Deburring Edge Radiusing Contour Machining Surface

Advanced Manufacturing Technologies

Deburring Edge Radiusing Contour Machining Surface Finishing Polishing

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ww w.ex t r u dehone. com

“The most important aspects of a part are its surfaces and edges. The rest of the part is there merely to hold the surfaces and edges together!”

Automotive

Dies & Molds

Medical

Aerospace

Diesel

Programmed for Success Abrasive Flow Machining (AFM) ........................................................................................4-7 Orbital AFM .................................................................................................................................... 7 MicroFlow™ AFM . ..................................................................................................................8-9 Thermal Deburring (TEM) .................................................................................................10-11 Electrolytic Machining (ECM) ..........................................................................................12-13 CoolPulse™ ECM ..................................................................................................................... 14 Contract Finishing Services (CFS)

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The success story of Extrude Hone began with the development of our patented Abrasive Flow process in 1965. Today, Extrude Hone, with its headquarters in Irwin PA, USA, is recognized as a global leader specializing in non-conventional technologies including, Abrasive Flow Machining (AFM), Electrolytic Machining (ECM), and Thermal Energy Method (TEM) used for deburring, polishing, surface finishing and edge conditioning. Since our establishment more than 40 years ago, one factor in Extrude Hone’s history has remained constant: we rely upon our innovation and deep understanding of our customer’s needs.

Extrude Hone – Specialist for Innovative Surface Finishing Technologies

Quality Providing Added Value Wherever deburring, edge radiusing and polishing of sophisticated components are required, Extrude Hone’s advanced processing technologies — Abrasive Flow Machining (AFM), Electrolytic Machining (ECM) and Thermal Energy Method (TEM) — provide a reliable and economic solution. As a leading supplier of advanced finishing technologies and contract finishing services, Extrude Hone successfully solves some of the most complex deburring and surface finishing challenges faced by industry today. In fact, many of the world’s largest manufacturers rely on our advanced solutions to deburr and polish the internal and external surfaces of critical components that have proven to be inaccessible by other means and technologies. Moreover, Extrude Hone customers value our innovative finishing solutions for the significant competitive advantage they provide in the areas of increased productivity, and profitability on the components they manufacture. Work parts processed with Extrude Hone technologies enjoy improved functional stability, extended service life, and higher conformance to dimensional specifications. Contract Finishing Services – a Flexible Alternative Perhaps the easiest way to discover all the benefits of Extrude Hone’s precision finishing technologies is by using our global network of Contract Finishing Services. These facilities are available to deburr, polish, and clean your workpieces and deliver them back to you quickly and conveniently.

Think Global – Act Local

Global Customer Service

Today, Extrude Hone has an extensive network of manufacturing facilities and customer service centers in the US, Brazil, China, Japan, Korea, Germany, United Kingdom, Ireland, France, Spain, and the Czech Republic. Our employees speak the language of our customers.

Serving the customer is of major concern to us. Our experienced technicians and design engineers are at your disposal throughout the project. If desired, they will accompany the project from the development and prototype phase, develop machining strategies and ensure trouble-free implementation in series production.

We are a preferred supplier to metalworking companies throughout the world. These include the global automotive industry, its firsttier suppliers, drive-train gear manufacturing, fluid power, medical, food processing, mold and die, aerospace, gas turbine, and other light engineering. Complete Metalcutting Solutions from Kennametal

We always remain at your service: In the event that your equipment requires a replacement part, our readily available stock of “on-the-shelf” parts allows for immediate delivery and replacement by our service personnel. Being close to customers is our mission.

Since becoming part of the Kennametal Inc. family of companies, Extrude Hone has leveraged its direct relationship with Kennametal to further meet and exceed the needs of our customers. By combining Extrude Hone’s advanced and innovative deburring and finishing technologies with Kennametal’s state-of-the-art metal-cutting tools and systems, we are able to offer our customers a complete metalcutting and finishing solution. Together, Extrude Hone and Kennametal provide a breadth of technologically advanced products and services – from high-quality surface finishing of critical components to innovative tooling systems for metal cutting – unmatched today in the marketplace.

www. ex t ru d e h o n e. co m

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Abrasive Flow Machining

AFM

We deburr brilliantly.

Precision Deburring, Polishing, and Edge Radiusing Anywhere the Media Flows. Media with Brilliant Properties At the heart of our AFM process, is our unique, abrasive laden polymer or media that changes its apparent viscosity when a shear stress is applied. before AFM improves surfaces and edges created by a variety of manufacturing methods, including EDM, cast, forged, drilled, milled, and turned surfaces.

after

Ideal for… • Cross-drilled holes • Stepped and intersecting bores • Concave and convex surfaces • Milled and broached slots • Internal radii and chamfers • Internal bends and curves • Polishing internal passageways • Eliminating hand deburring • Thousands of other applications

The rheological properties of AFM media constantly present abrasive particles to the workpiece surface in a continuous and uniform manner.

