cutting-edge solutions in deburring and surface · pdf filecutting-edge solutions in deburring...

Advanced Manufacturing Technologies

Deburring

Edge Radiusing

Contour Machining

High Quality Finishing

Polishing

Cutting-Edge Solutions in Deburring and Surface Finishing...

www.extrudehone.com

2 www.extrudehone.com

Programmed for Success

The success story of Extrude Hone began with the development of our patented Abrasive Flow process in 1965. Today, Extrude Hone, with its headquarters in Irwin PA, USA, is recognized as a global leader specializing in non-conventional technologies including, Abrasive Flow Machining (AFM), Electrolytic Machining (ECM), and Thermal Energy Method (TEM) used for deburring, polishing, surface finishing and edge conditioning.

Since our establishment more than 40 years ago, one factor in Extrude Hone’s history has remained constant: we rely upon our innovation and deep understanding of our customer’s needs.

Abrasive Flow Machining (AFM) .......................................................................................4-7

Orbital AFM .................................................................................................................................... 7

MicroFlow™ AFM ...................................................................................................................8-9

Thermal Deburring (TEM) ................................................................................................10-11

Electrolytic Machining (ECM) .........................................................................................12-13

CoolPulse™ ECM .................................................................................................................... 14

Contract Finishing Services (CFS) ............................................................................... Insert

“The most important aspects of a

part are its surfaces and edges.

The rest of the part is there merely to hold

the surfaces and edges together!”

Automotive Dies & Molds Medical Aerospace Diesel

3www.extrudehone.com

Extrude Hone – Specialist for Innovative Surface Finishing Technologies

unmatched today in the marketplace.Global Customer Service

Serving the customer is of major concern to us.Our experienced technicians and design engineers are at your disposal throughout the project. If desired, they will accompany the project from the development and prototype phase, develop machining strategies and ensure trouble-free implementation in series production.

We always remain at your service: In the event that your equipment requires a replacement part, our readily available stock of “on-the-shelf” parts allows for immediate delivery and replacement by our service personnel.

Being close to customers is our mission.

Quality Providing Added Value

Wherever deburring, edge radiusing and polishing of sophisticated components are required, Extrude Hone’s advanced process-ing technologies – Abrasive Flow Machining (AFM), Electrolytic Machining (ECM) and Thermal Energy Method (TEM) – provide a reliable and economic solution.

As a leading supplier of advanced finishing technologies and contract finishing services, Extrude Hone successfully solves some of the most complex deburring and surface finishing challenges faced by industry today. In fact, many of the world’s largest manufacturers rely on our advanced solutions to deburr and polish the internal and external surfaces of critical components that have proven to be inaccessible by other means and technologies.

Moreover, Extrude Hone customers value our innovative finishing solutions for the significant competitive advantage they provide in the areas of increased productivity, and profit-ability on the components they manufacture. Work parts processed with Extrude Hone tech-nologies enjoy improved functional stability, extended service life, and higher conformance to dimensional specifications.

Contract Finishing Services – a Flexible Alternative

Perhaps the easiest way to discover all the benefits of Extrude Hone’s precision finishing technologies is by using our global network of Contract Finishing Services. These facilities are available to deburr, polish, and clean your workpieces and deliver them back to you quickly and conveniently.

Think Global – Act Local

Today, Extrude Hone has an extensive network of manufacturing facilities and customer service centers in the US, Brazil, China, Japan, Korea, Germany, United Kingdom, Ireland, France, Spain, and the Czech Republic. Our employees speak the language of our customers.

We are a preferred supplier to metalwork-ing companies throughout the world. These include the global automotive industry, its first-tier suppliers, drive-train gear manufacturing, fluid power, medical, food processing, mold and die, aerospace, gas turbine, and other light engineering.

Complete Metalcutting Solutions from Kennametal

Since becoming part of the Kennametal Inc. family of companies, Extrude Hone has lever-aged its direct relationship with Kennametal to further meet and exceed the needs of our customers. By combining Extrude Hone’s advanced and innovative deburring and finishing technologies with Kennametal’s state-of-the-art metal-cutting tools and systems, we are able to offer our customers a complete metalcutting and finishing solu-tion. Together, Extrude Hone and Kennametal provide a breadth of technologically advanced products and services – from high-quality surface finishing of critical components to innovative tooling systems for metal cutting –


Media with Brilliant Properties

At the heart of our AFM process, is our unique, abrasive laden polymer or media that changes its apparent viscosity when a shear stress is applied.

As the media is forced to flow over or through a restricted flow path, its molecules “cross link,” transforming the media from a viscous fluid to an elastic – or even brittle – solid. Since our media sticks to little other than itself, it easily slips across edges and surfaces like elastic, abrasive “putty” with results similar to 3D flowable “sandpaper.” Abrasive action is highest in the most restric-tive passages with highest flow resistance.

