edge rounding and polishing of tools process and application straubenhardt, 2 june 2008 dipl.-ing....
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Edge Rounding and Polishing of Tools
Process and applicationStraubenhardt, 2 June 2008
Dipl.-Ing. (FH) Martin Bott
OTEC Präzisionsfinish GmbHDieselstrasse 8-1275334 Straubenhardtwww.otec.de
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Contents1.) TOOL CUTTING EDGE system
2.) Process for rounding the cutting edge
3.) Drag finishing 3.1) Process description 3.2) Processing goals
3.2.1) Edge rounding3.2.2) Polishing 3.2.3) Removal of droplets
3.3) Key factors3.3.1) Machine3.3.2) Media3.3.3) Workpiece
3.4) Machine specifications 4.) Outlook
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1.) TOOL CUTTING EDGE system
Nowadays tool experts are concerning themselves
with the
TOOL CUTTING EDGE system
consisting of:
tool material
tool cutting edge geometry
preparation of the cutting edge
coating of the cutting edge
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OTEC offers you a process for preparing
the cutting edge of the tool
consisting of
rounding of the cutting edges
and polishing of the cutting
surfaces
VIBRATORY DRAG FINISHING 4
1.) TOOL CUTTING EDGE system
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2.) Processes for rounding the cutting edges
- Sandblasting
- Brushing
- VIBRATORY DRAG
FINISHING
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3.) Drag finishing
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3.) Drag finishing
3.1) Process description
Since the workpieces can not come into contact with
each other, the result is a finishing process which is
gentle on the workpiece surfaces. In this process, it is
impossible for the workpieces to collide.
The drag finishing process enables multistage processes
such as fine grinding and polishing to be carried out.
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3.2) Drag finishing - processing goals
3.2.1) Edge rounding
achieves the following:
Removes grinding burs Stabilizes the cutting edge Gives uniform surface structure
at the cutting edge Extends tool life Gives better bonding for coatings Reduces jaggedness at the cutting edge Reduces chipping at the cutting edge Reduces build-up edges
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3.2.1) Edge rounding Example of a punching die
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3.2.1) Edge rounding Example of a die
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3.2.1) Edge rounding Example of an end milling cutter
Workpieces: Chip removing tools of all kinds requiring edge rounding.
Material: All materials used, but mainly carbides
Processing
goal:
Rounding of the primary and secondary cutting edges for immediate use
or prior to coating
Media: HSC granulates in the case of required edge rounding of up to 10 µm
SIX granulates in the case of required edge rounding of up to 30 µm
QZ 1-3 in the case of required edge rounding of more than 30 µm
Direction of
rotation:
100% clockwise
Processing
time:
1 – 20 minutes depending on degree of edge rounding required
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3.2.1) Edge rounding Example of an end-milling cutter
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3.2.1) Edge rounding unprocessed cutting edge
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3.2.1) Edge rounding processed cutting edge
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3.2) Drag finishing - processing goals
3.2.2) Polishing
achieves the following:
Improves the surface quality Reduces roughness Improves chip flow Improves flow characteristics when drawing Extends tool life Gives better bonding for coatings Reduces cutting forces needed Reduces tendency to cold welding
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3.2.2) Polishing Example of forming dies
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Unbearbeitet
Before processing After initial grinding
After polishing
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3.2.2) Polishing Example of a forming tool
unprocessed
processed
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3.2.2) Polishing Example of a forming die
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3.2.2) Polishing Example of a thread-cutting tap
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3.2.2) Polishing Example of a tool holder
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3.2) Drag finishing - processing goals
3.2.3) Droplet removal
achieves the following:
Improves surface quality Reduces roughness Improves chip flow Improves flow characteristics when drawing Extends tool life Reduces cutting forces required Creates microscopic lubricant pockets
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3.2.3) Smoothing of a coated surface
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3.2.3) Droplet removal Example of an end milling cutter
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3.2.3) Example: smoothing of a coated surface
As a result of the PVD coating process, droplets (tiny
balls of material embedded into the surface) often
become lodged in the protective coating.This in turn causes friction.
The drag finishing process removes these droplets.
The miniature “pockets” that remain improve the wetting
properties of the surface.
These “pockets” serve to store lubricant.
