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COUNTERSINKING TOOLS
AIRCRAFT INDUSTRY
COUNTERSINKING
Back Spot Facing in Inconel 718
For all your technical needs
Work piece geometry, material, fixturing, machining process and the requirements that cutting tools are expected to fulfill vary from industry to industry. Since no application is like any other, HEULE's unique cutting tool line offers standard and speciality tools for all your technical needs.
COUNTERSINKING TOOLS
AIRCRAFT INDUSTRY
COUNTERSINKING
Back Spot Facing in Inconel 718
Back Spot Facing in Inconel 718
Our customer, a company in the German Aircraft Industry, has been machining 30 back spot facings in a component made of Inconel 718 for some years. To do this, the customer had to set up the part several time because of the poor accessability of the some bores. These countersinks were carried out by a box column drill. For the other counterbores, he used a counterbore tool with a plug-in head for the back bore machining. The process time amounted to approx. 6 hours for one component. His goal was to simply and to speed up this process.
Due to the very demanding material and the partly difficult to access machining spots, the customer was very critical with regard to new solutions.
Application details
- Material: Inconel 718
- Counterbore diameter: Ø13.0 mm
- Counterbore depth: 0.7 mm
- Bore diameter: Ø6.6 mm
- Material thickness: 10.7 mm
- Angle to surface: 180 Degrees (Cast skin)
- Number of bores: 30
- Machine: 5-axis machining center
Proposed solution
HEULE proposed its BSF tool with a working length of 15 mm equipped with a blade type BSF-M-1175 with X special coating.
Machining parameters:
- Speed: N = 300 U/min.
- Feed: F = 0.015mm/U
- Coolant: Inner and outer coolant
Customer benefits
The customer expectation was to produce 10 to 15 back spot facings with one blade, so that he would not need more than two blades pro part.
With a uptime of 25 back spot facings per blade and a cycle time of 55 sec., the BSF tool exceeded his expectations considerably. Besides, the stability of the process could be improved because of the reduction to one single setup and by the omission of manual operations.
Customer satisfaction
Being able to produce the part now in 35 minutes instead of 6 hours, the customer is not only satisfied but virtually exited about the new solution.
Click below to see all case studies:
Compressor Piston
A subcontractor to a compressor manufacturer was looking for an improved production method to deburr the two bores for the gudgeon pin. Up to now, this process has been carried out by hand.
Application details
- Bore diameter: Ø6.8 mm
- Deburring capacity: 0.3 mm - 0.5 mm
- Material: Powder metal
- Volume: 10'000 Bores per day
Proposed solution
HEULE recommended their COFA deburring tool for even and uneven bore edges: C6/6.8/H-OM with the blade type C6-M-0006-T.
Machining parameter:
- Cutting data:
Speed: 600 rev/min.
Feed: 120 mm/min - External coolant
- Machine: Horizontal machining in special transfer line
Customer benefits
The customer gained efficiency considerably because he could replace the manual deburring operation of the four bore edges.
Customer satisfaction
The customer's staff member appreciate the fact that the laborious manual deburring outside the machine became superfluous. The production manager is pleased about the improved quality and the process capability.
Click below to see all case studies:
Flow Meter
The manufacturer of this flow meter needed a cross bore with a defined chamfer in his workpiece. The difficulty that had to be overcome was the access to the back bore edge.
Application details
- Bore diameter: Ø6.0 mm
- Chamfer at the back bore edge: 0.25x45°
- Material: SU304
- Volume: 3000 Bores per month
Proposed solution
HEULE chose for this application their VEX-S Combi Drill Tool (GH-Q-O-4002 with replaceable drill bit P-S-C2-0600-1T). This tool was equipped with a SNAP chamfering blade (GH-Q-M-30106).
Machining parameter:
- Cutting data:
Speed: 1500 U/min
Feed for chamfer: 120 mm/min - Vertical CNC machine
Customer benefits
In one single pass the VEX-S Combi Drill Tool drills the hole and applies the required chamfer at the back of the bore.
Gear Disc
A Chinese subcontractor to the Automotive Industry was looking for a more efficient solution to drill weight reduction holes into a gear disc. The present production process included two manual chamfering operations (front and back chamfering) outside the CNC machine.
