Streamfinishing Process and application OTEC Przisionsfinish GmbH - - PowerPoint PPT Presentation

Streamfinishing

Process and application

OTEC Präzisionsfinish GmbH Dieselstrasse 8-12 75334 Straubenhardt www.otec.de

06.11.2013

Content

• 1. Definition and process description
• 2. SF vs. DF
• 3. Setting of the SF-machine
• 4. Influencing factors
• 5. Areas and example of application
• 6. Special machines for special applications

06.11.2013

• 1. Definition and process description

Streamfinishing

Streamfinishing is a mass finishing method of DIN 8589. It is also called abrasion finishing, because there is not always a grinding process, but also a lapping and polishing depending on the process.

• Short processing times
• Easy automation
• Up to 5 processing stations
• Possibility to charge and discharge in

individual processing stations during the continuous processing

• Targeted mass finishing with programmable

(adjustable) angles

06.11.2013

• 2. SF vs. DF

06.11.2013

SF – Stream-finishing process DF – Drag-finishing machine

• Deburring, edge honing, k-factor

design, the smoothing and polishing is 5 – 10 times faster than in DF because

• f additional centrifugal forces
• Deburring, edge honing, smoothing and

polishing

• up to 5 processing stations, in manual
• peration up to 5 tools at once, easy to

automate with robot

• up to 60 tools per batch, for manual

charging, batch operation

• Targeted/focused localized surface

processing

• Low operating effort
• also suitable for the processing of long

tools

06.11.2013

2.1. Comparison of flow forces SF/ DF

20 40 60 80 100 120 2 4 6 8 10 12 14

Flow forces (%) Flow speed (m/s)

SF 3/200 Conventional drag-finishing systems

06.11.2013

2.2. Influence factors

Comparison of process forces SF/DF

SF DF Motion/Move ment

• Process container rotation
• Driven workpiece holders (up

to 8000 rpm)

• Superposition of three rotations:

rotor, holders, driven work piece holders

Pressure

• centrifugal force up to 30 G
• depth of immersion
• angle of the workpiece holder
• V max: ca. 15 m/s
• distance to process container

wall and floor

• dry/wet
• Immersion depth
• Increase/ decrease of velocity in

relation to speed of the holder/rotor

• V max: ca. 2 m/s
• distance to process container

wall and floor

• dry/ wet

06.11.2013

3.1. SF variations

SF-manually

• 3. Setting of the SF-machine

06.11.2013

SF-automatization

SF 1/30

06.11.2013

3.2. Process container size and processing stations

OTEC‘s stream-finishing machine is available with up to 5 processing stations (PS). The following container sizes are used:

• 30 mm (for 1 PS)
• 780 mm (from 1 to 2 PS)
• 1050 mm (from 1 to 5 PS)
• 1400 mm (from 1 to 5 PS)
• 2000 mm (from 3 PS)

Fast change of the process container without the need for tools.

06.11.2013

3.3. Quantity of lifting units

There is either a separate lifting unit per work piece holder or a centered one.

One lifting unit per work piece holder Centered lifting unit

06.11.2013

3.4. Standard holder

The stream-finishing machines are available with various work piece holders. This includes e.g. a 3-jaw chuck, drill chuck, collets, as well as in the automated case e.g. a gripper.

Drill chuck Gripper Collet Jaw chuck Interface S 8

06.11.2013

The work piece holding system has an integrated clamping system, which is activated by compressed-

• air. Thus, a work piece can

be clamped.

Clamping system for work pieces with boreholes

06.11.2013

3.5. Special work piece holder

Special equipment such as a high-speed spindle is necessary for certain applications.

• Significantly shortening of the processing time

because of an additional processing speed

• Rotation speed up to 8000 1/min
• Work piece

–

• Max. diameter of work piece: 150 mm

–

• Max. length of work piece: 200 mm

–

• Max. weight: 2 kg

Areas of application:

• Cam shaft
• Rotationally symmetrical parts

06.11.2013

3.6 Positioning of the work piece

In order to obtain the best possible quality of finish and the shortest processing times, it is often necessary to adjust the position of the work piece in order to align it in the media stream. The following setups are possible:

• Work piece immersion angle (Swivel around the X axis):

The tool can be immersed in the medium at any angle within the range of 0-35°. It is also possible to flow against the work piece in multiple steps (Pulsing)

• Angle of rotation (Swivel around the Y axis):

Positioning as close as possible to the drum wall

• Six-axis finishing by integrated robot:

Moving of the work piece through freely programmable paths during processing

06.11.2013

3.5.2. Pulsfinish

• The work piece is accelerated up to 4000 1/min in less than 1 second.
• After reaching 4000 1/min the work piece is being braked immediately and accelerated in the
• pposite direction (pulsing)
• Supported with the inertia of the media and the relative movement between work piece and

media hardly reachable areas can also be processed (e.g. intersecting bore holes of hydraulic components, recesses, etc.)

