streamfinishing process and application - edeltec
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Streamfinishing
process and application
OTEC Präzisionsfinish GmbH
Heinrich-Hertz-Straße 24, 75334 Straubenhardt-Conweiler
www.otec.de/en
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June 30, 2016 2
Agenda
• Company information
• Streamfinish process & machines
• Pulsfinish process
• OTEC finishing center
• Automotive applications & benefits for customers
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June 30, 2016 3
Company profile • Development and production of mass finishing machines
• Founded in 1996, today approx. 110 employees
• World wide sales and services
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June 30, 2016 4
Key markets • Cutting tools
• Automotive
• Textiles
• Medical technology
• Pharmaceutical industry
• Watches
• Jewelry
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June 30, 2016 5
Facts & figures
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1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
turnover in mio. €headcount number of employees turnover in mio. €
Export ratio: 63 %
Staff and turnover development since company´s foundation
Turnover 2015 approx. 21m. €
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June 30, 2016 6
Technological milestones • First compact disc finishing and drag finishing machine
• Dry process for drag finishing and disc finishing machines
• Zero gap system
• Streamfinish technology
• Fully automatic Streamfinishing machine for in-line production
• Pulsfinish process
• 50 patents and utility models
Technology focused and customer oriented
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June 30, 2016 7
Streamfinish (SF) process • Workpieces are clamped in a holder and immersed in a rotating
process container filled with grinding or polishing media
• Abrasion by relative movement between media and workpiece
• Deburring, rounding and
smoothing in one operation
• Very short process times
• Ideal for automated production
• High process reliability
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June 30, 2016 8
Streamfinish machines
rotating process container
filled with abrasive media
lift unit
• Allows automatic loading
during process
angle adjustment of holders
rotating holder for workpieces
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June 30, 2016 9
Streamfinish machines - properties • With up to 5 holders for workpieces
• Manually or automatic loading and clamping
• Manually or automatic angle
adjustment of holders
• Automated holder change possible
• For dry and wet processing
• Easy change of process container
• Very easy changeover between different products
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June 30, 2016 10
SF Machines – in-line production
SF machines with automatic loading for processing of camshafts in automotive industry
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June 30, 2016 11
SF • Alternating rotation of workpiece up to +/- 2000 rpm
• High tangential acceleration up to 40G
Intense abrasive effect
Very low process time
• Very low Rpk-values (<0,1µm)
possible in short time
• Finishing of inaccessible
areas
-2000
-1000
0
1000
2000
0 0,5 1 1,5 2 2,5 3 3,5 4 4,5 5 5,5 6
ho
lde
r sp
ee
d [
rpm
]
time [s]
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June 30, 2016 12
Workpiece holders • Specially designed holders for workpieces
Grippers, collets, mandrels etc.
• Suited for automatic loading of machines
• Clamping on inner or outer shapes
• Optional: with HSK 63 interface
• Optional: compressed air cleaning
Special clamping device
for automatic loading of
camshaft bushes
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June 30, 2016 13
OTEC Finishing Center – basis of success • Well-equipped with measurement technology
• Very experienced and highly qualified staff
• Joint process research with institutes & universities
• Free processing of customer samples
individual customer counselling
detailed documentation
development of individual finishing
process for every customer
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June 30, 2016 14
Processing of camshafts
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June 30, 2016 15
Racing camshaft • Camshaft for a racing car
• Process time < 2 min
• Huge quality improvement
00,20,40,60,8
11,21,41,6
surface quality development
Edge before (left) and after (right) processing
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June 30, 2016 16
Deburring & edge rounding • SF process combines surface finish with
Deburring
Edge rounding
while the shape of the workpiece
is kept intact
Before (left) and after (right) SF Process
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June 30, 2016 17
Gear wheels • Smoothing
• Deburring
• Edge rounding
• Surface conditioned for
better lubrication
Flanks of gear wheel before (left) and after (right) SF process
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June 30, 2016 18
Complex geometries • Processing of complex geometries
Deburring
Smoothing
Edge rounding
• All over improvement in short process times
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June 30, 2016 19
Residual compressive stress • SF Process causes residual
compressive stress
in the workpiece
• Higher resistance against
bending stress
• Longer lifetime Residual stress at
camshafts after SF process
Depth [µm]
Resid
ual str
ess [N
/mm
²]
com
pre
ssio
n
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1,82 Gpa
hertzian stress
1,94 Gpa
hertzian stress
Co
eff
icie
nt o
f fr
ictio
n
Conventionally
grinded
-30%
Pulsfinish
processed
Testing time [h]
June 30, 2016 20
Decrease in coefficient of friction • Friction measurement on
two-disk test rig (Amsler)
• With droplets of
Mobil SHC 624 oil and
10% slippage
• Coefficient of friction is
reduced by 30 %
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June 30, 2016 21
Surface improvement • Elimination of grinding marks
• Significant reduction of roughness
• Granulate impact creates self-contained
micro-cavities to improve lubrication
Surface after Pulsfinish Surface before Pulsfinish
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June 30, 2016 22
Customer benefits • Noise reduction (up to 6dB possible e.g. with gear wheels)
• Up to 10% lower heat generation
• Better lubrication of surfaces
• No roughness peaks (Rpk < 0,1 µm)
reduced wear, no run-in necessary, longer lifetime of oil
• Coefficient of friction can be reduced by up to 30%
Higher efficiency, less energy consumption
overall performance improvement
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Thank you for your attention!