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3.3) Key factors
3.3.1) Machine parameters
3.3.2) Media
3.3.3) Workpieces
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3.3.1) Machine parameters
3.3.1.1) Speed
3.3.1.2) Processing time
3.3.1.3) Direction
3.3.1.4) Immersion depth
3.3.1.5) Angle of holder
3.3.1.6) Control functions
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3.3) Key factors
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3.3.1) Machine parameters
Overview
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Parameter input
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3.3.1.1) Speed
Higher speeds give greater rounding values
N.B. The rounding at corners increases more quickly
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3.3.1.1) Effect of speed
Kantenverrundung "unterschiedliche Drehzahlen " HM Bohrer 10.0; Tges= 20 min; Drehricht. 50/50; Granulat: SIX 70/16; DF3 Tools
0,000
0,005
0,010
0,015
0,020
0,025
0,030
0,035
0,040
Zeit [min]
Ka
nte
nv
err
un
du
ng
[µ
m]
25 [1/min]
35 [1/min]
40 [1/min]
30 [1/min]
0 2 4 6 8 10 12 14 16 18 20
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3.3.1.2 + 3.3.1.3) Processing time and directionThe processing time and the direction of rotation
can be controlled during the process.
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3.3.1.2) Effect of processing time
Longer processing times give higher degrees of
rounding.
The increase in rounding values is not linear to the
processing time.
N.B. The rounding at the corners increases faster than
at the edges.
Depending on the media, the maximum value can
vary.
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3.3.1.2) Effect of processing time
Kantenverrundung "unterschiedliche Granulate " HM Bohrer 10.0; Tges= 20 min; Drehricht. 50/50; Drehzahl = 25 [1/min]; DF3
Tools
0,000
0,005
0,010
0,015
0,020
0,025
0,030
0,035
0,040
0,045
0,050
0,055
0,060
0,065
Zeit [min]
Ka
nte
nv
err
un
du
ng
[µ
m]
SIX 70/24
QZ 1/3
HSC 1/300
SIX 70/16
0 2 4 6 8 10 12 14 16 18 20
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3.3.1.3) Effect of direction
The choice of direction of rotation affects the flow of media
against the workpiece.
A change of speed is absolutely essential for homogeneous
media flow and uniform processing.
Uneven finishing, which is more pronounced on one side
than the other, is often undesirable.
Differences between the workpiece and the speed or
direction of the rotor affect have an effect on edge
rounding. (Low workpiece rotations give a uniform finish)
(High workpiece rotations give a more pronounced rounding of the
corners)
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3.3.1.4) Immersion depth
Different immersion depths can be achieved by
preselecting the operating modes.
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3.3.1.4) Effect of immersion depth
Because of the static pressure, the contact pressure of
the media increases with the immersion depth. In general
we can say that a difference of 100 mm in the vertical
results in a difference of about 25% in the amount of
material removed.
In the case of lightweight media with a low bulk density,
this effect is less pronounced.
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3.3.1.5) Effect of the angle of the holder and/or workpieces
An angled position for the holders and/or the
workpieces offers advantages for the processing of
the workpiece face and of large flat areas.
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3.3.1.6) Control functions
In addition to the adjustable machine parameters, the following
additional parameters are monitored:
-Media life for 5 different,
freely selectable, media types
-Workpiece length
(Sensor for avoiding collisions)
-Media level (Sensor for measuring the
level)
Goal: reliable processes
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3.3) Key factors
3.3.2) Media
H granulates polishing
HSC granulates gentle edge rounding 15-20 µm
K granulates gentle edge rounding < 15
µm
SIX granulates more pronounced edge rounding up to
30 µm
QZ granulates more pronounced edge rounding over
30 µm
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3.3.2) Media H granulates
- Finishing of HSS tools- Polishing, gentle deburring- Gentle edge rounding- Low rate of chip removal, depending on
grinding or polishing additive
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3.3.2) Media HSC granulates
- Finishing of HSS and carbide tools- Polishing of coated tools and
removal of droplets- Smoothing and polishing of carbide
tools- Edge rounding of carbide materials
up to max. 15 – 20 µm- Removal of solder residues- Rate of chip removal medium to high
depending on grain size- Creates very high surface qualities
(Rz 0.5 for an initial value of Rz 2.5)
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3.3.2) Media K granulates
- Finishing of HSS and carbide tools
- Polishing of coated tools and removal of droplets
- Smoothing and polishing of carbide tools
- Edge rounding of carbide materials up to max. 10 – 15 µm
- Natural granulate bonded with PP1 polishing powder
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3.3.2) Media SIX granulates
- Finishing of carbide tools- Deburring and edge rounding of HSS
tools- Smoothing and edge rounding of chip
removing tools in carbide up to max. 30 µm
- Finishing of inserts- High rate of chip removal- Creates high quality surfaces
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3.3.2) Media QZ granulates
- Finishing of carbide tools- Gives especially high degree of edge
rounding over 30 µm- Rate of chip removal approx. twice as
high as with SIX granulates- Carborundum with grain size of 1-3 mm- Very high rate of material removal- In the case of small edge radii under
30 µm; gives rougher surfaces than SIX or HSC granulates.