Application details
- Bore diameter: Ø15 mm
- Bore depth: 5.85 mm
- Chamfer: 0.25 x 45°
- Material: 20Cr Steel
- Machine: EMAG vertical CNC lathe
- Coolant: external coolant
Proposed solution
The HEULE representative proposed a standard VEX-P drill-chamfering combi tool. This tool allows to machine the complete hole in one setting and without any tool change.
VEX-Tool: GH-Q-O-4206
Drill: P-P-D-1500-1H
Chamfer blade: GH-Q-M-03846
Machining parameters:
- Cutting data drilling:
Speed: 1500 rev/min.
Feed: 0.2 mm/rev. - Cutting data chamfering:
Speed: 1000 rev/min.
Feed: 0.1 mm/rev.
Customer benefits
By using the VEX-P tool, the customer reduced the production time considerably by combining the two process operations into a single one.
Customer satisfaction
Besides the elimination of the chamfering as a secondary operation, the customer estimates the improved quality and the reliable process.
Sprocket Wheel
HALLA Industries Co. Ltd. - a subcontracting company to the automotive and the fittings industry - is located in South Korea. Among the components produced are flanges, sprockets and drive shafts.
Previously, the customer used a full carbide drill for the hole and a front and back deburring tool for removal of the burrs. The cycle time for all 12 bores amounted to 320 seconds. Since the deburring tool failed to produce a consistent chamfer, the sprockets had to be reworked manually outside of the machine.
Application details
- Bore diameter: Ø16 mm
- Bore depth: 12 mm
- Chamfer: 0.5 x 45°
- Material: Cast Steel, 500 N/mm2
Proposed solution
The customer decided to use a standard VEX-P drill-chamfering combi tool from HEULE. This tool allows to machine the complete hole in one setting and without any tool change.
Tool:
VEX-P Tool Ø16.0 1xd
VEX-P Insert Ø16.0 1H
SNAP12 Blade Ø17.0 TiN
Machining parameters:
- Cutting data:
Speed: 1500 rev/min
Feed: 0.2 mm/rev - Life time:
Drill insert: 100 m
Blade: 8'000 up to 10'000 Bores
Customer benefits
By using the VEX-P tool, the customer reduced the production time by 34 % to now 210 seconds.
Customer satisfaction
The customer is very satisfied about the reduction of the cycle time and the improvement of the process stability. He really likes the simple the handling of the HEULE tool and the very easy blade change of the SNAP system.
Rotor Wheel Wind Energy Plant
A manufacturer of wind rotors in China was looking for a more efficient and stable solution for the application of back spot faces to bores.
Application details
- Main bore: Ø14.0 mm
- Counterbore diameter: Ø22.0 mm
- Material: GG40
- Machining: Horizontally with internal coolant
- Machine: Gantry Boring and Milling Machine Center
Proposed solution
HEULE recommended the BSF tool with a working length of 80 mm, together with a TiAlN coated carbide blade type BSF-M-E-1A-5.0.
Machining parameters:
- Speed: N=500 rev/min
- Feed: F=20 mm/min
- Coolant: Internal coolant
Customer benefits
By choosing a new, more stable tool the customer reaches a better process capability. Furthermore, the better stability leads to an improved tool life of the blade.
Customer satisfaction
The customer is very happy with the new solution. The old tool (see image) - in contrast to the new BSF - needed preadjustments. This has left room for handling mistakes and has an influence on the saftey of the process.
Drive Plate
The customer, a manufacturer for car airconditioning systems, was looking for a better way to deburr the hinge type bores of his drive plate. The two through-holes with 4 bore edges should be deburred faster and more reliably in one single pass.
Application details
The image shows the existing solution with a fork type tool that did not satisfy the customer.
- Through hole bores: Ø6.5 mm
- Max. Deburr-Ø: Ø6.8 mm
- Material: GGG60
- Machine: Vertical Machining Center
- Volume: 50'000 pcs/month
Proposed solution
HEULE's recommendation for this application was the COFA tool C6/6.4/H-OM with the carbide blade type C6-M-006T. The blade is TlN coated.
