Tooling Guide, Kongsberg C

Contents

The C tooling system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tool units for heavy duty tool position (pos. 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

The Heavy-Duty Tool Unit tool pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

The Foam Cutting Unit tool pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

The High-Power Milling Unit (HPMU) tool pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Tool Units for the fast tool position (pos. 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

The VibraCut Knife Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

The High-frequency VibraCut Knife Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

The HiForce Knife tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

The Rigid Material Knife tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

The PressCut Knife Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

The RotaCut knife tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Tools for the insert position (pos. 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

The Tool Insert Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

The Ballpoint Pen Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

The Drill Tool Insert. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Tool inserts for the Heavy-Duty Tool Unit in pos. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Knife Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Crease tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Crease wheel profiles the Heavy-Duty Tool Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Crease blades. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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The C tooling system
The C tooling system consists of a wide variety of optional tool units. These can be quickly mounted in the tool
position accommodated for the tool and prepared to cut and finish a specific job, assuring exceptional quality
and prompt delivery. Three tool positions are available, enabling usage of three tools within the same job.

Tool position 1 is for heavy tools optimised for power while position 2 is for a set of knife tools optimised for fast
movements. There is also an optional third tool position that accommodates inserts for either pen plotting or drilling of
holes. In addition, the tooling system includes a material thickness probe and an optional camera for registering to printed
images. The layout is as follows:

1. Heavy-duty (HD) tool position

2. Fast tool position

3. Insert position (optional)

1 2 3

Heavy-Duty Tool Unit x

High-Speed Milling Unit x

1
2
High-Power Milling Unit x 3
Foam Cutting Unit x

High-frequency VibraCut Tool x

VibraCut Tool x

Hi-Force Knife Tool x

RM Knife Tool x

PressCut Tool x

RotaCut Tool x

Drill Tool Insert x

Ballpoint Pen Insert x

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Tool units for heavy duty tool position (pos. 1)

The Heavy-Duty Tool Unit tool pack

Sales code: 97AR5456

This tool unit is mounted in the heavy duty tool position and is capable of a down-­
pressure equivalent to 50kg – 110lbs; sufficient to crease triple and double-­wall
corrugated with heavy liners, when configured with the large-­size crease wheels with
150mm – 6” diameter. The large-size wheels also provide superior crease quality with
recycled corrugated board, since a higher pressure can be applied without cracking the
liner.

The HDU comes with a powerful head-rotation mechanism, required to accommodate

the various v-­notch adapters and HD knife tools that have been developed for triple-­
wall corrugated and other strong and rigid paperboard constructions. These tools are
optional (not included).

Included tooling:

• Three 150 mm (6”) crease wheels; a 4-point,

a 6-point and a V-shaped wheel for triple wall.

• Crease adapter for 26 mm (1”) diameter

wheels, plus a 2, 3 and 6 point / 26mm
Crease adapter for 26mm wheels
crease wheel.

150mm crease

The Foam Cutting Unit tool pack

Sales code: 97AR5458

The Foam Cutting Unit mounts in the heavy duty tool (HD) position. With this tool foam
material up to 50mm (2 ”) in thickness can be cut. The FCU features a reciprocating
knife for great cutting performance in a wide range of cellular foam material and also
honeycomb board.

Two different adapters are included, one for up to 32mm (1 ¼”) material thickness and
one for up to 50mm (2”) thickness. Both adapters accept the SR63xx and the SR65xx
style blades. Two blades of each type are also included.

The SR6313 blade The SR6523 blade

Appropriate blades: See Esko Consumables Catalogue

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The High-Power Milling Unit (HPMU) tool pack

Sales code: 97AR5457

This tool unit mounts in the heavy duty tool position. The included spindle features
3kW of milling power and adjustable spindle speeds up to 60,000 RPM. It allows
for milling, contour cutting, routing, drilling and engraving directly from CAD/
graphics designs. Materials with thickness up to 50mm (2”) can be milled. For
milling thickness exceeding 25mm it is beneficial to use milling bits with 8mm shank
size, which can be used in the HPMU with an optional collet that interchanges with
the standard 6mm collet.

The 3kW milling spindle offers 2-3 times faster feed rates than what is possible with
standard 1kW spindles, thus considerably widening the bottleneck that routing jobs
often present. It also offers much greater robustness against overloads, because of
the larger dimensions on bearings and shafts.

