Bar Feeder setup consists of these tasks:

Lathe Setup:

• Install the correct spindle liner for your application.
• Set up the correct workholding for a bar feed application.

Bar Setup:

• Load the bar stock.
• Adjust the charging tray angle (if necessary).
• Adjust the transfer tray height for the bar diameter.
• Install the correct push rod.
• Set up the bar feed variables.

1. Charging Tray
2. Push Rod
3. Set-up Lid Handle
4. Push Rod Storage
5. Load Mechanism
6. Transfer Tray Adjustment Wheel
7. Release Pedal
8. Spindle Liner Storage
9. Bar Pusher

Feed / Auto Position: This is the Bar Feeder’s normal operating position. You can command Bar Feeder motion at reduced speed with the lid open. In this position, you can set up your bar feed application, check and adjust tray height alignment, and run your application.

Lockout / Lathe Setup Position: Press the release pedal[1] at the base, and then push the Bar Feeder back. This mode disables all Bar Feeder motion. With the Bar Feeder in this position, you have easy access to change spindle liners, clean the coolant collector, or do other tasks on the lathe spindle.

A drawback collet is required for bar feed applications. The Bar Feeder holds the push rod in place while the lathe drawtube clamps. If the collet does not pull the bar stock against the push rod when the drawtube clamps, length variation can occur and accuracy cannot be guaranteed.

Note: Your collet should also have a chamfered lead-in for smooth bar feeding.

[A] Collet Unclamped

[B] Collet Clamped

[1] Chamfered Collet Lead-In

[2] Collet Closer Body

[3] Collet

[4] Bar Stock 

For installation instructions, refer to the Lathe Operator’s Manual and the documentation that came with your workholding.

Make sure that the bars you use are appropriate for your setup:

• Test the fit of the bar stock in the spindle liner. The liner must fit close but be large enough to let the bar pass through freely. Use a different liner if necessary.
• To determine the minimum bar length: Measure the gap between the end of the transfer tray and the lathe spindle liner. Multiply this distance by 2.25. Each bar must be at least as long as the result. For example, if the distance between the end of the transfer tray and the lathe spindle is 6.75" (171 mm), each bar must be at least 15.2" (386 mm) long.
• Bar stock must be straight.
• Add a chamfer to the leading end of the bar for better initial feeding. The leading end of the bar should have no sharp edges.
• Bar stock must be cut square on the end that contacts the bar pusher, to prevent protrusions or length variation.
• The bar stock should not extend outside of the spindle liner.
• Large-diameter, heavy bar stock must be shorter than 36" (813 mm).
• It is good practice to wipe the bars clean before you load them. Dirt and debris increase liner wear and could also become jammed inside the liner.

Load bars, one at a time, into the charging tray in a single layer. Push shorter bars toward the lathe. Do not let the bars stack. If the bars roll over each other as you load them, adjust the charging tray to a shallower angle.

Bar Loading Example. Align the Leading Ends of the Bars with the Edge of the Tray[1]. Do Not Stack the Bars[2].

The transfer tray provides the bar stock a path that leads into the lathe spindle. When your Bar Feeder was installed, the service technician adjusted the Bar Feeder height to align the lathe spindle with the adjustment range of the transfer tray. With this procedure, you raise or lower the transfer tray to adjust it for the bar diameter.

1. Press [EMERGENCY STOP] on the lathe.
2. Put the Bar Feeder in the Feed/Auto position.
3. Put a piece of bar stock in the transfer tray.
4. Use the wheel to adjust the transfer tray height. Turn it clockwise to raise the tray and counterclockwise to lower the tray. As you adjust the transfer tray height, move the bar into the spindle liner by hand. Continue to adjust the transfer tray height until the bar slides freely into the liner.
5. Make sure that the collet is set for the diameter of the loaded bar:
6. With the collet open and the spindle stopped, slide the bar into the spindle liner and collet by hand, and check for misalignment, binding or interference.
   
7. Remove the bar and place it in the charging tray

The Bar Feeder comes with push rods that are 3/4" and 3/8" in diameter. Use the 3/8" push rod for all round stock material that is smaller than 0.8" (20 mm) in diameter. Use the 3/4" push rod for material 0.8" (20 mm) in diameter and larger.

Caution: Do not use the 3/8" push rod to push bars larger than 0.8" in diameter. The push rod can bend.

To change the push rod:

1. Press [EMERGENCY STOP] on the lathe. Open the set-up lid.
2. At the lathe end of the push rod, slide the bushing retainer[1] away from the push rod.
3. At the other end of the push rod, pull the retention blade[2] off of the holder block.
4. Remove the push rod and bushing. Follow this procedure in reverse to install the other push rod.
5. Store the unused push rod and bushing under the set-up lid.
6. Close the lid and reset [EMERGENCY STOP] to resume operation.

Press [CURRENT COMMANDS] and navigate to the Bar Feeder page in the Devices tab.

1. Enter the length of the longest bar that will be used.
2. Enter the value from the cutoff face to the final push length desired (D).
3. Enter the value of the initial push length (F).
4. Enter the minimum clamping length, or remnant length (G). Make sure to leave enough length to safely hold the stock in the chuck.
5. Enter the maximum number of parts to run. Enter a value of 0 for unlimited parts.

Use the down cursor arrow to navigate between steps.

1. Press [F2] to load and measure the bar stock. Make sure only one bar loads.
2. Adjust the transfer tray height so the material slides into the spindle liner smoothly.
3. Press [F3] to advance the bar stock to the chuck.
4. Press [HANDLE JOG] and jog the bar stock to the face of the chuck.
5. Step on the foot pedal to clamp the chuck.
6. Press [F4] to set the chuck face position and feed the bar stock to the initial push length.

Press the [RECOVERY] button to access the bar feeder recovery mode.

The Bar Loader Status box will show the push rod position. If it displays an Unsafe Position, use the up/down cursor arrows to bump the loader into position.

Use the other function commands as needed.

EOB Switch Calibration only needs to be performed at first install, or if the EOB sensor, home switch, or trolley are disassembled or replaced.

To machine short bars:

1. Open the Bar Feeder door and place the short bar on the charging tray. Make sure that the bar is long enough so at least two of the pick-up arms can pick up the bar. If not the bar may not load properly.
2. Close the Bar Feeder door.
3. Press the [CURRENT COMMANDS] button and navigate to the Bar Feeder tab.
4. Press the [F2] button. The Bar Feeder will load and measure the bar.
5. Open the Bar feeder door and remove the short bar from the Bar Feeder tray.
6. Open the operator door and manually load the bar through the chuck.
7. Press the [F3] button. The Bar Feeder will load the push rod and advance the bar.
8. Press the [HANDLE JOG] button and slowly jog the bar until the bar is aligned with the chuck or collect face.
9. Press the Chuck Foot Pedal to clamp the bar.
10. Press the [F4] button to set the reference position. A window pop up will show Advance bar to initial length? Press [Y] or [N] to advance the bar. Repeat these steps for the next short bar.