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How to get large bore burnishing accurately right
An
Ecoroll product story
Edited by the Manufacturingtalk editorial team
Oct 9, 2001
Ecoroll has overcome a bore burnishing problem that has been bothering users of thin-walled hydraulic cylinder tube greater than 140mm diameter for some time.
Ecoroll has overcome a bore burnishing problem that has been bothering users of thin-walled hydraulic cylinder tube greater than 140mm diameter for some time.
Tubes having large diameters and thin walls exhibit more out-of-round tolerances caused by the tube-drawing and straightening process.
The usual remedy is to use twin cutter skiving heads.
After skiving, the tubes may still exhibit spiral rippling owing to distortion of the cylinder, producing polygon 'lobing'.
It means that correctly dimension pistons sometimes will not fit or the sealing gap between the piston and cylinder wall is inconsistent.
Ecoroll has developed its RDO skive-burnishing tool range equipped with its patented Omega skiving head.
In tests carried out, cylinder tubes of 156mm diameter by 8.5mm wall thickness, and with three-fold polygon diameter variations of 1 to 1.7mm were machined with the RDO skive-burnishing tool.
After skive-burnishing, the test showed that tubes with an initial error of 1.7mm on diameter showed only 0.07mm error at the entrance end and only 0.02mm after skive-burnishing over a length of 150mm.
Ecoroll says the tests showed that the Omega skiving head is able to improve the circular accuracy of cylinder tubes and avoid rippling.
Briefly, the RDO/Omega skive-burnishing tools offer: * improved circular shape, less rippling.
* High cutting performance, using cutting speeds up to 300m/min and feeds up to 6-9mm/rev.
* three to six skiving knives (according to bore diameter) in a common floating arrangement.
* Only one central adjustment screw is used to set the diameter of all knives.
* Precise adjustments are made using a scale in increments of 5 microns.
* Large guide pads ensure wobble-free tool operation.
* Existing Ecoroll tooling, type RDS-Retrac, can be retrofitted with Omega skiving heads * Over tube bore diameters of 400mm, Ecoroll recommends separate skiving and burnishing operations, using OSK skiving heads with Omega technology, followed by roller burnishing using Ecoroll GZ tooling.
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