• The processing is mainly depending of the density of the media (A higher density of the media

results in a higher abrasion)

Video SF 3/105 with pulse drive

• 4. Pulsfinish

06.11.2013

Advantages compared to other technologies:

• Shorter processing times
• Significant lower Rpk-value (e.g. Rpk <0,1µm)

 Lower coefficient of friction  Less abrasion  No running-in necessary => significantly less contamination of the oil  Up to 2x longer change intervals  Higher energy efficiency

18 Juni 2014

Examples for Pulsinish applications: Processing of cam shaft Rpk ≤ 0,1 µm

before processing after processing

06.11.2013

Possible improvement with Pulsfinish The four working station deburring, grinding, finishing and belt finishing can be replace with

• ne OTEC PULSFINISH working station.

OTEC PULSFINISH

for deburring, grinding, polishing and finishing (1 station directly after turning/ milling) Turning/ Milling Cleaning of the internal gear Deburring Hardening Hardening Grinding Finishing Belt finishing

02.09.2014 20

Possible improvements with Pulsfinish of cam shaft gears, etc.

• less noise
• lower temperature development
• No roughness peaks (Rpk below 0,1)
• No destroying of the lubricant film=> No punctual welding of the friction bodies

=> Reduction of surface pitting

• Less abrasion
• Less allowance of clearance necessary (Precision parts)
• No running in necessary
• No metal removal of running in => significantly cleaner oil
• Higher degree of efficiency

06.11.2013

5.1. Media

The choice of the media determines the machine‘s field of application. They can roughly be divided into 3 classes:

• 1. Media for deburring/ smoothing

(e.g. TZM 2/3, KXMA 24, DS 4/4, KM 6)

• 2. Media for polishing

(e.g. H1/100, H1/400, M3/400)

• 3. Media for tool preparation

(e.g. HSC 1/300) Many granulates can also be used for different tasks.

• 5. Influencing factors

06.11.2013

5.2. Machine parameters

Number of rotation and depth of immersion are crucial to the intensity of the processing. By choosing the rotation direction and alignment of the work piece, certain areas of the work piece can be streamed precisely. Depending on the surface of the work piece, the processing time has to be varied.

5.3. Work piece geometry

Different work piece geometries can be processed in the SF-machine. Especially rotationally symmetrical parts work well.

06.11.2013

6.1. Cutting edge preparation/ Polishing

• Removal of micro-defects
• Adjustment of the cutting edge (Micro geometry)
• Ensuring the quality characteristics of postponed processes

Source: TIK - 08

• 6. Areas and example of application

06.11.2013

6.1.1. Advantages

Very great improvement of the chipping volume by rounding and polishing (factor >10 compared with untreated tools).

Not rounded Not rounded but droplets removed Rounded but droplets not removed Rounded and droplets removed Chipping volume Q

06.11.2013

• Faster chip flow – higher feed rate and cutting speed possible
• Less chipping on the cutting edge (lower jaggedness), because of less notching
• Better adhesion of the coating

Special toolØ 32

0,02 0,04 0,06 0,08 0,1 0,12 0,14 0,16 0,18 0,2 Rauhigkeit Ra [µm] unprocessed processed

Source: TIK - 08

06.11.2013

6.1.2. Measurement

• 1. Circular edge
• 2. Chamfers and angles – Negative chamfer
• 3. Chamfers and angles – supporting chamfer

Source: ALI - 13

06.11.2013

6.2. Further examples of use

Deburring of drilling, milling and rotating drill, turn and mill bodies → Process: QZ 1-3W with SC 15 ca. 150 seconds of processing time

before/ after processing

06.11.2013

Advantages of polishing of drilling templates

• Better chip flow in the flute; this results in a high

productivity of the tool

• Significantly less corrosion: generally this kind of

tools get a surface coating which wears quiet fast

• Better appearance for selling

06.11.2013

Task: Polishing of forming tools

→ Process: M4/300 with ca. 5-10 minutes of processing time

06.11.2013

Task: Deburring/ polishing of worm spindles

→ Process: KXMA 24 ca. 1 minute of processing time

06.11.2013

Task: Deburring/ polishing of tool holders

→ Process: H1/400 ca. 5 minutes of processing time

06.11.2013

Task: Rounding/ Polishing of bone screws

→ Process: H1/400 ca. 1 minute of processing time

06.11.2013

Task: Deburring/ smoothing of gear wheels

→ Process: QZ 1-3 W ca. 2 minutes of processing time

06.11.2013

Task: Deburring with minimum edge honing and smoothing

Processing time: 3 min. Angle B: 35° Direction of container rotation: 100% CC Speed of container: 70 1/min. Direction of work piece rotation: 6 sec. C/6 sec. CC (Pulsfinish) Speed of work piece: 3000 1/min. Media: H1/400 + M18

Before processing After processing

Test: 11263-22013

06.11.2013

Task: Smoothing of guide blades

Processing time: 16 min. Angel B: 0° Direction of container rotation: 100% cc Speed of container: 40 1/min. Direction of work piece rotation: 8 min. +30° /8 min. -30° (Cycling) Speed of work piece: 0 1/min. Media: KM 6