The HPMU-­C milling spindle is liquid cooled in order to utilize its full power potential.
The cooling unit sits in a small cabinet that can be placed near or away from the machine.

The milling tool comes with a function to supervise and monitor the spindle current, which is useful to adjust the feed rate
and RPM settings for new materials. It also features a switch operated bit clamping for fast and tool-free bit exchange,
and in combination with the automatic tool measurement feature milling bit exchange is really safe and efficient.

Due to the high acceleration of the machine the milling tool comes with a free-standing boom for carrying the chip suction
hose and the electrical cables for the milling spindle. In order to reach all over the table the boom needs to be quite high,
3500mm – 11½’.

Milling bit starter kit:

Included with the High-Power Milling Unit is a set of milling bits:

• 1x Acrylic, single flute, 3 mm tip, 11 mm flute length • 1x Multi-purpose, 3 mm tip, 11 mm flute length

• 1x Acrylic, single flute, 5 mm tip, 22 mm flute length • 1x Multi-purpose, 5 mm tip, 22 mm flute length

The milling spindle comes with 6mm bit collet as standard. The following collet sizes are available as options: 3mm, ¼”,
8mm

Included Milling underlays:

Included with the High-Power Milling Unit is a set of milling underlays made from hard pressed felt. Section sizes and
numbers are listed in the table below. The felt underlay is approx. 3mm thick and is placed on top of the standard cutting
mat or conveyor belt.

Milling underlay, hard felt, per section C60: 1500x3250mm + 750x3250mm

C64: 1500x3200mm (2x) + 750x3200mm

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Tool Units for the fast tool position (pos. 2)

The VibraCut Knife Tool

Sales code: 97AR5464

This tool is suitable for single-wall corrugated board and other light-duty fibrous materials. An internal electrical motor
provides knife reciprocation. The tool comes with a slotted cup that pushes down on the material while the blade is
coming out of the narrow slot. Tests show that this is an efficient method for improving cutting ability and increased knife
blade life in corrugated board with high recycle content. The cup is made of synthetic material to avoid scratching of
printed surfaces. Different knife adapters allow for different knife types. Maximum cutting thickness is 10-20mm - 3/8”-¾”
depending on blade. The VibraCut-C reciprocating Knife Tool includes 3 x SR-6223 and 3 x SR-6224 knife blades.

Sales codes:

97AR909 VibraCut Knife Tool, including 3x SR6223 and 3x SR6224 knife blades

97AR931 Separate knife blade adapter for SF216 and SF217, including 4x SF216 and 4x SF217 blades

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The High-frequency VibraCut Knife Tool

Sales code: 97AR5463

Special variant of the reciprocating knife tool for cutting a lot of different materials, such as foamboard, corrugated plastic
and corrugated paperboard.

It runs at twice the frequency and four times the amplitude of the standard VibraCut knife tool. These properties, along
with a more powerful motor, enable cutting of heavily recycled board at efficient speed.

To reduce material tear and also to keep the material down as the knife is pulled out, a detachable foot is included.

Different knife adapters allow for different knife types.

Technical specifications

• Maximum cutting thickness: 20mm – 3/4” with short foot, 30mm – 11/4” with long foot

• The knife blade is centered (lag = 0).

• Applicable knife blades (all with cylindrical shaft): SR6xxx type

• Another knife blade adapter is available for SF216 and 217 (flat stock blades).

Included in the package: 3x SR6223, 3x SR6224, 3x SR6310 and 3x SR6303 knife blades with corresponding adapter
and foot.

Sales codes:

97AR5147 Hi Frequency VibraCut Knife Tool, including 3x SR6223, 3x SR6224, 3x SR6310 and 3xSR6303 blades

97AR931 Separate knife blade adapter for SF216 and SF217, including 4x SF216 and 4x SF217 blades

97AR5148 Long plastic foot for SR6xxx blades

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The HiForce Knife tool

Sales code: 97AR5461

SF216

SF217

SF212

SF213

The Hi-Force knife is a general purpose tool suitable for cutting thin, rigid materials such as polypropylene sheets,
polycarbonate, clear vinyl and folding carton.

A foot is included to reduce material tear and also to keep the material down when the knife is pulled out The knife blade
is centered (lag = 0).

Included in the package is the knife holder for SF216 and 217 knife blades, plus 2x SF216 blades and 2x SF217 blades.
Using a different knife holder SF212 and SF213 blades can be used as well.

