealPart No. individual: 2198006 Part No. 100 pieces: 2197989

22

Specifications HT3 HT11 HT22

Weight of upper part D20 1.76 kg 1.70 kg 2.30 kg

Tightening torque500 Nm(corresponds to 370 lbf ft)



First servicing interval, check torque 10 hours 10 hours 10 hours

Second servicing interval, check torque 250 hours 250 hours 500 hours

Third servicing interval, check torque 500 hours 500 hours 1000 hours

Fourth servicing interval, check torque 750 hours 750 hours 1500 hours

Additional servicing intervals, check torque Every 250 hours Every 250 hours Every 500 hours

1

4

2

5

3

6 7

23


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

WIRTGEN GmbHReinhard-Wirtgen-Str. 253578 WindhagenGermanyT: +49 26 45 / 131 0F: +49 26 45 / 131 [email protected]

> www.wirtgen.de

JOSEPH VÖGELE AGJoseph-Vögele-Str. 167075 LudwigshafenGermanyT: +49 621 / 81 05 0F: +49 621 / 81 05 [email protected]

> www.voegele.info

HAMM AGHammstr. 195643 TirschenreuthGermanyT: +49 96 31 / 80 0F: +49 96 31 / 80 [email protected]

> www.hamm.eu

KLEEMANN GmbHManfred-Wörner-Str. 16073037 GöppingenGermanyT: +49 71 61 / 206 0F: +49 71 61 / 206 [email protected]

> www.kleemann.info

parts and more compact quick-change toolholder system ht22

Documents