AFM media is reusable for extended periods although life expectancy is dependent on severity of use and application.

Extrude Hone offers a wide selection of standard media formulations to service a broad range of customer applications. Custom engineered media formulations for special applications and process optimization are also available.

Our ISO 9001 certified manufacturing procedures assure a dependable and repeat-able AFM process every time.

Precision Deburring,

Polishing, and Edge

Radiusing Anywhere

the Media Flows.

Typical AFM Media abrasives include silicon carbide and diamond abrasives. Particle sizes range from 5 to more than 4,000 microns (1,000 to 8 mesh).

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Media Properties:

• Lifecycleofthemedia: The media provides a matrix for homogene-

ous suspension of the abrasive particles.

• Consistent“grindingquality”: Stock removal can be controlled using a

combination of pressure, flow rate and flow volume.

• Universalapplicationpossibilities: More than 200 media formulas developed

to process a variety of workpiece materi-als and achieve precise surface and edge conditioning.

The rheological properties of AFM me-dia constantly present abrasive particles

to the workpiece surface in a continu-ous and uniform manner.

Abrasive Flow Machining

We deburr brilliantly.

Ideal for…

• Cross-drilled holes

• Stepped and intersecting bores

• Concave and convex surfaces

• Milled and broached slots

• Internal radii and chamfers

• Internal bends and curves

• Polishing internal passageways

• Eliminating hand deburring

• Thousands of other applications

AFM improves surfaces and edges created by a variety of manufactur-

ing methods, includ-ing EDM, cast, forged,

drilled, milled, and turned surfaces.

AFM


In fact, AFM is now recognized as one of the most cost-effective methods available for internal and external deburring and surface finishing of workpieces.

Our AFM process uniformly smoothes and blends in features, automatically and controllably, to a quality level and speed unachievable by hand or other forms of machine finishing. Plus, it finishes internal curved and complex surface locations previously unreachable by any other means.

These delicate heart valves are finished using AFM, resulting in a superior, ultra-clean smooth surface.

Abrasive Flow

Machining


Internal passages within this turbine engine diffuser are polished to increase airflow to the combustion chamberof the engine by ±2 %.

The surfaces of extrusions dies for the aluminum and plastic industries are polished accurately and uniformly in a fraction of the time when compared to hand finishing.

AFM produces dramatic improvements on a wide range of materials from drawn stainless steel elbows and fittings used by the semi-conductor industry (above) to investment cast aluminum turbo impellers (below).

Workpiece

Non-conventional and High Performance The Extrude Hone AFM process defined a new level of quality and manufacturing productivity upon its introduction. As a result of ongoing advancements, AFM continues to be a leading and revolutionary deburring and polishing process today. AFM significantly improves the overall quality and product performance of cast, forged, and machined components at a reasonable and predictable cost.

Vector Series

Two-Way-Fow AFM

AFM


One-Way-Flow AFM

The patented one-way-flow process extrudes medium through the workpiece in one direction only. The medium flows through the workpiece and into a hopper from where it is automati-cally returned to the single working cylinder.

This type of processing is particularly useful in series production of hot runners where the handling and cleaning operations are considerably simplified.

Multi-Flow AFM

The multi-flow AFM process utilizes multiple media cylinders which can be selectively actu-ated to provide precisely controlled abrasive flow machining to each edge and passage in a complex part.

Process Features at a Glance:

• High precision deburring, radiusing and polishing

• Suitable even for hard-to-reach areas

• Improved surface finish and integrity

• Increased life cycles and reduced wear rates

• Removal of thermal recast layers and surface flaws

• Accurate process control and excellent repeatability

• Applicable to single-parts as well as small lots and batch production


AFM is used to polish

and deburr parts

where high-quality

surfaces and edge

conditions are

critical to a product’s

performance,

strength and reliability.

A Finishing Solution for Many Industries AFM processing is used to finish some of the most critical components made by man for the automotive, aerospace, gas turbine, food processing, pharmaceutical, mold and die, fluid power, and general engineering industries. Whether it’s medical instruments, diesel engines, parts for the Space Shut-tle or finishing dies used to make extruded aluminum building products, Extrude Hone’s AFM process has a global record of delivering reliable, precision results.

Deburring, radiusing and

polishing of fir-tree slots.

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Abrasive Flow Machining

Mulit-Flow AFM

One-Way-Flow AFM

AFM


This detail of a mold used to form the bottom of a beverage bottle shows the superior polishing results of Orbital AFM.

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We give surfaces the final touch.

The Process

Precision surface and edge finishing is achieved by rapid, low-amplitude, oscillations of the workpiece relative to a self-forming polishing tool – the abrasive-laden visco-elastic media.