Machining parameters:
- Speed: N = 1500 rev/min
- Feed: F = 300 mm/min
- Coolant: external coolant
Customer benefits
The new solution allowed the customer to run higher machining parameters and generated considerable savings. In addition, the use of COFA led to the envisaged quality increase.
Customer satisfaction
The decision makers as well as the machine operators are pleased with the result. The process is running smoothly and hassle-free. The savings as well as the increased reliability of the process have exceeded the customer's excpectations
Turbo Charger Housing
The customer, a German compressor manufacturer, was looking for back spot facer with high process capability in combination with a reasonable price.
Application details
- Bore-Ø: 14.0 mm
- Countersink-Ø: 26.0 mm
- Countersinking depth: 2.0 mm
- Material: GGG40
- Machine: MAZAK-INTEGREX e 1060V/6
- Machining concept: horizontal machining with internal coolant
- Volume: 50'000 pumps/a with 4 bores each
Proposed solution
The HEULE BSF tool is simply predestined for this kind of applications. We recommended our BSF-E-1400/050/-16.0-HB with carbide blade BSF-M-E-1A-10.0 to our customer.
Machining parameters:
- Speed: 400 rev/min
- Feed: 20 mm/min
- Coolant: internal coolant
Customer benefit
The most important criteria for the customer have been the quality of the back spot facing and the process capability of the tool. By choosing BSF, the customer improved both. In addition, the process could be automated fully which increased the efficiency of the process enormously.
Customer satisfaction
The new solution met the customer's demands (high process capability at reasonable cost). The previous tool (a back spot facer with fast rotation direction change) required a two spindle stops and direction changes for every bore.
CRFP plate
The aircraft industry uses the longer more CFK and other with carbon fibres reinforced materials. HEULE, having been active at the forefront of CFK machining for quite some time now, carried out trials for this customer and developed a solution.
Application details
- Bore-Ø: 4.81 mm
- Material 1: CFRP (Carbon fiber-reinforced plastic)
- Material 2: GFRP (Glass fiber-reinforced plastic)
- Machine: Mori Seiki NV5000 / 4 Axis Milling Machine
- Processing: Vertical Machining
The image shows on the left the bore entry and on the right the bore exit before deburring.
Proposed solution
HEULE developed a special tool based on the COFA C3. The carbide blade has a cutting geometry that is optimized for CFK and is coated.
Machining parameters:
- Speed: 2000 U/min
- Feed: 0.04 mm/U
Customer benefits
The picture shows on the left the bore entry and on the right the bore exit after the deburring.
The difficulty in deburring bores in carbon-reinforced materials is to cut the fibres neatly and not fray them. Furthermore, these materials are very abrasive which leads to heavy wear on the cutting edge of the blade.
Customer satisfaction
The customer is satisfied by the deburring result and by the tool life of the blade. The next step now is to implement the new procedure into production.
Mounting Bracket for Suspension
A subcontractor to the German automotive industry produces a mounting bracket for the suspension. In the course of process optimizing, the customer wanted to eliminate the manual deburring of the four through holes and to machine the workpiece to completion in one setup.
Application details
- Bore-Ø: 11.0 mm
- Bore depth: 1xd
- Chamfer: at front bore edge and at back bore edge
- Material: Cast aluminium alloy
- Machine: MC
- Machining orientation: Vertical machining
- Volume: 320'000 units per year
Proposed solution
For this application, the drill-chamfer-combination tool VEX-P GH-Q-O-4126 with indexable insert P-P-C-1100-1D and a SNAP8 blade GH-Q-M1327 was selected. In order to access the bore edge in between the two ridges, the customer reduced the tool body diameter by turning it simply to the suitable size. The trial ended successfully.
Machining parameters:
- Speed: 2500 rev/min
- Feed: 0.2 mm/rev
Customer benefits
The manual deburring could be abandoned. The high cutting data of the new process are responsible for being able to maintain the cycle time of the previous full carbide drill. Now, the hole is being drilled and deburred front and back in one single pass.
Customer satisfaction
The competent person at the customer's site comments: "By using VEX-P we can replace the manual deburring process. The workpiece leaves the machine completely finished. In addition the quality and uniformity of the chamfer is guaranteed. Also, there has not been any compromise as far as the tool life of the indexable insert as well as the cycle time is concerned."
