Mobile Edition
Print
Get the Mag
Weekly Updates[ILLUSTRATION OMITTED]
Skyway Precision, a CNC machining operation, was a shop experienced in producing automotive components, but when faced with a job machining hubs for earth-moving machines it moved into unknown territory. Deburring the hubs proved to be more expensive and time-consuming than planned, decreasing efficiency and affecting the bottom line.
The Plymouth, MI-based shop turned to an area neighbor, E-Z Burr Tool Co., also of Plymouth, for help. Skyway contacted E-Z Burr to develop a deburring solution. The proximity allowed the engineers of each company to meet and develop a quick solution.
One of the challenges was that the hub was three times the size of comparable automotive parts Skyway was used to handling, as well as being much heavier.
The nodular iron component weighed 80 lb with an 11.6" hub and 22 holes, 10 of 0.425" diameter and 12 of 1.093" diameter. The problem faced by the shop was how to deburr the holes on the backside of the hub.
Manual Labor
Before incorporating the E-Z Burr solution, Skyway removed the hub from its Hyundai-Kia Hi-V50D machine, placed it on a workbench, and manually deburred the rear of the holes by using a countersinking tool in an air drill. This proved to be cumbersome, time-consuming, and expensive.
The hub required heavy lifting and positioning by hand for the deburring. The countersink tool was expensive, and tool life was limited. It would wear quickly and required re-sharpening or replacing. That's when Skyway sought E-Z Burr's help. The deburring company offered Skyway options designed to deburr the rear of the holes while the hub was still on the machine.
"While we have a standard selection of diameters and lengths available off the shelf, we designed a special 9" tool for Skyway's application," Bill Robinson, E-Z Burr president, said. "The tool was tested at 550 rpm at 8.8 ipm in a 1.093" hole, to accommodate the specifications. This gives the shop the ability to deburr the backside of the hole while the hub remained in the machine."
For the smaller holes on the hub, a standard length tool at 1,750 rpm at 11 ipm in a 0.425" hole is used to deburr both the top and bottom in one pass.
Skyway, founded in 1968, preferred a more aggressive carbide insert. The increased angles and positive cutting features provided the pressure and engagement needed to produce the desired chamfer.
Better Focus
The introduction of the E-Z Burr tool to the process eliminated the need to remove the part from the machine to deburr the rear of the holes. The time, effort, and cost spent manually countersinking were eliminated. Countersinking while on the machine also let the machine operators focus on performance and meeting production schedules.
The solution led to an increase in productivity, saving Skyway 15 to 20 minutes per part.
While the manual countersinking tool previously-used lasted a day or two, the E-Z Burr carbide insert ran for a month before Skyway had to replace it. The tool remained in the machine while the insert was being replaced.
The deburring process then led to further engineered improvements by using a short pilot drill to start the hole and chamfer the top of the large holes. The pilot hole eliminated tool-walking and breakage problems and prolonged the life of the long drill.
"E-Z Burr prides itself on more than just providing superior deburring tools," Robinson said. "Through our 50-year history, we get involved with our customers to solve production problems where deburring parts is important in the final product. The tool we customized for Skyway was designed and delivered in less than two weeks." E-Z Burr Tool Co.
[ILLUSTRATION OMITTED]
[ILLUSTRATION OMITTED]
Visit www.rsleads.com/905mn-203 for more information
FEED