The media flows over the workpiece, finishing the surfaces by a combination of vertical oscil-lation and orbital motion of the workpiece in the horizontal plane. In this way surfaces that do not allow any through-flow can also be pe rfectly polished.

Super Polishing

and Finishing of

Complex Shapes

and Cavities.


• Reduces or eliminates skilled hand finishing

• Produces extremely fine finishes on complex geometries while maintaining critical dimensional tolerances

• Delivers repeatable, uniform results every time

• Improves surface quality roughness by a factor of 20

Ideal for …

• Blow molds

• Surgical and prosthetic implants

• Coining dies

• Pill compacting dies

• Racecar pistons

• Aerospace components

• Ball-valves, etc.

Orbital AFM: Surface finishing improvement of a PET blow mold.

Autoflow™ Control

On request our units can be equipped with computer-controlled media flow which reduces fluctuations in temperature, pressure, flow rate and flow velocity. Thus even more consistent production results are achievable.

AFM processing is also available through our Contract Finishing Services.

Broad Selection of Machines to Meet Every Need and Budget

Extrude Hone offers various standard models of AFM machines with more than 20 different size capacities:

77 Seriesideal for die polishing applications as well as short-run deburring, polishing and radiusing work

Vector Seriesfor medium to heavy duty

Spectrum Seriesfor series production applications

For more detailed technical data please go to www.extrudehone.com

Abrasive Flow

Machining


before after

Orbital vibration

Workpiece

Media

Injector bodies, valves and nozzle holders are processed using AFM to produce generous radii from 0.1 to 0.4 mm, on the intersections of the high pressure holes to improve high cycle fatigue strength.

AFM

AFM

Orbital


Achieving a Consistent Flowrate

When precision finishing and maximum performance matters most in your workpieces, our MicroFlow process delivers. While very similar to our standard AFM processing, MicroFlow AFM is distinctive in three key areas. First, MicroFlow uses a much lower viscosity media. Second, the abrasive particle size within the media is much smaller. Lastly, MicroFlow features a more highly advanced process control feedback system.

MicroFlow AFM is ideally suited for the diesel and automotive industry in the manufacturing of fuel delivery and distribution systems, including the sizing and flow tuning of advanced high-pressure diesel fuel spray injector nozzles. MicroFlow AFM delivers unequalled manufacturing control over orifice surface finishes and entry edges. Our MicroFlow AFM process provides consistent hole quality and enhanced flow characteristics for improved atomization, deeper jet spray penetration, and better fuel/air mixing, resulting in increased fuel economy, more horsepower, and a cleaner burning engine.

Precise Sizing

and Flow Tuning for

Diesel Fuel and Fluid

Atomization Systems.

The MicroFlow Process

Prior to MicroFlow, precision orifices in fuel injectors and metering nozzles were first machined and then, in a separate process,flow tested. Now, with our advanced MicroFlow AFM processing, Extrude Hone combines both of these critical and necessary steps into one process.

Workpieces are machined and tested as part of the same process to provide tightly con-trolled volumetric flow rates that significantly enhance their discharge coefficient. This method of processing is well above the typi-cal EDM discharge coefficient of 0.6 to 0.8. MicroFlow AFM incorporates sophisticated sensing and precision algorithms in a closed-loop system that monitors and accurately maintains all aspects of the process – from media viscosity and media pressure to shear- force history and temperature. The result is virtually any spray nozzle can be fine tuned to less than ±1 % of a targeted flowrate.

MicroFlow processing can be performed by either of two distinctly different methods, depending upon your needs. Each method has its own advantages.

HV – High Viscosity MediaProcessing: This method is suited to processing multiple parts simultaneously to achieve a superior hole geometry.

LV – Low Viscosity MediaProcessing: This method is ideal for achieving a target flow rate in a single step process.

Both methods achieve similar results in that a set of nozzles produced today will flow at the same predetermined less than ±1 % flow rate as a similar set of nozzles produced from one batch run to the next.

The MicroFlow AFM process can be employed on virtually any precision nozzle or metering hole where gas,

liquid, or fine particles flow at a precise volumetric rate.

With our advanced control systems and

unique MicroFlow media, our precision

MicroFlow process assures high quality,

“right on target” holes that avoid the unfavorable

asymmetric geometries produced by standard

EDM processing.