Sales codes:

97AR5028 HiForce Knife Tool including 4x SF216 and 4x SF217 blades.

97AR452 Separate knife blade adapter for half length DF112/113 including 2x DF112 and 2x DF113 blade.

97AR5011 Separate blade adapter for the SR61xx-series

The Rigid Material Knife tool

Sales code: 97AR5460

The Rigid Material Knife Tool is a static knife tool suitable for cutting in heavy rigid materials like
plastic, display carton and thin foamed PVC (Forex® / Sintra®)

Applicable knife blades: The tool is using blades with an 8 mm cylindrical shaft; DR8160 and
DR8180 knife blades. Two of each is included with the tool.

Sales code:

97AR5029 Rigid Material Knife tool including 2 x DR8160

and 2 x DR8180 knife blades

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The PressCut Knife Tool

Sales code: 97AR5462

This tool comes with an internal motor providing exact tool pressure control and extremely fast-response on tool up/down
movements.

Maximum downward knife pressure is 10N. The tool features a software function that enables speed dependent tool
pressure control, which is important to ensure reliable cutting when velocity ramps up and down.

Tool pressure can be changed between different line types, to switch between kisscutting and through cutting of vinyl
foils.

Maximum tool lift is 4 mm. The knife blade is centered (lag = 0).

A software function is available to adjust the tool pressure to the correct level.

Applicable knife blades KC101, KC102. The PressCut Tool includes 1x KC101 and 1x KC102 knife blades.

Sales code:

97AR904 PressCut Knife tool, incl. 3x KC101 and 3x KC102 knife blades

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The RotaCut knife tool

Sales code: 97AR5459

The RotaCut Tool is specifically developed for cutting printed textiles such as banners and flags. Since most textiles are
more or less air transparent the vacuum hold-down system of the table will not be effective when cutting such materials.
The RotaCut Tool has been designed with this in mind. It operates by rotating a 10-facetted knife blade at high speed,
and the blade protrudes from a slot in a hold-down foot that presses down on the material. The foot is made from a
material that reduces friction to a minimum, and these properties, in connection with the fibrous surface of the conveyor
belt, or felt mats, provide a hold-down sufficient for cutting most textile materials.

Applicable knife blades RC10 decagonal knife blade. A set of five blades is included with the tool.

Sales code:

97AR5050 C/XE RotaCut Tool, incl. 5 x RC110 decagonal knife blades and tools for blade change.

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Tools for the insert position (pos. 3)

The Tool Insert Fixture

Sales code: 97AR5030

The optional Tool Insert Fixture is a prerequisite for

mounting tool inserts such as the Ballpoint Pen Tool and
the Power Drill Tool. These inserts are also optional.

The Ballpoint Pen Insert

Sales code: 97AR5031

The Ballpoint Pen Insert option mounts into the Tool

Insert Fixture. NOTE! This fixture is an option.
Two pen refills; Black, Medium line weight, are included.

The Drill Tool Insert

Sales code: 97AR5032

The drill tool Insert option mounts into the Tool Insert
Fixture. NOTE! This fixture is an option.

The drill tool is aimed at light-duty drilling in materials

such as RE-board, X-Board and triple wall corrugated.
This tool has a 70W geared motor and spins with
approximately 1000 rpm.

The adjustable chuck accepts drill bits ranging from 0.5

– 6.5mm, or 1/64” – ¼”.

Two 3mm and two 4mm drill bits are included

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Tool inserts for the Heavy-Duty Tool Unit in pos. 1
For cross-referencing of knife tool and knife blades, please ref. to the Esko Consumables Catalogue

Knife Tools

HD Knife 17 Heavy-duty knife tool used for rigid board such as RE-
Sales code: 97AR379 board and triple wall material. Limited to straight lines
Knife lag: 10.0mm longer than 50mm (2”).

Max. cutting thickness is 17mm.

Sold as a kit including five appropriate blades

HD Knife 30 Similar to the above knife but permits cutting of max.

Sales code: 97AR725 30mm – 1.18” material thickness.
Knife lag: 10.0mm
Uses a specially designed, Tungsten Carbide knife blade.

Will also cut 22mm materials nicely, due to the very rigid
knife blade.

Sold as a kit including two appropriate blades

V-notch knife 45 For 45° V-notch cutting in TW corrugated, corrugated

Sales code: 97AR620 plastic and RE-board. . Its application is to make a 90°
partially cut V-notch for folding functionality or a through-
cut leaving a slanted cutting edge.