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Our ISO 9001 certified manufacturing procedures assure a dependable and repeatable AFM process every time.

As the media is forced to flow over or through a restricted flow path, its molecules “cross link,” transforming the media from a viscous fluid to an elastic – or even brittle – solid. Since our media sticks to little other than itself, it easily slips across edges and surfaces like elastic, abrasive “putty” with results similar to 3D flowable “sandpaper.” Abrasive action is highest in the most restrictive passages with highest flow resistance.

Media Properties:

AFM media is reusable for extended periods although life expectancy is dependent on severity of use and application.

• Life cycle of the media: The media provides a matrix for homogeneous suspension of the abrasive particles.

Extrude Hone offers a wide selection of standard media formulations to service a broad range of customer applications. Custom engineered media formulations for special applications and process optimization are also available.

• Consistent “grinding quality”: Stock removal can be controlled using a combination of pressure, flow rate and flow volume. • Universal application possibilities: More than 200 media formulas developed to process a variety of workpiece materials and achieve precise surface and edge conditioning.

Typical AFM Media abrasives include silicon carbide and diamond abrasives. Particle sizes range from 5 to more than 4,000 microns (1,000 to 8 mesh).


AFM


Internal passages within this turbine engine diffuser are polished to increase airflow to the combustion chamber of the engine by ±2 %.

Non-conventional and High Performance The Extrude Hone AFM process defined a new level of quality and manufacturing productivity upon its introduction. As a result of ongoing advancements, AFM continues to be a leading and revolutionary deburring and polishing process today. AFM significantly improves the overall quality and product performance of cast, forged, and machined components at a reasonable and predictable cost.

In fact, AFM is now recognized as one of the most cost-effective methods available for internal and external deburring and surface finishing of workpieces. Our AFM process uniformly smoothes and blends in features, automatically and controllably, to a quality level and speed unachievable by hand or other forms of machine finishing. Plus, it finishes internal curved and complex surface locations previously unreachable by any other means.

Workpiece

Two-Way-Flow AFM

AFM produces dramatic improvements on a wide range of materials from drawn stainless steel elbows and fittings used by the semi-conductor industry (above) to investment cast aluminum turbo impellers (below).

The surfaces of extrusions dies for the aluminum and plastic industries are polished accurately and uniformly in a fraction of the time when compared to hand finishing.

These delicate heart valves are finished using AFM, resulting in a superior, ultra-clean smooth surface.

Vector Series


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AFM


AFM is used to polish and deburr parts where high-quality surfaces and edge conditions are critical to a product’s performance, strength and reliability.

A Finishing Solution for Many Industries AFM processing is used to finish some of the most critical components made by man for the automotive, aerospace, gas turbine, food processing, pharmaceutical, mold and die, fluid power, and general engineering industries. Whether it’s medical instruments, diesel engines, parts for the Space Shuttle or finishing dies used to make extruded aluminum building products, Extrude Hone’s AFM process has a global record of delivering reliable, precision results.

Deburring, radiusing and polishing of firtree slots.

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after

Multi-Flow AFM

One-Way-Flow AFM

The multi-flow AFM process utilizes multiple media cylinders which can be selectively actuated to provide precisely controlled abrasive flow machining to each edge and passage in a complex part.

The patented one-way-flow process extrudes medium through the workpiece in one direction only. The medium flows through the workpiece and into a hopper from where it is automatically returned to the single working cylinder.

Process Features at a Glance: • High precision deburring, radiusing and polishing • Suitable even for hard-to-reach areas • Improved surface finish and integrity • Increased life cycles and reduced wear rates • Removal of thermal recast layers and surface flaws

One-Way-Flow AFM

• Accurate process control and excellent repeatability • Applicable to single-parts as well as small lots and batch production 6


Multi-Flow AFM

This type of processing is particularly useful in series production of hot runners where the handling and cleaning operations are considerably simplified.


Broad Selection of Machines to Meet Every Need and Budget Extrude Hone offers various standard models of AFM machines with more than 20 different size capacities:

We deburr brilliantly. before

77 Series ideal for die polishing applications as well as short-run deburring, polishing and radiusing work

AFM

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AFM processing is also available through our Contract Finishing Services.

Profile Series for light to medium duty

Injector bodies, valves and nozzle holders are processed using AFM to produce generous radii from 0.1 to 0.4 mm, on the intersections of the high pressure holes to improve high cycle fatigue strength.