Ball Valve / Hydraulic T-Piece
A Korean manufacturer of hydraulic components and fittings was looking for a more efficient and safer deburring solution for the crossbore of a ball valve. The goal was to automate the process if possible. Up to this date, workmen removed the burrs of the bore edge elaborately by hand with a brush.
Application details
- Cross bore / lateral bore: Ø10.4 mm
- Main bore: Ø10.4 mm
- Material: SS316
- Machine: DOOSAN CNC Center
Proposed solution
The deburring of crossbores with bore-Ø-ratio of 1:1 represented a particular challenge for HEULE. The solutions that were available so far could not cope with the extreme sloping of a 1:1 bore. A complete new approach was needed. HEULE found the answer to the problem by making use of new machine capabilities on one hand and by developing a special version of the COFA tool (COFA-X) on the other hand. Combining the two elements led to the success.
Machining parameters:
- Speed: 10 m/min
- Feed: 0.06 mm/U
- Coolant: external coolant
Customer benefits
The fact that the deburring could be carried out in an automated process together with the considerably improved reliabilty resulted in significant savings.
Customer satisfaction
The images in the top row show the bore before deburring and in the bottom row the result after deburring by COFA-X .
The successful pilot project is followed by a number of similar T pieces.
pring Pivot Bolt
A subcontractor to the Aircraft Industry was looking for a solution to eliminate the manual deburring of the backward bore edge of a main bore by replacing it by a more efficient process. Its intention was to be able to machine the spring pivot bolt completely in one setup.
Application details
The bore edge to be deburred is marked by a red circle. The challenges of this bore were the steeply inclined bore edge due to the diameter ratio and the proximity of the bore exit to the wall.
- Bore Ø4+0.03 mm exiting in groove/oblong hole Ø4.1 mm
- Material: stainless steel / 1,4301
- Machine: Gildemeister Langdreher G20
- Machining: Horizontally
- Cooling: Coolant Oil
- Volume: 400'000 bores/year
Proposed solution
These demands cannot be met by using a standard tool. For this reason HEULE designed a customer-specific tool based on the COFA C3-X tool (C3-X Ø3.8 mm). As a blade, an only-backward-cutting blade with a free angle of 30° (C3X-M-0001-X) has been selected.
Machining parameters:
- Speed: N = 800 rev./min.
- Feed: Fz = 0.03 mm
- Life time blade: approx. 9500 bores/blade (at present)
Customer benefits
The new setup allows a fully automatic machining of the workpiece including deburring.
Customer satisfaction
The deburring is complete and clean. The life time achieved so far is satisfactory. In order to explore the maximal possible life time, further tests will be carried out.
Bearing Bushing
The customer, a subcontractor to the German automotive industry, was looking for a suitable to chamfer the backward bore edge in a tube in a reliable and constant manner. The existing solution using a competitior's tool achieved no constant deburring result and thus caused quite some manual reworking.
Application details
In every workpiece, there are four bores of which the bore edges at the back of the bores only need to be deburred / chamfered:
- Bore-Ø d: 4 mm
- Outer Tube-Ø: 30 mm
- Inner Tube-Ø D: 26 mm
- Chamfer diam. burr free: max. 0.5 mm
- Material: Steel 1.0580 E 355
- Production volume: 680'000 bores per year
- Machine: Long turning lathe
- Processing: Radial processing from bar
- Coolant pressure: 30 bar
Proposed solution
HEULE proposed the follwing solution:
Tool: COFA 4M/4.0/Z1-OM
Blade: GH-C-M-0914-T nrs
Machining parameters:
- Cutting speed: S = 1200 min-1 / v = 15 m/min
- Feed: f = 0.2 mm/rev. (F = 240 mm/min)
Customer benefits
The capabitlity of the deburring process has been proven and the manual reworking has become no longer necessary. The cycle time could be improved. This resultet in productivity gains of at least 20 %.
Customer satisfaction
Long term member of the staff possessing a large amount of knowhow are as much excited about the results with the new tool as the head of production who can rely on a reliable solution now.
Case Car Hydraulics
A manufacturer of car hydraulics components faced the problem that their solid carbide chamfer tool did not produce the required chamfers in the desired quality on the cast surface.