Ideal for …

• Fine tuning spray nozzles to less than ±1 % of targeted flow rate

• Smoother, more uniform orifice geometry

• Higher discharge coefficient than EDM

• Precise entrance radii for better atomization and fuel distribution

• Capable of producing identical hole sizes every time

• Ideal for systems requiring controlled or metered fluid distribution

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after

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MicroFlow™ AFM

9

Microflow™ LV

-1 % +1 %

www.extrudehone.com

MicroFlow AFM Machines

Extrude Hone is the world’s leading producer of precision flow tuning equipment and testing systems for diesel fuel injectors, flow metering and fluid atomization devices. Extrude Hone offers two standard models of MicroFlow™ AFM machine:

MicroFlow LV andMicroFlow HV

Both models can be configured to suit your specific requirements from laboratory development equipment to total turnkey production systems. Both systems can be designed to be semi-automated or fully-automated with workpiece loading and unloading. MicroFlow AFM systems are fully capable of providing …

• Sizing and flow tuning of hole diameters down to 50 µm

• Different flow conditions -higher discharge coefficients

• Reduction of flow tolerance to less than ±1 % from ±6 % total mass flow – typical of EDM

• Nozzle pre-aging-purposely introduced wear at the spray hole entrance-resulting in high stability and consistency of the nozzle’s performance throughout its operational life

• All nozzle geometries -conventional sac, VCO, minisac, etc.

• Total automation, including part handling, cleaning, testing, and sorting

• Process data records, storage, and analysis

Visit www.extrudehone.com for complete specifications.

MicroFlow™ AFM

delivers unparalleled

control over micro-hole

surface finishes

providing consistent

quality and enhanced

atomization and

flow characteristics.

MicroFlow Optimizes Flow Discharge Coefficient A typical EDM orifice hole has a flow coefficient between 0.6 – 0.8, while a hole processed with MicroFlow has a typical flow coefficient in excess of 0.95, increasing flow velocity and improving atomization from an identical orifice diameter.

Another critical flow application

example is aircraft turbine blade cooling holes.

MicroFlow is also used to process high and low pressure atomization nozzles for: • Oil heating systems• Water and humidity systems• Washing and cleaning systems• Paint spraying systems• Spray coating medical, pharmaceutical,

and electronic devices

Degree of edge/surface modification

Dis

char

geco

effic

ient

Inletedge

radiusingSurface

smoothing Streamlining

AFTER EDMTARGET

FLOWDISTRIBUTION

Conventional nozzles

After 20 % flow enhancementand precision flow

tuning from MicroFlow™

High precision flow tuning

MicroFlow™ AFM


The TEM Process

First, workpieces are securely sealed in a bell-shaped combustion chamber. Depending upon the size of your TEM machine and the containment chamber, several to hundreds of workpieces can be processed at a time.

A pressurized mixture of a combustible gas – typically natural gas or methane and oxygen – is injected at 5 to 10 atmospheres of pressure, which is determined by the amount of material to be removed and the volume of parts in the chamber.

A spark plug ignition system ignites the gas mixture, releasing heat energy from the oxidation of fuel in a 20 millisecond, high-speed heat wave. The surface of the combustion chamber absorbs the majority of the heat, harmlessly raising the tempera-ture of the workpieces a few degrees.

With their raised surface areas and thin cross-section features, burrs and flashing burn away instantly. Depending upon the heat diffusivity of the workpiece material, most, if not all burrs absorb the heat faster than the core of the workpiece. The burr becomes progressively hotter until it reaches the material’s oxidation temperature and ignites.

The ignition process continues until the cross-section of the burr increases in thickness as it intersects the edge of the

Complete

Internal and External

Burr Removal in one

Quick Operation.

Ideal for…

• Automotive parts

• Screw machine parts

• General hardware

• Gears and pinions

• Intersecting drilled holes

• Internal grooves and undercuts

• Thousands of other applications

TEM is unique among material removal processes primarily becaus it removes

burrs and flash simultaneously throughout

the workpiece, including inernal an external

locations.

after

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Burr before TEM Burr is vaporized Deburred part after TEM

Fast and Economical

Today, manufacturers are improving workpiece performance with increasingly more complex designs, resulting in greater surface finishing challenges. Our Thermal Energy Method (TEM) uses intense heat to deburr and deflash workpieces accurately, quickly and cost-effectively.

Invented more than three decades ago, our TEM process is distinctive in that it removes internal and external burrs and flashings simultaneously and without affecting or compromising adjoining workpiece surfaces. The actual removal of burrs and flashings happens in a flash with a mere 20 milliseconds completion time. Through hundreds of installations and continued refinement of our TEM equipment, one factor remains constant: TEM is a rapid, low-cost, high-production process that can produce a million or more parts per year by a single machine.


• Simultaneous removal of all internal and external burrs

• Only simple tooling required

• Short process times (ms)

• Suitable for small lots and very high-volume production

• Particularly suitable for deflashing of die-cast parts

• Easily controllable process and excellent repeatability

• Process reliability in production

• Lowest cost for total deburring

We deburr lightning fast.

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after

Thermal Energy Method TEM

11

TEM S-250

www.extrudehone.com

A single

Extrude Hone TEM

machine is capable

of processing millions

of parts per year.

The TEM processing is also available through our Contract Finishing Services.