Vector Series for medium to heavy duty Spectrum Series for series production applications For more detailed technical data please go to www.extrudehone.com

Autoflow™ Control On request our units can be equipped with computer-controlled media flow which reduces fluctuations in temperature, pressure, flow rate and flow velocity. Thus even more consistent production results are achievable.

Orbital

AFM

We give surfaces the final touch.

The Process

Super Polishing and Finishing of Complex Shapes and Cavities.

Precision surface and edge finishing is achieved by rapid, low-amplitude, oscillations of the workpiece relative to a self-forming polishing tool – the abrasive-laden viscoelastic media. The media flows over the workpiece, finishing the surfaces by a combination of vertical oscillation and orbital motion of the workpiece in the horizontal plane. In this way surfaces that do not allow any through-flow can also be perfectly polished.

before This detail of a mold used to form the bottom of a beverage bottle shows the superior polishing results of Orbital AFM.

after

Orbital AFM: Surface finishing improvement of a PET blow mold.

Process Features at a Glance: • Reduces or eliminates skilled hand finishing • Produces extremely fine finishes on complex geometries while maintaining critical dimensional tolerances • Delivers repeatable, uniform results every time • Improves surface quality roughness by a factor of 20 Ideal for …

Orbital vibration Media Workpiece

• Blow molds • Surgical and prosthetic implants • Coining dies • Pill compacting dies • Racecar pistons • Aerospace components • Ball-valves, etc.


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MicroFlow™

AFM

Precise Sizing and Flow Tuning for Diesel Fuel and Fluid Atomization Systems.

With our advanced control systems and unique MicroFlow media, our precision MicroFlow process assures high quality, “right on target” holes that avoid the unfavorable asymmetric geometries produced by standard EDM processing.

before

after

Achieving a Consistent Flowrate

The MicroFlow Process

When precision finishing and maximum performance matters most in your workpieces, our MicroFlow process delivers. While very similar to our standard AFM processing, MicroFlow AFM is distinctive in three key areas. First, MicroFlow uses a much lower viscosity media. Second, the abrasive particle size within the media is much smaller. Lastly, MicroFlow features a more highly advanced process control feedback system.

Prior to MicroFlow, precision orifices in fuel injectors and metering nozzles were first machined and then, in a separate process, flow tested. Now, with our advanced MicroFlow AFM processing, Extrude Hone combines both of these critical and necessary steps into one process.

MicroFlow AFM is ideally suited for the diesel and automotive industry in the manufacturing of fuel delivery and distribution systems, including the sizing and flow tuning of advanced high-pressure diesel fuel spray injector nozzles. MicroFlow AFM delivers unequalled manufacturing control over orifice surface finishes and entry edges. Our MicroFlow AFM process provides consistent hole quality and enhanced flow characteristics for improved atomization, deeper jet spray penetration, and better fuel/air mixing, resulting in increased fuel economy, more horsepower, and a cleaner burning engine.

Workpieces are machined and tested as part of the same process to provide tightly controlled volumetric flow rates that significantly enhance their discharge coefficient. This method of processing is well above the typical EDM discharge coefficient of 0.6 to 0.8. MicroFlow AFM incorporates sophisticated sensing and precision algorithms in a closedloop system that monitors and accurately maintains all aspects of the process – from media viscosity and media pressure to shearforce history and temperature. The result is virtually any spray nozzle can be fine tuned to less than ±1 % of a targeted flowrate. MicroFlow processing can be performed by either of two distinctly different methods, depending upon your needs. Each method has its own advantages. HV – High Viscosity Media Processing: This method is suited to processing multiple parts simultaneously to achieve a superior hole geometry.

Ideal for … • Fine tuning spray nozzles to less than ± 1 % of targeted flow rate • Smoother, more uniform orifice geometry • Higher discharge coefficient than EDM • Precise entrance radii for better atomization and fuel distribution • Capable of producing identical hole sizes every time • Ideal for systems requiring controlled or metered fluid distribution 8


before LV – Low Viscosity Media Processing: This method is ideal for achieving a target flow rate in a single step process. after The MicroFlow AFM process can be employed on virtually any precision nozzle or metering hole where gas, liquid, or fine particles flow at a precise volumetric rate.

Both methods achieve similar results in that a set of nozzles produced today will flow at the same predetermined less than ±1 % flow rate as a similar set of nozzles produced from one batch run to the next.