Application details
- Bore-Ø: 6.7 mm
- max. Chamfer-Ø on front and backside of the bore: 7.0 mm
- Material: Cast steel 304 stainless
- Volume: 50'000 parts per year
- Machine: MAZAK Vertical machining center
- Machining: vertical
- Coolant: external coolant
Proposed solution
- Tool: SNAP5/6.5
- Blade: GH-Q-M-30207
Machining parameters:
- Speed: 1800 rev./min.
- Feed: 0.12 mm/rev.
Customer benefit / customer satisfaction
The SNAP tool is producing the chamfer on the desired quality level constantly.
Furthermore, the production employees found out that the adjustment of the SNAP tool is much easier than before.
Cantilever support
Our customer, a Swiss subcontracter to the machine building industry, manufactures a tube piece with 4 bores. Lacking an alternative, they deburred the holes manually.
Application details
The workpiece shows 2 x 2 bores. Per year, 50'000 units are manufactured. This results in 200'000 bores to be deburred annually.
- Bore-Ø d: 14.0 mm / 20.0 mm
- Inner tube-Ø D: 30.0 mm
- Outer tube-Ø: 35.0 mm
- Deburr size: max. 0.5 mm
- Material: Steel
- Machine: Long turning lathe
- Machining: Radially, from the bar, coolant pressure 30 bar
Proposed solution
The tools proposed by HEULE are:
- Ø14.0 mm:
Tool: COFA C12/13.5/H-OM
Blade: C12-M-0008-T (M/25°) - Ø20.0 mm:
Tool: COFA C12/19.5/H-OM
Blade: C12-M-0009-T (M/30°)
Machining parameters:
- Speed:
Ø14.0 mm: S = 455 min-1 (v = 20 m/min)
Ø20.0 mm: S = 280 min-1 (v = 17 m/min) - Feed:
Ø14.0 mm: f = 0.4/0.13 mm/rev (F = 182/60 mm/min)
Ø20.0 mm: f = 0.5 mm/rev (F = 140 mm/min)
Customer benefits
- Costs economies:
Automatic, process capable deburring - Elimination of manual work
Use of "unmanned" hours - Reduction of cycle time:
Cycle time can be reduced by 20% at least.
Customer satisfaction
"COFA is a most suitable possibility to eliminate manual processes and to make use of the ghost shift.", reports the customer.
Knee Replacement
Our customer, a artificial joint manufacturer in the medical technology field, was not happy with the exisiting manual deburring solution of a crossbore for the thread-run-out in the knee system in terms of quality and process capability. The increasing volume of bores to be deburred aggravated the issue so that the customer decided to contact the HEULE representative.
Application details
- Bore diameter: Ø6.0 mm in main bore Ø14.0 mm
- Material: CoCrMo
- Machine: Haas
- Machining: horizontally
In 2013, approximately 65.5 millions cars were produced. According to a forecast published by PwC this number shall rise to 100 millions until 2017. The automotive industry is a synonym for mass production, lean production and global consolidation. The "Lean Production" philosophy involves improvement programmes such as "Time saving activities", "Labor cost savings" or "CIP Continuous improvement process“. To support such endeavours HEULE develops tools that reduce the production time, that are simple in respect of handling and preadjustments and that meet the quality requirements.
AUTOMOTIVE INDUSTRY
Connecting Rod
HEULE Cassette tool with Special tool holder for the deburring of large bore diameters.
AUTOMOTIVE INDUSTRY
Cylinder Head
Back Spot Facing tool with adapted working length for simple and cost-effective backward machining
AUTOMOTIVE INDUSTRY
Common Rail
The process capable deburring of Common Rail applications has been assured by HEULE for years now.
Various possible applications
Workpiece geometry, material, clamping, machine concept - the demands on cutting tools are complex. No application is like any other.
The Universal Deburring Tool
Consistent deburring of even and uneven bore edges, front and back in One Operation.
The COFA tool removes burrs on the front and back of a drilled through-hole on even and uneven surfaces in a single cycle. It radially removes the burrs off the bore edges, without requiring the work piece to be turned or the spindle to be stopped. It can be applied universally in manual or automatic operations – for high volume production.
Specifics/Benefits
- Uniform radial deburring of uneven and even bore edges.