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after

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workpiece, allowing the heat to diffuse into the body of the workpiece faster than it is being generated by the reaction, whereupon the process is completed.

Because the gas mixture engulfs the entire workpiece, all internal and external surfaces are exposed to the rapid oxidation. Internal cross-drilled holes and intersecting edges that are difficult or impossible to reach are instantly processed.

A Low-cost Deburring and Finishing Solution

Because of its overall low processing costs, high-production rates and repeatable results, TEM is used throughout many industries – large and small. From high-volume automotive parts and hardware fittings to one-off prototypes, TEM is the unanimous and preferred choice over the more erratic and often unpredictable media tumbling and manual systems.

Hundreds of Extrude Hone TEM installations at major manufacturers worldwide quickly and economically deburr and deflash billions

of edges annually. These robust, field-proven systems are dependable, easy to operate and incorporate extensive safety features.

Tooling used in the process is generally simple, and often not required. As a result, TEM is quite flexible, allowing for the same system setup of different parts and different materials with only modest time required for changeover.

Post-Cleaning

As for post-TEM cleaning, while not normally required if workpieces are later heat treated, some users prefer to remove oxidized material from the surface of the finished workpiece.

Extrude Hone provides cleaning and drying systems specifically designed and suited to the needs of TEM.

Broad Selection of TEM Machines to Meet Every Need and Budget

As an ideal solution for any contract or production shop, Extrude Hone offers several standard models of TEM machines from our compact P-80 and the cost-efficient entry-level TEM S-250 through to medium-sized units P-250 and P-350 up to model P-400 that accommodates large parts. Our TEM machines are designed and constructed to operate 24/7, pausing only for routine maintenance and cleaning. Actual machine cycle time, including indexing, sealing, safety checks, gas injection, and unclamping, requires only 20 seconds to 60 seconds while the TEM processing takes a mere 20 milliseconds.

For more detailed data please go to www.extrudehone.com

We deburr lightning fast.

Thermal Energy

Method TEM


Selective Deburring,

Contouring and

Polishing to the Highest

Surface Quality.

Use of multiple fixtures increases productivity.


• High-precision deburring and edge radiusing at pre-defined points

• Straightforward machining at hard-to-reach areas

• Deburring and contouring in a single operation

• No formation of “secondary burrs”

• Short process times (normally 10 – 30 sec)

• No mechanical or thermal stresses for the workpieces

• Machining of tough and hardened metals feasible

• Controlled process

after

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• ECM– ElectrolyticMachining:

Used to machine workpieces with unique contours or specific edge geometries that normally cannot be produced by conven-tional machining methods, such as the internal galleries of diesel fuel injector nozzles, recesses in gear teeth of synchro-nizers, and rifling inside gun barrels.

ECM Calibration Our ECM process is also capable of

calibrating flow resistance. Example: Break-through edges of drilled cross- holes are deburred and radiused while flow-volumes through the bores are simultaneously metered – two important and necessary operations performed in a single step!

• ECD–ElectrolyticDeburring:

Used to deburr holes and edges in difficult to reach locations on such workpieces as drilled break-through holes on the interior surface of air bag propellant systems and cross-drilled holes inside manifold blocks or to radius edges on gear teeth.

• ECP – ElectrolyticPolishing:

Provides high-quality polishing of complex 3D contour milled surfaces such as found on medical implants and biopharmaceutical diaphragm valves.

We do more than just deburr.

Planet gear before … … and after ECM

The deburring fixture plays a major role in ECM processing and is matched to the workpiece to be machined. Finally, it is the fixture which determines the deburring result.

Designing deburring fixtures is one of our core competences, based on many years of experience, as well as practical know-how. Deburring fixtures are designed and manufac-tured in-house and tested until they produce results which meet our customer’s expectations. The result: Quality without compromise.

Electrolytic Machining, Deburring, and Polishing (ECM/ECD/ECP)

Extrude Hone’s electrolytic technology provides fast, accurate, and highly controll-able surface finish improvements for your precision workpieces. Our electrolytic process can machine, deburr, and polish surface locations previously unreachable by other methods, including manual work.

The electrolytic process removes metal without direct contact between the tool and workpiece through the dissolution of surface atoms. In adhering to Faraday’s law of electrolysis, this selective metal removal process ensures the amount of material removed is proportional to the time and intensity of an electrical current flowing between the tool and workpiece.

While ECM, ECD, and ECP are essentially the same process, they are used to achieve slightly different results or objectives depending upon your workpieces:

ECM processing can produce exceptional surface finishes on a wide variety of mate-rials. This aluminum sample with low Si content was machined on a multi-axis CNC mill then finished using Electrolytic Polishing (ECP). The finish went from an Ra of 2.0 µm to 0.5 µm in 35 seconds.