High precision flow tuning After 20 % flow enhancement -1 % and precision flow tuning from MicroFlow™

MicroFlow™ +1 %

AFM

Conventional nozzles

FLOW DISTRIBUTION

MicroFlow AFM Machines

AFTER EDM TARGET

Extrude Hone is the world’s leading producer of precision flow tuning equipment and testing systems for diesel fuel injectors, flow metering and fluid atomization devices. Extrude Hone offers two standard models of MicroFlow™ AFM machine:

Discharge coefficient

MicroFlow LV and MicroFlow HV Inlet edge radiusing

Surface smoothing Streamlining

Degree of edge/surface modification

MicroFlow Optimizes Flow Discharge Coefficient A typical EDM orifice hole has a flow coefficient between 0.6 – 0.8, while a hole processed with MicroFlow has a typical flow coefficient in excess of 0.95, increasing flow velocity and improving atomization from an identical orifice diameter.

Both models can be configured to suit your specific requirements from laboratory development equipment to total turnkey production systems. Both systems can be designed to be semi-automated or fully-automated with workpiece loading and unloading.

MicroFlow™ AFM delivers unparalleled control over micro-hole surface finishes providing consistent quality and enhanced atomization and flow characteristics.

MicroFlow AFM systems are fully capable of providing … • Sizing and flow tuning of hole diameters down to 50 µm • Different flow conditions -higher discharge coefficients • Reduction of flow tolerance to less than ±1 % from ±6 % total mass flow – typical of EDM

Another critical flow application example is aircraft turbine blade cooling holes.

MicroFlow is also used to process high and low pressure atomization nozzles for: • Oil heating systems • Water and humidity systems • Washing and cleaning systems • Paint spraying systems • Spray coating medical, pharmaceutical, and electronic devices

• Nozzle pre-aging-purposely introduced wear at the spray hole entrance-resulting in high stability and consistency of the nozzle’s performance throughout its operational life • All nozzle geometries-conventional sac, VCO, minisac, etc. • Total automation, including part handling, cleaning, testing, and sorting • Process data records, storage, and analysis Visit www.extrudehone.com for complete specifications.

microflow™ LV


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Thermal Energy Method

TEM

We deburr lightning fast.

Complete Internal and External Burr Removal in one Quick Operation.

before TEM is unique among material removal processes primarily becaus it removes burrs and flash simultaneously throughout the workpiece, including inernal an external locations.

after

Burr before TEM

Fast and Economical

The TEM Process

Today, manufacturers are improving workpiece performance with increasingly more complex designs, resulting in greater surface finishing challenges. Our Thermal Energy Method (TEM) uses intense heat to deburr and deflash workpieces accurately, quickly and cost-effectively.

First, workpieces are securely sealed in a bell-shaped combustion chamber. Depending upon the size of your TEM machine and the containment chamber, several to hundreds of workpieces can be processed at a time.

Invented more than three decades ago, our TEM process is distinctive in that it removes internal and external burrs and flashings simultaneously and without affecting or compromising adjoining workpiece surfaces. The actual removal of burrs and flashings happens in a flash with a mere 20 milliseconds completion time. Through hundreds of installations and continued refinement of our TEM equipment, one factor remains constant: TEM is a rapid, low-cost, high-production process that can produce a million or more parts per year by a single machine.

Burr is vaporized

Deburred part after TEM

Process Features at a Glance: • Simultaneous removal of all internal and external burrs • Only simple tooling required • Short process times (ms) • Suitable for small lots and very high-volume production • Particularly suitable for deflashing of die-cast parts • Easily controllable process and excellent repeatability • Process reliability in production • Lowest cost for total deburring

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A pressurized mixture of a combustible gas – typically natural gas or methane and oxygen – is injected at 5 to 10 atmospheres of pressure, which is determined by the amount of material to be removed and the volume of parts in the chamber. A spark plug ignition system ignites the gas mixture, releasing heat energy from the oxidation of fuel in a 20 millisecond, high-speed heat wave. The surface of the combustion chamber absorbs the majority of the heat, harmlessly raising the temperature of the workpieces a few degrees. With their raised surface areas and thin cross-section features, burrs and flashing burn away instantly. Depending upon the heat diffusivity of the workpiece material, most, if not all burrs absorb the heat faster than the core of the workpiece. The burr becomes progressively hotter until it reaches the material’s oxidation temperature and ignites. The ignition process continues until the cross-section of the burr increases in thickness as it intersects the edge of the

Ideal for…

before

after

• Automotive parts • Screw machine parts • General hardware • Gears and pinions • Intersecting drilled holes • Internal grooves and undercuts • Thousands of other applications