- Exchangeable carbide blade with material-specific coating.
- Robust and reliable process due to simple design and dependable handling.
- No injury of the bore surface during penetration of the bore.
- Can be applied for bore diameters of 2.0 mm and larger.
Pictures of machined workpieces
Deburring tools
Application
Connecting rod oil bore
The potential of this application is not the big annual volume of this customer but the many possible applications for many customer. The basically difficult accessibility is solved cleverly through the tool concept of HEULE PRECISION TOOLS.
The customer is looking for a solution to deburr the cross bores of a pipe for industrial cleaners automatically front and back.
Application details
- Oil bore Ø6.0mm
- Deburr strength 0.3mm, radially
- Material forged steel
Proposed solution
The worldwide first and still convincing COFA tool system which deburrs consistently even and uneven bore edges front and back in one operation. It delivers the bore edges radially of the burr, without turning the workpiece or without any need to stop the spindle.
To deburr the front and back side a standard tool COFA6/Ø6.0 with a Z-spring and a special working length of 90 mm is used.
Machining parameter:
Speed 100 rev/min, cutting speed vc 2 m/Min, working feed 0.15 mm/rev
Due to the large superelevation it is important to work with very small cutting data.
Customer benefits
Through the automated deburr the piece is now able to be treated completely on the machine.
Customer satisfaction
The customer is completely satisfied with the deburr quality.
Aluminium wheel - mounting bore
Our customer in the automotive industry in China produces about 12 million aluminium wheels for passenger vehicles per year.
The customer is looking for a solution to produce the mounting bore cost-effectively in one operation without having to turn the workpiece.
Application details
- Through bore: Ø14.0mm
- Counterbore forward: Ø36.0 mm
- 60° Sinking forward on the bore: Ø14.0 mm
- Back chamfer: 1.0 mm x 45º
- Material: aluminium
Proposed solution
The solution from HEULE is a VEX-P combined drill and countersink tool which has been specially adapted for the customer. In one pass and without any further tool change the four form elements can be machined.
The back deburring is executed by the proven SNAP principle.
For the forward counterbore a WSP plate made out of carbide is used.
Machining parameters:
Drill operation:
Speed 3500 rev/min, cutting speed vc 155 m/Min, working feed 0.3 mm/rev
Sinking forward / chamfering backward:
Speed 2800 rev/min, cutting speed vc 140 m/min, working feed 0.1 - 0.15 mm/rev
Customer benefits
The production of bores and counterbores in aluminium wheels required the use of four different tools. Furthermore, the operation plan included one turning of the workpiece. The maintenance effort and the down time for the readjustment of the repaired tools were considerable. The high costs for the existing tools and the non-guaranteed process capability have been reason enough to rethink the present production sequence.
Customer satisfaction
The customer is very satisfied by the result and the achieved savings of time and money
Aluminium wheels - valve holes
Our customer from Germany produces approx. 800‘000 aluminium wheels for cars per year, among others also for the premium brands.
The customer was looking for a solution to produce the valve hole more cost effective. He wanted to have it done in a single pass and without requiring the work piece to be turned.
Application Details
- Valve hole Ø11.6mm
- Countersink forward Ø16.25mm
- Chamfer backward Ø13.1mm x 90º
- Material Aluminium ALMg3Si7.
The production lines have used emulsion as a coolant so far. The new lines will be equipped with microlubrication (minimum quantity lubrication) only.
Valve hole: Forward machining
Valve hole: Backward machining
Proposed Solution
The solution from HEULE is a VEX-S Combi-Drilling-Chamfering-Tool which has been tailored to the specific needs of the customer. The tool is capable to machine the 3 form elements in one operation and without further tool changes.
The deburring at the back is carried out by the prove SNAP function priniciple whereas indexable inserts made of carbide are applied for the shaped chamfer at the the front side of the bore.
Machining parameters:
Drilling and countersinking forward:
Speed 2750 rpm, Cutting speed vc 100 m/min,
Feed 0.2 mm/rev.
Chamfering backward:
Speed 2750 rpm, Cutting speed vc 115 m/min,
Feed 0.15 mm/rev.
