properly. This translates into a component that won’t perform correctly. Certain parts need to have the same surface roughness after burrs are removed, or actually need to have a rougher surface. Stainless steel wire disk brushes are ideal for deburring where roughing is required,” said Akuszewski.
“Product design flexibility can aid in automated finishing with the ability to add flow-through coolant that provides an ideal working environment for ATB products and has many finishing benefits for the manufacturer. Coolant keeps the nylon fila- ment rigid for consistent finishing and aids in achieving a finer surface finish. Cool- ant also lowers the risk of warping and distorting parts, especially in applications where smaller or thinner parts are being processed,” said Akuszewski.
Sizing Up Upstream Production for Parts Deburring It’s a bit of a conundrum: Burrs are produced in upstream processes that are performed by cutting tools that, due to wear, produce burrs that change size over time. At the same time, deburring tools, like brushes, also wear. “One of the first questions we ask is, what is the upstream process and what are the best and worst- case burr geometries that are likely to be produced by that upstream process,” said John Sockman, director, industrial production, Weiler Corp. (Cresco, PA). “Once we have a good understanding of that operating window from best to worst case, we evaluate parts in our application laboratory to select tools, operating parameters, and develop wear compensation scenarios. For example, the brush will work this way when it’s new, but we have to know how it will work when it’s 10% worn or 30% worn. We have to build a wear compensation system that is robust enough to handle the wear of the media and the fact that the upstream process is producing a burr that itself will vary over time. When the cutting tools are new, the burrs are small. But when the cutting tools wear, the burrs get larger,” said Sockman. “And you can be sure that production parts will not mimic the parts which were used for process development. This fact needs to be considered when the process is prototyped.” In addition to planning for the variation introduced by the upstream process, another critical element of process design is the selection of operating parameters. This selection is not intuitive. “Inexperienced machine builders will commonly select operating parameters, speeds, feeds, and the brushing equivalent of depth-of-cut incorrectly. Another common mistake is thinking that smaller parts require the use of smaller media. That’s rarely a good decision. Generally, the largest media with the highest filament density that is allowed by the part geometry is the best solution. That’s the way to develop the most robust process with the lowerst cost per part. The smaller products tend to wear faster, resulting in more machine downtime, so using larger tools is almost always better,” said Sockman.
Aerospace, Automotive Automate in Different Ways “Today, we are seeing a lot of automation projects in factories that are bring- ing work back from Asia, as well as for new programs that would have been sent overseas a decade ago. The economic benefits of having a shorter supply chain and bringing production closer to the end market are trumping lower labor costs,” said Sockman. Weiler gets involved in three different types of automation.
October 2014 |
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