Thermal Energy Method

TEM

We deburr lightning fast. after

before before workpiece, allowing the heat to diffuse into the body of the workpiece faster than it is being generated by the reaction, whereupon the process is completed. Because the gas mixture engulfs the entire workpiece, all internal and external surfaces are exposed to the rapid oxidation. Internal cross-drilled holes and intersecting edges that are difficult or impossible to reach are instantly processed. A Low-cost Deburring and Finishing Solution Because of its overall low processing costs, high-production rates and repeatable results, TEM is used throughout many industries – large and small. From high-volume automotive parts and hardware fittings to one-off prototypes, TEM is the unanimous and preferred choice over the more erratic and often unpredictable media tumbling and manual systems. Hundreds of Extrude Hone TEM installations at major manufacturers worldwide quickly and economically deburr and deflash billions

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of edges annually. These robust, field-proven systems are dependable, easy to operate and incorporate extensive safety features. Tooling used in the process is generally simple, and often not required. As a result, TEM is quite flexible, allowing for the same system setup of different parts and different materials with only modest time required for changeover. Post-Cleaning

A single Extrude Hone TEM machine is capable of processing millions of parts per year.

As for post-TEM cleaning, while not normally required if workpieces are later heat treated, some users prefer to remove oxidized material from the surface of the finished workpiece. Extrude Hone provides cleaning and drying systems specifically designed and suited to the needs of TEM.

The TEM processing is also available through our Contract Finishing Services.

Broad Selection of TEM Machines to Meet Every Need and Budget

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As an ideal solution for any contract or production shop, Extrude Hone offers several standard models of TEM machines from our compact P-80 and the cost-efficient entry-level TEM S-250 through to medium-sized units P-250 and P-350 up to model P-400 that accommodates large parts. Our TEM machines are designed and constructed to operate 24/7, pausing only for routine maintenance and cleaning. Actual machine cycle time, including indexing, sealing, safety checks, gas injection, and unclamping, requires only 20 seconds to 60 seconds while the TEM processing takes a mere 20 milliseconds. For more detailed data please go to www.extrudehone.com

TEM S-250


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Electrolytic Machining

ECM

We do more than just deburr.

Selective Deburring, Contouring and Polishing to the Highest Surface Quality. Electrolytic Machining, Deburring, and Polishing (ECM/ECD/ECP) Extrude Hone’s electrolytic technology provides fast, accurate, and highly controllable surface finish improvements for your precision workpieces. Our electrolytic process can machine, deburr, and polish surface locations previously unreachable by other methods, including manual work. The electrolytic process removes metal without direct contact between the tool and workpiece through the dissolution of surface atoms. In adhering to Faraday’s law of electrolysis, this selective metal removal process ensures the amount of material removed is proportional to the time and intensity of an electrical current flowing between the tool and workpiece.

• ECM – Electrolytic Machining: Used to machine workpieces with unique contours or specific edge geometries that normally cannot be produced by conventional machining methods, such as the internal galleries of diesel fuel injector nozzles, recesses in gear teeth of synchronizers, and rifling inside gun barrels. ECM Calibration Our ECM process is also capable of calibrating flow resistance. Example: Break-through edges of drilled crossholes are deburred and radiused while flow-volumes through the bores are simultaneously metered – two important and necessary operations performed in a single step!

While ECM, ECD, and ECP are essentially the same process, they are used to achieve slightly different results or objectives depending upon your workpieces:

Process Features at a Glance:

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Provides high-quality polishing of complex 3D contour milled surfaces such as found on medical implants and biopharmaceutical diaphragm valves.

before

ECM processing can produce exceptional surface finishes on a wide variety of materials. This aluminum sample with low Si content was machined on a multi-axis CNC mill then finished using Electrolytic Polishing (ECP). The finish went from an Ra of 2.0 µm to 0.5 µm in 35 seconds.

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The deburring fixture plays a major role in ECM processing and is matched to the workpiece to be machined. Finally, it is the fixture which determines the deburring result.

The fuel gallery of a diesel fuel injector is machined using ECM. The unique ability to precisely machine features to interior passages makes ECM a valuable tool for many industries.

• High-precision deburring and edge radiusing at pre-defined points • Straightforward machining at hard-to-reach areas • Deburring and contouring in a single operation • No formation of “secondary burrs” • Short process times (normally 10 – 30 sec) • No mechanical or thermal stresses for the workpieces • Machining of tough and hardened metals feasible • Controlled process

to radius edges on gear teeth. • ECP – Electrolytic Polishing:

Designing deburring fixtures is one of our core competences, based on many years of experience, as well as practical know-how. Deburring fixtures are designed and manufactured in-house and tested until they produce results which meet our customer’s expectations. The result: Quality without compromise.