Max. cutting depth is 15mm - .590”. Limited to straight

lines only.

Sold as a kit including five appropriate blades

V-notch knife 45 10mm Similar to the above knife but limited to 10mm – 7/8”
Sales code: 97AR274 cutting depth. Will provide a more accurate cut in thinner
material due to the shorter (=more rigid) eCosed blade.

Sold as a kit including five appropriate blades

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V-notch knife 15 The 15° V-notch cutting in TW corrugated, corrugated
Sales code 97AR982 plastic and RE-board. Its application is to make a 30°
partially cut V-notch for folding functionality, such as 12-
edge polygonal pillars or a through-cut leaving a slanted
cutting edge.

Max. cutting depth is 16 mm - .590”. Limited to straight

lines only.

Included with the tool is a package of five appropriate

knife blades.

V-notch knife 30 The 30° V-notch cutting in TW corrugated, corrugated

Sales code: 97AR983 plastic and RE-board.. Its application is to make a
60° partially cut V-notch for folding functionality, such
as 6-edge polygonal pillars or a through-cut leaving a
slanted cutting edge.

Max. cutting depth is 16 mm - .590”. Limited to straight

lines only.

Included with the tool is a package of five appropriate

knife blades.

Crease blade adapter Crease blades are typically used for polypropylene
sheets and will in this type of material give better folding
Sales code: 97AR5307 capabilities than what can be achieved with a crease
wheel.

Two crease blades are included with the adapter,

enabling crease widths of 0.5 and 1.0mm.

The adapter also accepts BLD-DF212 and BLD-DF213

knife blades, for through-cutting of simple shapes. To
compensate for the difference in length between the
knife blades and the crease blades the plastic end stop
piece must be flipped when going from one type to the
other.

Replacement crease blades:

0.5mm crease blade: G42442764

1.0mm crease blade: G42442772

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Crease tools

Crease profiles for C tools

An adapter for using crease wheels with diameter 26mm [1”] in the HDU is available as an option. The application of this
adapter is to enable a smaller sized wheel for micro flutes and folding carton.

It will also allow creasing of plastic corrugated with smaller wheels and heavy crease power, which normally has a good
effect on defeating the ‘memory’ of the plastic material.

The standard Ø26mm crease wheels will fit the adapter, with no need for resetting the height reference when the adapter
replaces the Ø150mm crease wheel.

Crease adapter for Ø26mm wheels

Included in the Heavy-Duty Tool Unit tool pack

1 point 10 point
Sales code: g32532129 Sales code: g32529091

2 point 12 point
Sales code: g32524837 Sales code: g32529117

3 point 14 point
Sales code: g32529075 Sales code: g32547051

4 point Triple wall

Sales code: g32536542 Sales code: g32537706

6 point R Crush, R=15

Sales code: g32522880 Sales code: g32524811

8 point Double edge, 1 point (0.6 mm spacing)

Sales code: g32529240 Sales code: g32546640
   

12
Crease wheel profiles the Heavy-Duty Tool Unit

Crease wheel - U-shape, 150mm [6”] diameter.

For double- and triple wall of good quality.
Sales code: g34007096

Crease wheel - V-shape, 150mm [6”] diameter.

For recycled board with brittle liners.
Sales code: g34007906

Crease wheel - 6-point, 150mm [6”] diameter.

For single wall corrugated
Sales code: g34023234

Crease wheel - 4-point, 150mm [6”] diameter.

For solid board (carton), chipboard, etc.
Sales code: g34010306

Crease Blades
The crease blades can improve fold lines in thin, synthetic materials such as polypropylene and polyethylene (PET)
The crease tips scribe into the material and provide a more distinct fold line than a wheel, due to smaller impact area.

Crease Blade 0,5 mm for Tang. Static Knife double

edge. Sales code: g42442764

Crease Blade 1 mm for Tang. Static Knife double

edge. Sales code: g42442772

Crease Blade 0,5 mm half length. HC Force knife tool.

Sales code: g42444711

Crease Blade 1 mm half length. HC Force knife tool.

Sales code: g42444729

Crease Blade 0,5 mm. RM Knife tool. Sales code:

g42459503

Crease Blade 1 mm. RM Knife tool. Sales code:

g42459511

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