Electrolytic Machining

The fuel gallery of a diesel fuel injector is machined using ECM. The unique ability to precisely machine features to interior passages makes ECM a valuable tool for many industries.

ECM


ECM Machines

Extrude Hone offers a broad selection of ECM machines to cover a full range of applications and customer needs:

EcoLine

This space-saving ECM machine with a single workstation is suitable for batch production and incorporates maximum economy with minimum machine space, providing an outstanding cost-benefit ratio.

ECLine

With its modular configuration, the ECLine series offers a broad array of options. The unit contains all of the functions required for deburring and contour machining of precision metal parts. Various automation configurations also make the system suitable for high-volume production.

The series is also available with two working stations.

ECM provides a

highly controllable,

yet cost-effective

method of machining

and polishing high

quality surfaces and

edges.

The ECM processing is also available through our Contract Finishing Services.

Electrolyte

Workpiece(Anode)

Tool(Cathode)

Pulsed high current output

Extrude Hone developed Pulse Electrolytic Technology (PET) to produce fine surface

finishes on materials, such as stainless steel, aluminum, and

others that meet or exceed electropolished finishes.

We do more than just deburr.

Automated Systems – Tailored to Customer’sRequirements

Automated Standard SolutionsExtrude Hone’s ECM equipment is very flexible and can easily be configured with robots and other automation equipment to achieve extremely high production rates.

“SysLine”SeriesFor high-volume production we also supply automated systems with integral process technology comprising pre-treatment, EC processing, post-treatment and media conditioning in a totally-enclosed system.

AuxiliaryEquipmentandAccessories

Our customers can obtain everything they need from a single source: complete deburr-ing and surface finishing systems with all the necessary peripherals such as pre and post-treatment systems, chamber filter presses, industrial coolers and chillers, gauging, workpart handling and much more. Precision aqueous cleaning systems for post-processing complement our product range.

The Electrolytic Process

In electrolytic machining, metal is removed without direct contact between the tool and workpiece. The electrolytic equipment uses a programmed, low-voltage direct current (DC) while a conductive electrolyte solution flows between the tool (cathode –)and workpiece (anode +). The exchange of charge between the poles leads to material removal, atom by atom, in precisely defined areas.

Interior bore intersections can be perfectly EC-machined.

Fully automated ECM system, “SysLine” series, for high-volume production.

Electrolytic Machining ECM


Perfect Finishing

CoolPulse is a unique electrolytic deburring and polishing process that allows manu-facturers of small, complex, or delicate parts to greatly improve product quality. The process delivers micro-burr removal and electropolish-like results on small parts without the need for unstable, heated acid solutions.

This innovative process provides surface finishing free from stresses, abrasion and distortion because no close-fitting electrodes are used. The process is therefore especially suitable for precision deburring and polishing of small and fragile parts such as medical/surgical instruments and other high-precision components.

The CoolPulse Process

The unique CoolPulse process uses a specially formulated electrolyte solution with a computer-controlled DC pulse power source. The electrolyte is chilled, non-fuming/odourless and near pH neutral.

This electrolyte solution has a high electrical resistance. When a machined workpiece is immersed in the solution and a pulsed, low DC voltage charge is applied between the part and a stationary cathode, an electrostatic charge is concentrated at any sharp features – i.e. the burrs of the workpiece.

In the area of concentrated electrical field, burrs are dissolved and flushed away by the electrolyte. By applying the voltage in controlled pulses, it is possible to provide a polishing effect concentrating on the edges only, or over the entire workpiece.

CoolPulse is compatible with most workpiece materials such as mild steel, cast iron, stainless steel, aluminium, magnesium, etc.

Normally, the process duration lies in the range 15 seconds to 3 minutes.

Fast Surface Polishing

and Removal of

Micro-Burrs Without

Impairing Part Integrity.


• Low operating costs – no conformal tooling required

• Fast set-up – typically in minutes

• Safe operation – no harmful chemicals or acids

• Consistent production finishing – thousands of parts

• Repeatable and reliable results – easy-to-control process

• Simple operation – no special skills required

CoolPulse is an innovative electrolytic process for surface finishing.

“CoolPulsed” bone plate

We create perfection in detail.

The CoolPulse ECM processing is also available through our Contract Finishing Services.

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CoolPulse – Five Key Functions:

Deburring, polishing, stress-relieving, cleaning and passivating – all in a single finishing process.