• ECD – Electrolytic Deburring: Used to deburr holes and edges in difficult to reach locations on such workpieces as drilled break-through holes on the interior surface of air bag propellant systems and cross-drilled holes inside manifold blocks or

Planet gear before …

… and after ECM

Use of multiple fixtures increases productivity.

Electrolyte Workpiece (Anode)

Electrolytic Machining

ECM

We do more than just deburr. Tool (Cathode) Extrude Hone developed Pulse Electrolytic Technology (PET) to produce fine surface finishes on materials, such as stainless steel, aluminum, and others that meet or exceed electropolished finishes.

Pulsed high current output

The Electrolytic Process

Auxiliary Equipment and Accessories

In electrolytic machining, metal is removed without direct contact between the tool and workpiece. The electrolytic equipment uses a programmed, low-voltage direct current (DC) while a conductive electrolyte solution flows between the tool (cathode –) and workpiece (anode +).

Our customers can obtain everything they need from a single source: complete deburring and surface finishing systems with all the necessary peripherals such as pre and posttreatment systems, chamber filter presses, industrial coolers and chillers, gauging, workpart handling and much more. Precision aqueous cleaning systems for post-processing complement our product range.

The exchange of charge between the poles leads to material removal, atom by atom, in precisely defined areas.

ECM Machines

Automated Systems – Tailored to Customer’s Requirements Automated Standard Solutions Extrude Hone’s ECM equipment is very flexible and can easily be configured with robots and other automation equipment to achieve extremely high production rates. “SysLine” Series For high-volume production we also supply automated systems with integral process technology comprising pre-treatment, EC processing, post-treatment and media conditioning in a totally-enclosed system.

Extrude Hone offers a broad selection of ECM machines to cover a full range of applications and customer needs: DeskLine The compact yet highly versatile DeskLine model is designed as an inexpensive solution for deburring and finishing of low-production runs and prototypes. EcoLine

Interior bore intersections can be perfectly EC-machined.

ECM provides a highly controllable, yet cost-effective method of machining and polishing high quality surfaces and edges.

This space-saving ECM machine with a single workstation is suitable for batch production and incorporates maximum economy with minimum machine space, providing an outstanding cost-benefit ratio. ECLine With its modular configuration, the ECLine series offers a broad array of options. The unit contains all of the functions required for deburring and contour machining of precision metal parts. Various automation configurations also make the system suitable for high-volume production. The series is also available with two working stations. ECLine

Fully automated ECM system, “SysLine” series, for high-volume production.

The ECM processing is also available through our Contract Finishing Services.


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Auto Raise and Lower

CoolPulse™

ECM

Workpiece and Anode

Variable Speed Agitation

Pulsed DC Power Supply

We create perfection in detail.

Fast Surface Polishing and Removal of Micro-Burrs Without Impairing Part Integrity.

High Resistance Electrolyte Cathodes

Burrs Concentrated Electrical Field

CoolPulse is an innovative electrolytic process for surface finishing.

Workp ie

ce

Less Concentrated Electrical Field

Perfect Finishing CoolPulse is a unique electrolytic deburring and polishing process that allows manufacturers of small, complex, or delicate parts to greatly improve product quality. The process delivers micro-burr removal and electropolishlike results on small parts without the need for unstable, heated acid solutions. before

after

This innovative process provides surface finishing free from stresses, abrasion and distortion because no close-fitting electrodes are used. The process is therefore especially suitable for precision deburring and polishing of small and fragile parts such as medical/ surgical instruments and other high-precision components.

before The CoolPulse Process

“CoolPulsed” bone plate

after

Process Features at a Glance: • Low operating costs – no conformal tooling required • Fast set-up – typically in minutes • Safe operation – no harmful chemicals or acids • Consistent production finishing – thousands of parts • Repeatable and reliable results – easy-to-control process • Simple operation – no special skills required 14


The unique CoolPulse process uses a specially formulated electrolyte solution with a computer-controlled DC pulse power source. The electrolyte is chilled, non-fuming/ odourless and near pH neutral. This electrolyte solution has a high electrical resistance. When a machined workpiece is immersed in the solution and a pulsed, low DC voltage charge is applied between the part and a stationary cathode, an electrostatic charge is concentrated at any sharp features – i.e. the burrs of the workpiece.

The CoolPulse ECM processing is also available through our Contract Finishing Services.