Test: 11181-21813

Before processing After processing

06.11.2013

Task: Deburring of air brake pipes

Processing time: 0,5 – 1 min. Angle B: 25° Machine: SF 3-105 Speed of container: 60 1/min Speed of work piece: 2500 1/min Media: KXMA 24 To date process: Brushing Result: After 30 sec. the burr at the tube entrance is removed

Before processing After processing

06.11.2013

Task: Wet polishing/ wet deburring

Processing time: 1 min. Angel B: 0° Material: Aluminum Media: KXMA 24 Spindle: 2000 1/min (2 sec. cc, 2 sec. c, Pulsfinish) Speed of container: 65 1/min

Test: 23473

06.11.2013

Work piece Initial burring in the transverse bore hole After 1 minute without Pulsfinish After 1 minute with Pulsfinish

06.11.2013

Task: Wet polishing/ wet deburring

Processing time: 1 min. Angel B: 15° Material: Aluminum Media: KXMA 24 Spindle: 2000 1/min (1 sec. cc, 1 sec. c, Pulsfinish) Speed of container: 60 1/min

Before processing After processing Before processing After processing

Test: 23560

06.11.2013

Task: Polishing of tap drills

Processing time: 1 min. Angle B: 0° Material: HSS Media: H1/400 Spindle: 2000 1/min (1 sec. CC, 1 sec. C, Pulsfinish) Speed of container: 80 1/min

Test: 23169

06.11.2013

Task: Deburring of inner contours

2 x 1 min., Media: HSC 1/300, Spindle: 4000 1/min, Angle B = 15°, Speed of container: 80 1/min

Before processing After processing

06.11.2013

Task: Polishing

Measuring point

Before processing After processing Before processing After processing

06.11.2013

Task: Polishing of carbide stamps

Target of polishing is to reach a Ra < 0,1µm. Starting quality is generally around Ra 0,2 µm. Processing time: 8-12 min. Media: M4/300 Machine: SF-3

06.11.2013

Task: Processing of crimping tools

Processing time: 10 – 20 min. Machine: SF 3-1050 Media: H1/500 + 5 kg M18 Speed of container: 85 1/min Speed of work piece: 0 (fixed rotating angel A)

Before processing After processing

06.11.2013

Task: Processing of blisk and turbine blades

Machine: SF-3 Media: M4/300 Processing time: 40 min. Rotating speed of container: 20 1/min Rotating speed of work piece: 5 1/min Result: Turbine blades deburred, edge honing, Ra. 0,08 µm Machine: SF-3 Media: QZ 1-3 Processing time: 30 min. Rotating speed of container: 20 1/min Rotating speed of work piece: 5 1/min Result: Groove deburred, edge honing around 0,1 mm

06.11.2013

• 7. Special machines for special

applications

7.1. SF 3-200

The new SF 3-200 Streamfinishing Machine from OTEC is characterized by :

• Very robust and strong design
• Powerful main drive of 50 KW
• Speed container: up to 150 1/min at a diameter of 2000mm
• Weight: 4.700 kg
• Required space: 3000mm x 3000mm
• 3 stations for work piece holders; work piece can be fixed

pneumatically

• Available for dry processing
• Extremely short processing times
• Automatic sequence of events
• Robot loading possible
• During the process, the work piece can be rotated or even

angular movements can be performed. This machine is especially suitable for processing of faucets, decorative work pieces etc.

06.11.2013

06.11.2013

7.2 Machine for polishing of performing tools (SF-4)

06.11.2013

SF- 4 Loading situation

06.11.2013

7.3 SF 2-680

Work piece: Piston for fuel injection systems in the automotive industry

• Machine consists of a lifting unit with 2 work piece holders
• The guidance systems have extremely high rigidity to ensure high levels of

repeatability during the loading and unloading of work pieces

• Work pieces are fixed pneumatically with chucks
• Tensioning with disk springs and release with pneumatic air cylinder
• Both work piece are processed at the same time
• Automatic blowing of the work pieces during the lifting up out of the container
• Video SF 2-680

06.11.2013

7.4 Machine for polishing of injection plunger (SF-2)

06.11.2013

06.11.2013

06.11.2013

7.5 SF-5 with robot for tools

06.11.2013

06.11.2013

7.6 Use of the SF-machine into the line production to process camshafts

Streamfinishmachine with pulse drive which is prepared for a fully automatic operation to integrate into the line production

• Smoothing of the contact area (radius of the cam)
• Smoothing of the cam (Rpk <=0,1µm)
• Smoothing of the spiral groove
• Deburring/ edge honing of the spiral groove
• Deburring/ edge honing of the toothed camshaft

06.11.2013

Preview SF-procedure

• Development of procedures and plants for mechanical surface

processing

• Easy automatable for charging and discharging
• Process ability by monitoring and controlling of all process

parameters

• permanent further development of the processing

06.11.2013

Thank you very much for your attention!