StreamfinishingProcess and application

OTEC Präzisionsfinish GmbHDieselstrasse 8-1275334 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 ofDIN 8589. It is also called abrasion finishing,because there is not always a grinding process,but also a lapping and polishing depending onthe 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 of additional centrifugal forces

• Deburring, edge honing, smoothing and polishing

• up to 5 processing stations, in manual operation 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

0

20

40

60

80

100

120

0 2 4 6 8 10 12 14

Flow

forc

es(%

)

Flow speed (m/s)

SF 3/200

Conventional drag-finishing systems

06.11.2013

2.2. Influence factorsComparison of process forces SF/DF

SF DF

Motion/Movement

• 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 availablewith 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 theneed 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 opposite 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

18Juni 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 one 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

HardeningGrinding 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 roundedbut droplets

removed

Rounded but droplets not removed

Rounded and droplets

removed

Chi

ppin

gvo

lum

eQ

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

00,020,040,060,080,1

0,120,140,160,180,2

Rauh

igkeit Ra

 [µm]

unprocessedprocessed

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% CCSpeed 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 processingTest: 11263-22013

06.11.2013

Task: Smoothing of guide blades

Processing time: 16 min.Angel B: 0°Direction of container rotation: 100% ccSpeed 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: 11181-21813Before processing After processing

06.11.2013

Task: Deburring of air brake pipes

Processing time: 0,5 – 1 min.Angle B: 25°Machine: SF 3-105Speed of container: 60 1/minSpeed of work piece: 2500 1/minMedia: KXMA 24

To date process: BrushingResult: 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: AluminumMedia: KXMA 24Spindle: 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: AluminumMedia: KXMA 24Spindle: 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: HSSMedia: H1/400Spindle: 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: M4/300Machine: SF-3

06.11.2013

Task: Processing of crimping tools

Processing time: 10 – 20 min.Machine: SF 3-1050Media: H1/500 + 5 kg M18Speed of container: 85 1/minSpeed of work piece: 0 (fixed rotating angel A)

Before processing After processing

06.11.2013

Task: Processing of blisk and turbine blades

Machine: SF-3Media: M4/300Processing time: 40 min.Rotating speed of container: 20 1/minRotating speed of work piece: 5 1/min

Result: Turbine blades deburred, edge honing, Ra. 0,08 µm

Machine: SF-3Media: QZ 1-3Processing time: 30 min.Rotating speed of container: 20 1/minRotating 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 muchfor your attention!