• Selective removal of micro-burrs, also on internal surfaces and edges, without impair-ing part integrity

• Material stress relief through overall surface improvement

• Super polishing of surfaces

• Surface cleaning through elimination of free-iron (rust) particles

• Stainless steel passivation as rust and corrosion inhibitor

afterbefore

after

before

Auto Raiseand Lower

VariableSpeed Agitation Pulsed

DC PowerSupply

High Resistance Electrolyte

Cathodes

Workpiece and Anode

Workpiece

ConcentratedElectrical

Field

Burrs

LessConcentrated

ElectricalField

CoolPulse™ ECM


Extrude Hone Processes

Along with offering capital equipment, Extrude Hone maintains a global network

of Contract Finishing Services. The following is a sampling

of typical applications: AFM

Mic

roFl

owTM

AFM

Orbi

tal

AFM

TEM

ECM

Cool

Puls

eTM E

CM

deburr internal/external surfaces (including intersecting holes)

deflash internal/external surfaces

controlled corner and edge radius in hole sizes > 0.062” dia. (1.5 mm)

controlled corner and edge radius in hole sizes < 0.062” dia. (1.5 mm)

diesel fuel system components (common rails, runners), (improved high cycle fatigue resistance)

diesel fuel injector nozzles (annulus, gallery, hole shaping, flow tuning)

finishing hole sizes < 0.015” dia. ( < 0.4 mm)

finishing hole sizes > 0.015” dia. ( > 0.4 mm)

polishing and forming contoured surfaces

polishing mold & die (blind cavity)

polishing mold & die (through cavity)

polishing extrusion dies (aluminum & others)

polishing internal surfaces & passages (ultra-high purity valves and medical components)

removal of thermal recast layer

removal of EDM/spark erosion recast layer

removal of laser erosion recast layer

removal of sharp edges and burrs (elimination or radiusing)

smooth & blend internal surfaces & passages (automotive intake/exhaust manifolds, headers, etc.)

surface finish improvements 0.05 µm Ra or lower

surface finish improvements 0.05 µm Ra and higher

surface machining, contouring, and polishing

AFM

Mic

roFl

owTM

AFM

Orbi

tal

AFM

TEM

ECM

Cool

Puls

eTM E

CM

Extrude Hone Czech s.r.o.Zdebradská 56CZ-251 01 Rícany, JazloviceTel.: +420 724 127 712Fax: +420 323 637 [email protected]

Extrude Hone Ltd.1 Sovereign Business ParkJoplin Court, CrownhillMilton Keynes MK8 0JPTel.: +44 (0) 1908 26 36 36Fax: +44 (0) 1908 26 21 [email protected]

Extrude Hone Corp.1 Industry Blvd.Irwin, PA 15642USATel.: +1 724-863-5900Fax: +1 724-863-8759www.extrudehone.com

Extrude Hone do BrasilAv. Marginal Direita 137, Prédio C.Rudge Ramos, S ao B. do Campo.S ao Paulo, CEP 09696-005BrasilienTel.: +55 11 4177 [email protected]

Extrude Hone Spain S. L.Calle de la Quimica No 11Poligono Industrial „La Ferreria“Montcada i ReixacES-08110 BarcelonaTel.: +34 93 575 3570Fax: +34 93 564 [email protected]

Extrude Hone Ltd.East Park, ShannonCounty ClareIrlandTel.: +353 61 705 060Fax: +353 61 705 [email protected]

Extrude Hone KKShinwa 3-137-2Misato-shiSaitama 341-0034JapanTel.: +81-48-954-0811Fax: +81-48-954-0818misato.eh-info@kennametal.comwww.extrudehone.co.jp

Extrude Hone Korea Co., Ltd. #502, Ace Techno Tower 1st197-17, Guro 3 Dong, Guro-guSeoul, Korea 152-766Tel.: +82-2-854-0451Fax: [email protected] www.extrudehone.co.kr

Worldwide Locations

Extrude Hone GmbHMemminger Strasse 37D-87746 ErkheimTel.: +49 (0) 83 36 – 80 05-0Fax: +49 (0) 83 36 – 80 05-500E-Mail: [email protected]: www.extrudehone.com

Extrude Hone GmbHBerghauser Strasse 62D-42859 RemscheidTel.: +49 (0) 21 91 – 900-250Fax: +49 (0) 21 91 – 900-254E-Mail: [email protected]: www.extrudehone.com

References That Speak for Themselves

Extrude Hone (Shanghai) Co., LtdNo. 1508, Chen Qiao RoadFenpu, Fengxian DistrictShanghai 201401P.R. China Tel.: +86 21 5690 5809Fax: +86 21 5630 6554www.extrudehone.com.cn

Extrude Hone FranceZl Bois de l‘EpineAvenue Jules Guesde, BP 10209FR-91007 Evry CédexTel.: +33 (0) 1-60 79 83 20Fax: +33 (0) 1-60 77 69 [email protected]

Specifications and availability are subject to change without notice.Printed in Germany 02/2008© Extrude Hone Corporation

Extrude Hone GmbHMemminger Strasse 37D-87746 ErkheimTel. : +49 (0) 83 36 – 80 05-0Fax : +49 (0) 83 36 – 80 [email protected]

Extrude Hone GmbHBerghauser Strasse 62D-42859 RemscheidTel. : +49 (0) 21 91 – 900-250Fax : +49 (0) 21 91 – [email protected]

Whenever burrs need to be reliably removed, edges radiused, profiles generated or metal surfaces polished, our process technologies AFM, ECM and TEM come to the fore regard-less of whether it is deburring and surface finishing of internal bore intersections, machining delicate parts or workpieces with complex forms.