Customer Benefits
So far, the valve holes have been produced by stepped drills. Then, the bore ø11.6 on the back has been deburred manually because of the insufficient accessabilty at the backside. According to the customer, the resharpening of the stepped drill has been very complicated and time-consuming.
Customer Satisfaction
The customer is very pleased by the reached result and production time.
The new solution eliminates the manual deburring operation. The bore is manufactured completely and process capable by machine. The blades can be replaced easily and without readjustment of the machine.
Valve cylinder
The customer is looking for a solution to deburr bores of a cylinder valve for the automotive industry.
Application details
- Bore: Ø8.0 mm
- Bore depth: 5.0 mm
- Material: FCD 300
- Machine: WIA vertical machine
Proposed solution
The solution from HEULE is the standard tool COFA8/8.0/W with the blade GH-C-M-003.
Machining parameters:
Working speed: 1200 rev/min
Working feed: 0.35 mm/rev
Coolant: external coolant
Outer bearing
The bearing manufacturer would like to reduce the cycle time. The present time consumption for machining for drilling and interpolar milling amounts to 26 seconds.
Application details
- Four through holes Ø8.5mm.
- Three operations:
Drilling
Countersinking forward Ø11.0 x 90°
Deburring backwards max. 0.5 x 45° - Material: S55CR (approx. 700 - 900 N/mm2)
- Volume: 1.8 Mio. workpieces per year = 7.2 Mio. bores per year
Proposed solution
HEULE designed a customized tool based on the VEX-S technology for this application. Together with the SNAP chamfering blade and the indexable inserts for the countersinking this tool combines all three machining steps to on single operation.
The following machining parameters enable the combination tool to achieve a cycle time of under 16 seconds:
Machining parameter:
Drilling: Speed 3500 rev/min., Feed 0.2 mm/rev.
Countersinking: Speed 2000 rev/min., Speed 0.12 mm/rev.
Deburring backwards: Speed 2000 rev/min., Feed 0.12 mm/rev.
Customer benefits
Reducing the cycle time by approx. 10 seconds (= less 38%) resulted in an overall reduction of the machining time of 20'000 hours.
Flange
The customer, a subcontracting company to the German automotive industry, looked for a machine capable solution to deburr a cross bore. Up to now, the customer had to do the burring manually in a separate operation step .
Application details
Main bore: Ø89.0 mm
Cross bore: Ø12.0 mm H7
Axle offset: 15.4 mm with angle 5.3°
Material: X15CrNiSi20-12 (Tensile strength approx. 550-750 N/mm2)
Proposed solution
Caused by the axle offset and the angle, the inner bore edge is extremely uneven what makes it difficult to machine it automatically.
Initially, we intended to realise the processing by implementing 2 operation steps (1x COFA tool rotating clockwise and 1x COFA tool rotating anti-clockwise) and thus introducing a safe procedure. Unfortunately, there was no additional tool storage place available. This is why we started a small trial series using a COFA Special Blade with a clearance angle of 45°. Involved risk: the „aggressive“ blade could break.
The trials have led to positive results. The fears were not justified. The special COFA8 blade with Alcrona coating was able to stand the load (back machining only). It is important to mention that relatively low cutting values had to be applied in order to allow the blade to continuously adapt to the unevenness.
Machining parameters:
Working speed: 300 rev/min.
Working feed: 0.1 mm/rev.
Coolant: External coolant
Customer benefits
The new process allows the workpiece to be finished on the machine fully. Apart from the considerable cost savings, a stable process capable deburring process is resulting
lange for Double Row Taper Bearing
A roller bearing manufacturer in South Korea wanted to implement the most cost efficient method to drill and deburr holes into a bearing flange into their new development.
Application details
- Drilling: 9 holes Ø8.8 mm
- Drilling: 3 holes Ø7.1 mm
- Workpiece thickness: 6.0 mm
- Chamfering: front and back
- Material: Alloyed tool steel
- Production volume: 2 million parts/a
- Machine: DMG MORI Tapping Center
Proposed solution
HEULE proposed two VEX-S combination drilling tools, for each diameter one. The combination of drilling and chamfering at the front and the back of the bore reduces the three different operation steps to a single on.