In the area of concentrated electrical field, burrs are dissolved and flushed away by the electrolyte. By applying the voltage in controlled pulses, it is possible to provide a polishing effect concentrating on the edges only, or over the entire workpiece. CoolPulse is compatible with most workpiece materials such as mild steel, cast iron, stainless steel, aluminium, magnesium, etc. Normally, the process duration lies in the range 15 seconds to 3 minutes. CoolPulse – Five Key Functions: Deburring, polishing, stress-relieving, cleaning and passivating – all in a single finishing process. • Selective removal of micro-burrs, also on internal surfaces and edges, without impairing part integrity • Material stress relief through overall surface improvement • Super polishing of surfaces • Surface cleaning through elimination of free-iron (rust) particles • Stainless steel passivation as rust and corrosion inhibitor

before

after

ECM ECM

CoolPulseTM ECM

TEM TEM

Orbital AFM

MicroFlowTM AFM

Along with offering capital equipment, Extrude Hone maintains a global network of Contract Finishing Services. The following is a sampling of typical applications:

AFM

Extrude Hone Processes

deburr internal/external surfaces (including intersecting holes) deflash internal/external surfaces controlled corner and edge radius in hole sizes > 0.062” dia. (1.5 mm) controlled corner and edge radius in hole sizes < 0.062” dia. (1.5 mm) diesel fuel system components (common rails, runners), (improved high cycle fatigue resistance) diesel fuel injector nozzles (annulus, gallery, hole shaping, flow tuning) finishing hole sizes < 0.015” dia. ( < 0.4 mm) finishing hole sizes > 0.015” dia. ( > 0.4 mm) polishing and forming contoured surfaces polishing mold & die (blind cavity) polishing mold & die (through cavity) polishing extrusion dies (aluminum & others) polishing internal surfaces & passages (ultra-high purity valves and medical components) removal of thermal recast layer removal of EDM/spark erosion recast layer removal of laser erosion recast layer removal of sharp edges and burrs (elimination or radiusing) smooth & blend internal surfaces & passages (automotive intake/exhaust manifolds, headers, etc.) surface finish improvements 0.05 µm Ra or lower surface finish improvements 0.05 µm Ra and higher

CoolPulseTM ECM

Orbital AFM

MicroFlowTM AFM

AFM

surface machining, contouring, and polishing


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References That Speak for Themselves

Worldwide Locations Extrude Hone Corp. 1 Industry Blvd. Irwin, PA 15642 USA Tel.: +1 724-863-5900 Fax: +1 724-863-8759 www.extrudehone.com

Extrude Hone Ltd. 1 Sovereign Business Park Joplin Court, Crownhill Milton Keynes MK8 0JP Tel.:+44 (0) 1908 26 36 36 Fax:+44 (0) 1908 26 21 41 [email protected] www.extrudehone.com

Extrude Hone Czech s.r.o. Zdebradská ˇ 56 ˇ cany, CZ-251 01 Rí ˇ Jaˇzlovice Tel.:+420 724 127 712 Fax:+420 323 637 016 [email protected] www.extrudehone.com

Extrude Hone do Brasil Av. Marginal Direita 137, Prédio C. Rudge Ramos, Sao ˜ B. do Campo. Sao ˜ Paulo, CEP 09696-005 Brasilien Tel.: +55 11 4177 5585 [email protected]

Extrude Hone France Zl Bois de l‘Epine Avenue Jules Guesde, BP 10209 FR-91007 Evry Cédex Tel.:+33 (0) 1-60 79 83 20 Fax:+33 (0) 1-60 77 69 97 [email protected] www.extrudehone.fr

Extrude Hone (Shanghai) Co., Ltd No. 1508, Chen Qiao Road Fenpu, Fengxian District Shanghai 201401 P.R. China Tel.: +86 21 5690 5809 Fax: +86 21 5630 6554 www.extrudehone.com.cn

Extrude Hone Ltd. East Park, Shannon County Clare Irland Tel.:+353 61 705 060 Fax:+353 61 705 200 [email protected] www.extrudehone.com

Extrude Hone Spain S. L. Calle de la Quimica No 11 Poligono Industrial „La Ferreria“ Moncada i Reixac ES-08110 Barcelona Tel.:+34 93 575 3570 Fax:+34 93 564 7503 [email protected] www.extrudehone.es

Extrude Hone KK Shinwa 3-137-2 Misato-shi Saitama 341-0034 Japan Tel.: +81-48-954-0811 Fax: +81-48-954-0818 [email protected] www.extrudehone.co.jp Extrude Hone Korea Co., Ltd. #317-4Ba, Shihwa Industrial Complex, 719-5, Sunggok-Dong, Danwon-Gu, Ansan-City, Kyonggi-Do, 425-836, Korea Phone: +82-31-497-4012 Fax: +82-31-497-4043 [email protected] www.extrudehone.co.kr

Specifications and availability are subject to change without notice. Printed in Germany 8/2007 © Extrude Hone Corporation

