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Including ideas of some techniques of jewellery manufacturing Including ideas o

Including ideas of some techniques of jewellery manufacturing Including ideas of some techniques of jewellery manufacturing DURSTON DURSTON ROLLING MILLS ROLLING MILLS Instructions Instructions for Usage for Usage Maintenance & Safety Maintenance & Safety ….thank you for choosing your Durston Rolling Mill which will give you many years of trouble free and high performance use. Please ensure that you read the instructions below and also page 4,”Rolling Mill Safety, Care and Tips” before unpacking and using your new mill INSTRUCTIONS / MAINTENANCE FOR HAND OPERATED ROLLING MILLS • The bearings are self-lubricating and need no maintenance. • The drive gears at left hand end (behind guard A) should be greased every 6 months. Remove the circlips and extension rollers and then the two screws for the cover for access to the 2 gears. Use standard gear grease. • Oil the 4 end faces of the rolls daily. (F) See enlarged view of rolls below. MICRO MILL 70, MINI MILL 80 and MINI MILL 100 DRM 100, DRM 130 and DRM 150 • The bearings are self-lubricating and need no maintenance. • The drive gears at left hand end (behind guard A) should be greased every 6 months. Remove the circlips and extension rollers and then the two screws for the cover for access to the 2 gears. Use standard gear grease. • The gearbox at the right hand end (B) should be greased every 6 months. Remove the turninglever (C). Slacken the 10mm set screw first (5mm Allan key). The lever should slide off. If not, gently tap it. Now remove the four 5mm cap screws (4mm Allan key). The lid of the gearbox should now come off. You may need to gently tap this as well. Use standard gear grease. (Not applicable for economy models) • Oil the 4 end faces of the rolls daily. (F) See enlarged view of rolls above. Unpacking and preparing your new mill for use. Lifting. Please unpack rolling mill very carefully. For all mills, have at least two people lifting and moving mill onto its final place. Never lift from hand wheel. Always lift from the base of the mill or for the D2 130 and D4 158 lie these down and lift from both ends. The approximate weights of the machines are as follows. Micro Mill–9kgs, Mini Mill–16kgs, DRM 100–32kgs, DRM 130 & DRM 150– 50 kgs, D2 130–75kgs and D4 158–85kgs. Securing. Bolt machine securely to a Durston stand or a strong secure bench. Ensure that the stand or bench is bolted down to the floor. Fitting turning lever. You now need to fit the lever. Slide the lever on as shown in picture (you may need to tap it) and do up the 10mm grub screw with the alan key provided. Do not over tighten, you may damage the shaft. Check that this screw is tight every 3 months. Removing rust preventative. You will now need to remove the rust preventative on the rolls. Close the rolls and then open the rolls up 1 turn of the hand wheel (D). Apply some white spirit (ordinary household paint solvent) onto a clean cloth sparingly and hold the cloth into the gap of the rolls and roll backwards. Do not use any stronger liquid than white spirit / lacquer thinners. It will take a little longer on the grooves as you have to do one at a time. All Durston Rolling Mills have: • Calibrated dials fitted to the top and are marked in 0.001” and 0.025mm increments giving the roll gap These dials are useful for repetition work and will assist in providing a constant product size • Extension rollers with “4” half rounds. 4, 3, 2 and 1.5mm. Other sizes can be ordered • Guards (black covers) covering all gears MAINTENANCE A A B C F D D • Reduction gearbox (not Mini or Economy models) making turning easier • The bearings are self-lubricating and need no maintenance. • The drive gears at left hand end (behind guard A) should be greased every 6 months. Remove the circlips and extension rollers and then the two screws for the cover for access to the 4 gears. • The gearbox at the right hand end (B) should be greased every 6 months. Remove the lever. Slacken the 10mm set screw first (5mm alan key). The lever should slide off. If not, gently tap it. Now unscrew the 4 screws holding on the black guard. The cover can now be removed. Use standard gear grease. • Oil the 8 end faces of the rolls daily. (F) See enlarged view of rolls below right. D4 158 • The D4 158 has a second lever (D) which is used for doubling the turning speed of the rolls. This second lever is useful when you are rolling out the smaller jobs where not so much effort is required, making the rolling quicker. For the larger jobs the lower lever, (C) which is located on the wire roll, is the best to use as it gives you the maximum reduction ratio on the gearbox. • To change from the standard lever (C) (lower lever on wire roll) to the second lever. Remove the circlip on the wire roll right hand side and the first lever will slide off. Now insert the second lever (D) into cover (E) on the lower sheet roll. The two hardened dowels will locate into the gear. Now tighten up the two 10mm bolts (17mm spanner). • When turning with standard lever turn lever anti-clockwise. When using second lever turn clockwise. Please note that the following is only a guide. 1. Anneal the piece of sheet or ingot, pickle it, and rinse it with clean water. Now dry it. 2. Feed the dry metal into the mill, applying snug (but not overpowering) pressure on rollers. 3. After rolling metal through the mill, flip the piece end to end before you roll it through again. You will get a more even roll. 4. Before passing the metal through the rollers, lower the rollers until you have a snug fit (as in step 2). 5. If the metal becomes too hard to roll, it must be annealed again. Then roll the piece through the rollers, repeating as necessary until the desired thickness is achieved. 6. When rolling silver sheet it may be necessary to anneal the sheet after rolling it from 3.0mm to 1.0mm in thickness. For 14Kt gold the annealing may be necessary after rolling from 3.0mm to 2.0mm. Please note that the following is only a guide. Reduce wire by rolling 2 or 3 times in each groove rotating the wire 90 degrees on each pass. Rolls should be nearly closed for last pass before moving to next groove. Depending on material, passes of up to 30% can be achieved. The material should be annealed as often as necessary to avoid excessive force when rolling. Indications of excess hardness are frayed edges, wrinkling of surface, surface cracking or excessive force needed to turn the rolls. WIRE ROLLING D2 130 and D4 158 PROCEDURE FOR ROLLING B A B A C E D F ROLLING MILL SAFETY, CARE AND TIPS 1. ALWAYS bolt down your rolling mill to a secure bench or secure stand for stability & safety. 2. Ensure guards are in place at ALL times. The guards are the black plastic covers, covering the gears. 3. When the rolling mill is not in use, apply a thin coating of rust preventative liquid. (we recommend that you use Durston rust preventative). Using a clean and dry paint brush (approximately 12mm wide) apply the rust preventative across the rolls. Turn the rolls as you do this. Make sure the rolls are nearly closed. This will spread the liquid evenly over the surface. It is very important that your rolls are always protected, especially in moist/wet/hot conditions or where temperatures are changing. Once your rolls are marked/rusty/corroded they will be like this for life until you have them removed and reground. (However, please note that it is almost impossible that you will end up with perfect rolls. Over time and use they will get slightly marked). It is also recommended that you cover your mill when not in use. This is to prevent the rust preventative from collecting dust and dirt. When using your mill again remove all rust preventative and ensure your rolls are clean and dry before you start to roll material. See “Removing rust preventative” on page 2. 4. KEEP ROLLS CLEAN. Do not touch the rolls. Oils and acids from your body can damage the rolls leaving behind small marks and eventually rust. Only roll through dry materials 5. Do not use your mill with the rolls completely closed. 6. DO NOT roll ferrous metals such as iron or steel through the mill. 7. ALWAYS release pressure on rollers after you have completed your job. 8. Do not lift mill from hand wheel. Only lift from base. (See “lifting” on page uploads/Litterature/ durston-guide-2008 1 .pdf