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3.3.2) Media - Changing the media
It is a quick matter to change the media by simply
changing the process container. This makes it possible to
carry out multi-stage processing very efficiently.
The drag grinding or drag finishing process is the only type
of vibratory grinding that enables targeted surface
finishing such as deburring, grinding, polishing and
targeted edge rounding – all from the same machine.
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3.3.2) Media - Changing the media
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3.3) Key factors
3.3.3) Workpiece
3.3.3.1) Workpiece size
3.3.3.2) Workpiece geometry
3.3.3.3) Workpiece materials
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3.3.3.1) Effect of workpiece size
In the case of single-drive DF machines, the transmission ratio between rotor and workpiece can not be adjusted. Here the diameter accounts for only about 10% of the effect.
In the case of dual drive versions with two motors, the satellite speed can be set independently of the rotary speed.
Areas of application:Thread-cutting taps high satellite speed, low rotor speedCarbide drills low satellite speed, high rotor speed
In the case of high satellite speeds, the diameter of the workpiece has a much greater effect than it does with low satellite speeds.
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3.3.3.2) Effect of workpiece geometry
Larger workpieces displace more media, which ‘glides’
over the edges and removes more material.
The processing has little effect on the central areas of
large, flat workpieces.
“Scooping” workpieces push the media away from
themselves.
This reduces the effect of processing.
Inner surfaces can be processed to a limited extend. With
small bore holes, the media grain size should not be too
large.
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3.3.3.3) Effect of workpiece materials
Workpieces made from hard materials can be rounded
more accurately than soft ones.
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3.4) Machine specifications
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DF-3 DF-4 DF-5 DF-6 DF-10Maximum immersion depth
250 mm 250 mm 250 mm 250 mm 250 mm
Holder connections 3 4 5 6 10Maximum workpiece diameter
250 mm 210 mm 250 mm 210 mm 200 mm
Maximum holder weight 15 kg 15 kg 15 kg 15 kg 15 kgAdapter interfaces for 4-way / 6-way holders
12 / 18 16 / 24 20 / 30 24 / 36 40 / 60
Maximum workpiece diameter with 4-way / 6-way adapter
85 mm 55 mm
82 mm55 mm
85 mm55 mm
82 mm55 mm
65 mm55 mm
Maximum workpiece weight with adapter
0.5 / 2 kg
0.5 / 2 kg
0.5 / 2 kg
0.5 / 2 kg
0.5 / 2 kg
Extra drive optional optional optional optional optionalConnection voltage 400 V 400 V 400 V 400 V 400 V
Power requirement depending on configuration
2-3 kW 2 -3 kW 3 – 5 kW 3 – 5 kW 3.5 – 7 kW
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3.4) Machine specificationsIndependently rotating holder systems
Holder type 4-way 2B up to 500 g
Holder type 6-way 2B up to 500 g
Holder type 4-way 2B up to 2 kg
Holder type 6-way 2B up to 2 kg
Holder type 4-way 2B SL
Holder type 6-way 2B SL
Special types on request
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4.) Outlook
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DF-3/4 and DF-5/6 available with additional drive
unit
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4.) Outlook
DF-3/4 and DF-5/6
with angled holders
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4.) Outlook
DF-6 Automation
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4.) Outlook
DF-6 Automation
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4.) Outlook
DF-6 Automation
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Thank you
for your attention !