Extrude Hone GmbH Memminger Strasse 37 D-87746 Erkheim Tel.: +49 (0) 83 36 – 80 05-0 Fax: +49 (0) 83 36 – 80 05-500 E-Mail: [email protected] Internet: www.extrudehone.de

Extrude Hone GmbH Berghauser Strasse 62 D-42859 Remscheid Tel.: +49 (0) 21 91 – 900-250 Fax: +49 (0) 21 91 – 900-254 E-Mail: [email protected] Internet: www.extrudehone.de

Contract Finishing Services

CFS

Three Processes – Precision to the Power of 3. As a systems supplier, Extrude Hone, a Kennametal Company, is a recognized partner to the global automotive industry and other areas of industry offering, with AFM, ECM and TEM, three high performance methods for deburring, polishing and surface finishing.

AFM – a method for deburring, radiusing and polishing in a single process.

ECM – a process for selective deburring, edge radiusing and contour machining. TEM – a thermal process for removing internal and external burrs in a fraction of a second.

Whenever burrs need to be reliably removed, edges radiused, profiles generated or metal surfaces polished, our process technologies AFM, ECM and TEM come to the fore regardless of whether it is deburring and surface finishing of internal bore intersections, machining delicate parts or workpieces with complex forms. Extrude Hone’s process technologies are engineered to increase productivity, reduce operating costs and help you produce a higher quality product. The result: Precision with Perfection.

No matter which process is involved: we deburr and finish your parts quickly and reliably.

CFS


Contract Production – a Genuine Alternative. Precise. Fast. Economical.

Extrude Hone has gained an enviable reputation as a machine builder and specialist in surface finishing of sophisticated precision metal parts. However, we not only build machines we also offer deburring and finishing services. For many well-known customers we have become an “extended workbench” where deburring, polishing and surface finishing is concerned. At Extrude Hone, we understand that keeping complex finishing operations in-house is not the preferred course of action for every manufacturer. However, for some, making a significant capital investment in finishing and deburring equipment may not be within the scope of their business model or financial resources. In such cases, outsourcing this function is the optimal solution.

The Benefits of Contract Production at Extrude Hone: • • • • • • • • • •

High flexibility No personnel costs No capital commitment Fixed cost-per-piece pricing Any lot size feasible Complete machining incl. pre- and post-processing services Consistent and repeatable results Quality management acc. to ISO 9001 24-hour turnaround capability Logistics services available on request

For more information on high-end finishing solutions go to www.extrudehone.com.

A pool of high-performance machines provides the basis for extensive flexibility in contract production at Extrude Hone.


CFS

Our Most Important Process is called Quality. For us Quality Means: The Customer Comes Back again and not the Product. “Total Quality Management“ at each of our contract service centres guarantees, amongst other things, that the required quality level throughout the production process is performed with microscopic inspection and gauging as well as statistical process control. All quality related information is documented, stored for future reference, and systematically audited. A process-oriented quality management system in compliance with ISO 9001 ensures consistently high quality.

Comprehensive Service Nowadays, cost reduction, quality management and just-in-time delivery are decisive factors. We work closely with customers so that we consistently meet their quality and delivery requirements. At our contract service centres we carry out trials, then test and optimise until the final result is perfect. However, deburring is not the whole job. Accepting an order from a customer also means “serving the customer“ – and we take that very seriously.

We manufacture your success.

In other words, our contract staff also provide the customer with practical advice and support where required, together with planning and controlling the process so that the contract is carried out professionally and to the full satisfaction of the customer.

If desired, we will also take care of the necessary logistics and ensure “just in time” delivery.

CFS


Services Around the Globe.

Grand Rapids, MI, USA • • Shelby Huntley, Ill, USA • Township, MI, USA • Irwin, PA, USA • Columbia, SC, USA

Extrude Hone is represented with its own service and contract production centres around the world: in the US, Brazil, China, Japan, Korea, Germany, UK, Ireland, France, Spain and the Czech Republic. We are always close to our customers.

Shannon, Ireland Remscheid, • • Milton Keynes, UK Erkheim, Germany •• • Prague, Czech Republic Babenhausen • Paris, France Barcelona, Spain

Seoul, Korea • Shanghai, China •

• Tokyo, Japan

• Sao Paulo, Brazil

Partner for Global Industry Extrude Hone offers a broad range of deburring, polishing and finishing services for, amongst others, the automotive industry, gas turbines, aerospace, food processing, fluid power, medical engineering, dies & molds and general engineering.

Extrude Hone can draw on more than 40-years of experience in providing finishing services for automotive, aerospace, medical and other industry segments.

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Deburring Edge Radiusing Contour Machining Surface

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