Extrude Hone’s process technologies are engineered to increase productivity, reduce operating costs and help you produce a higher quality product.

The result: Precision with Perfection.

Three Processes –

Precision to the

Power of 3.

Contract Finishing Services

No matter which process is involved: we deburr and finish your parts quickly and reliably.

AFM – a method for deburring, radiusing and polishing in a single process.

ECM – a process for selective deburring, edge radiusing and contour machining.

TEM – a thermal process for removing internal and external burrs in a fraction of a second.

As a systems supplier, Extrude Hone, a Kennametal Company, is a recognized partner to the global automotive industry and other areas of industry offering, with AFM, ECM and TEM, three high performance methods for deburring, polishing and surface finishing.

CFS


Contract Production –

a Genuine Alternative.

Precise. Fast.

Economical.

Extrude Hone has gained an enviable reputa-tion as a machine builder and specialist in surface finishing of sophisticated precision metal parts. However, we not only build ma-chines we also offer deburring and finishing services. For many well-known customers we have become an “extended workbench” where deburring, polishing and surface finishing is concerned.

At Extrude Hone, we understand that keeping complex finishing operations in-house is not the preferred course of action for every manufacturer. However, for some, making a significant capital investment in finishing and deburring equipment may not be within the scope of their business model or financial resources. In such cases, outsourcing this function is the optimal solution.

A pool of high-performance machines provides the basis for extensive flexibility in contract production at Extrude Hone.

For more information on high-end finishing solutions go to www.extrudehone.com.

The Benefits of Contract Production at Extrude Hone:

• Highflexibility

• Nopersonnelcosts

• Nocapitalcommitment

• Fixedcost-per-piecepricing

• Anylotsizefeasible

• Completemachiningincl.pre- and post-processing services

• Consistentandrepeatableresults

• Qualitymanagementacc.to ISO 9001/14001

• 24-hourturnaroundcapability

• Logisticsservicesavailable on request

CFS


Comprehensive Service

Nowadays,costreduction,qualitymanage-ment and just-in-time delivery are decisive factors. We work closely with customers so that we consistently meet their quality and delivery requirements.

At our contract service centres we carry out trials, then test and optimise until the final result is perfect. However, deburring is not the whole job. Accepting an order from a customer also means “serving the customer“

– and we take that very seriously.

In other words, our contract staff also provide the customer with practical advice and support where required, together with planning and controlling the process so that the contract is carried out profes-sionally and to the full satisfaction of the customer.

If desired, we will also take care of the necessary logistics and ensure “just in time” delivery.

A process-oriented and integrated quality management system in compliance with ISO 9001 and ISO 14001 ensures consistently high quality.

Our Most Important

Process is called

Quality. For us Quality

Means: The Customer

Comes Back again

and not the Product.

“Total Quality Management“ at each of our contract service centres guarantees, amongst other things, that the required quality level throughout the production process is performed with microscopic inspection and gauging as well as statisti- cal process control. All quality related information is documented, stored for future reference, and systematically audited.

We manufacture your success.

CFS

Services Around

the Globe.

Extrude Hone is represented with its own service and contract production centres around the world: in the US, Brazil, China, Japan, Korea, Germany, UK, Ireland, France, Spain and the Czech Republic. We are always close to our customers.

Extrude Hone can draw on more than 40-years of experience in providing finishing services for automotive, aerospace, medical and other industry segments.

Partner for Global Industry

Extrude Hone offers a broad range of deburring, polishing and finishing services for, amongst others, the automotive industry, gas turbines, aerospace, food processing, fluid power, medical engineering, dies & molds and general engineering.

At Extrude Hone, we have solved thousands

of complex deburring, edge radiusing, and surface

finish problems for our customers. Before you

spend valuable time on your problem job,

Extrude Hone may already have the solution!

Contract Finishing ServicesCFS

• Tokyo, JapanShanghai, China •

Seoul, Korea •• Barcelona, Spain

• Paris, France

Remscheid,Erkheim, Germany •Babenhausen

• Milton Keynes, UKShannon, Ireland •

• Irwin, PA, USA

• Sao Paulo, Brazil

• Prague, Czech RepublicGrand Rapids, MI, USA • • Shelby

Township, MI, USA

• Columbia, SC, USA

Huntley, Ill, USA •

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