Machining parameters:
- Drilling Ø8.8 mm & Ø7.1 mm:
Working speed: 88 m/min
Working feed: 0.25 mm/rev. - Front and Back chamfer
Working speed: 88 m/min.
Working feed: 0.2 mm/rev. - Cycle Time for both operations: 3 sec.
Customer benefits
The benefits are enormous. Since this solution divides the cycle time by two, the production time saved amounts to 20'000 hours (2 million parts x 12 bores x 3 sec.). The cost savings not only concern the production time but also the investments in machinery that have been rendered redundant.
Oil holes in gear shaft
The customer, a Chinese transplant of a renowned German gear manufacturer, wanted to deburr four oil holes in a gear shaft.
Application details
- Bore diameter: 3.0 mm
- Material: steel
- Production volume: 420'000 units p.a. / 1'680'000 bores p.a.
- Machine: CNC Vertical machine center
Proposed solution
In this case, there are two possible solutions. The job could be done either by a COFA or by a SNAP tool. The unevenness of the bore edge is not too high so that the SNAP tool can handle the task too. Since the customer favoured a larger chamfer, the choice was evident.
Chamfering tool: SNAP3/3.0/10
Blade: GH-Q-M40201, Ø3.6 90°, TIN coated, front and back cutting
Machining parameters:
Working speed: 3500 rev./min.
Working feed: 100 mm/min.
Customer benefits
The customer has implemented a very cost efficient process not only because of the speed and its outspoken reliability but also because of the long tool life of the blades.
Another advantage is the very simple blade change that guarantees a most efficient servicing of the tool.
Bushing
Our customer, a mechanical engineering company, has been deburring the bores in this bushing manually. What made the deburring difficult was the fact that the bores were located in the lubrication groove. The task was to deburr the outer and the inner bore edge of these cross bores automatically.
Application details
- Outer diameter: Ø144.0 mm
- Inner diameter: Ø130.0 mm
- Crossbore diameter: Ø6.0 mm
- Material: Brass
Proposed solution
The following tool has been selected:
Tool: COFA6/6.0/H
Blade: GH-C-M-0002
The difficulty to deburr the bores thouroughly lies in interior of the bushing. These grooves put high demands on the blade. This is why low cutting values have to be applied. The blade has to be given enough time to follow the bore edge.
Machining parameters:
Working speed: 500 rev./min.
Working feed: 0.1 mm/rev.
Coolant: external coolant
Customer benefits
Goal reached! The time-consuming manual deburring operation could be replaced successfully
Brake disc
The automotive industry requires millions of car brake discs. Therefore, the manufacturing method must be optimized to 100%. In this application, there are two different types of holes that ought to be drilled and finished in the shortest possible time.
Application details
Bore Number 1:
- Core hole for M8 thread
- Chamfer front and back: Ø8.5x90°
- Material: Cast
Bore Number 2:
- Bore: Ø8.6 mm
- Countersink forward: Ø17.2x90°
- Chamfer backward: Ø0.5x45°
- Material: Cast
Proposed solution
Bore Number 1:
The core hole is drilled, chamfered front and back Ø8.5x90° in one singe pass with a VEX-S / SNAP5 drill cominbation tool.
Machining parameters:
- Cutting data VEX:
Speed: 3200 rev/min.
Feed: 0.25 mm/rev.
Coolant: dry
Tool life: 250 m, = approx. 30'000 bores - Cutting data SNAP:
Speed: 1900 rev/min.
Feed: 0.15 mm/rev.
Coolant: dry
Tool life: > 30'000 bores
Bore Number 2:
This hole is drilled, countersinked forward Ø17.2x90° and back chamfered Ø0.5x45° in one single pass too. It is made by a special VEX drill-countersink cominbation tool.
Machining parameters:
- Cutting data VEX:
Speed: 2600 rev/min.
Feed: 0.26 mm/rev.
Coolant: dry
Tool life: 250 m, = approx. 30'000 bores - Cutting data Indexable insert:
Speed: 1500 rev/min.
Feed: 0.15 mm/rev.
Coolant: dry
Tool life: > 15'000 bores - Cutting data SNAP5:
Speed: 1500 rev/min.
Feed: 0.15 mm/rev.
Coolant: dry
Tool life: > 30'000 bores
Customer benefits
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