Thermal Deburring – Precise and Efficient

Thermal Deburring –
Precise and Efficient
The reliable solution for complex workpieces
with difficult-to-reach contours
2
Contours without disruptive burrs on complex
and safety-relevant components
Cost pressures in a tough competitive environment require maximum production
efficiency and minimal production costs. Benefit from our many years of engineering
expertise in thermal deburring to achieve top results efficiently and reliably. With
Rexroth’s TEM method, precise and economic deburring of workpieces with complex
geometries and difficult-to-reach contours is simple – with maximum productivity and
without compromising on quality.
3
Improve your cost structure significantly with Rexroth’s
TEM method
Not every burr on a complex, safety-relevant component is
easy to reach. Rexroth’s thermal deburring method (TEM)
has proven to be a reliable and clean procedure for
removing burrs and residue – especially wherever
mechanical methods are inefficient or downright
impossible.
X Removal of burrs in inaccessible tapped holes or
concealed behind a workpiece edge
X Deburring in a single work step
X Optimum results without compromises
X As a stand-alone unit or completely integrated into
automated production lines
4
Top results with an
economic deburring process
Thermal deburring –
efficient technology for ultimate quality
Burrs develop on workpieces during machining and other
Your advantage: TEM does not affect the workpiece surface
production processes, such as die-casting, and must later
and is characterized by extremely low energy costs and
be removed to ensure a smooth surface and thus optimal
unbeatable flexibility compared with other processes.
component functionality. Contours are often in areas which
It is suitable both for small batches with a wide variety of
are difficult to see and access.
models as well as large batches with different materials.
Rexroth’s thermal burring method (TEM) has proven to be a
The TEM method ensures consistently high quality,
reliable, clean solution for removing any burrs and residue
sustainable process stability, and extremely cost-effective
on workpieces in a single step.
processes.
5
Thermal deburring –
your benefits:
Lightning-fast processes
Maximum efficiency and fast
Unparalleled reliability
X Cycle time:
return on investment
X Reliably reproducible and
between 25 and 45 seconds
per machining cycle
X Possible to deburr several
X Simple fixtures or workpiece
bulk deburring in baskets
X Cost-efficient deburring (on
workpieces simultaneously in
exterior and interior) of
series production of large
complex workpieces with
quantities
X Short change-over times for
extremely short cycle times
X TEM process works for all
process parameters and
component materials and parts
fixtures
geometries
documentable deburring
processes
X Suitable for deburring safetyrelevant components
X Continuous three-shift
operation possible
X Certified TÜV safety
6
Thermal deburring
with maximum precision
Combustion gas
Oxygen
Workpiece before deburring
Sophisticated process for optimal results
A thermochemical process is initiated using heat and
pressure. Igniting a concentrated gas-oxygen mixture
achieves a temperature of 2500 to 3200°C for
approximately 20 milliseconds.
Compared with labor-intensive mechanical processes,
thermal deburring with hydrogen, methane, or natural gas
Combustion through
thermochemical process
in deburring chamber
has clear advantages:
X Adjusting the chamber filling pressure defines targeted
deburring results
X With gas as the energy source, the volume can be dosed
exactly via the pressure
X Gas is distributed uniformly in space, reliably removing
burrs even in hollow spaces and tapped holes
Precise result:
workpiece after deburring
7
Functional principle
with reliable deburring quality
Milling device
Chamfer
Drill burr
Any
thread
Burr
from
grinding
Burrs from drill
insertion
Flash with
die-casting
Sharp edge
Casting burr on
aluminum and
zinc parts
Schematic diagram of
typical burrs and edges
Steel and grey cast iron
Zinc and aluminum
Brass
Schematic diagram of results (shown enlarged)
after the burrs and edges have been removed from various materials
Exact deburring results – with any material
Thermal deburring is ideal for a variety of metallic materials
and is particularly suitable for non-hardened parts:
X Steel and grey cast iron parts: Deburring results range
from sharp, burr-free edges to semi-rounded edges.
Thread tips are not affected.
X Zinc and aluminum parts: Deburring achieves sharp,
burr-free edges on parts with cutting burrs. Burrs on
molded parts with a large burr foot can be reduced
Unprocessed part
After deburring
After cleaning
significantly. Thread tips are not affected.
X Brass parts: Results range from sharp, burr-free edges
to a small chamfer. Thread tips are not affected.
Pre-treatment and after-treatment:
Before thermal deburring, workpieces must be washed and
dried. They must be completely free of grease. During the
deburring process, a deposit of metal oxide forms on the
surface of the workpiece. Deburred workpieces can
normally immediately undergo further processing, such as
painting, surface finishing, or heat treatment. Alternatively,
they can be cleaned using acidic or neutral cleaners
supported by ultrasound.
8
Convincing
deburring results
Die-cast hydraulic housing
Aluminum hydraulic housing
Steel spool
Die-cast aluminum pump housing
9
Steel turned part
Steel housing part
Brass fitting
Die-cast zinc lock barrel
10
Maximum flexibility
and versatility
A wide range of applications in various industries
Thermal deburring is optimally designed to remove
internal and external burrs
on nearly all metallic workpieces. In fact, it doesn’t
matter what application the
parts will be used in and
whether they are made of
steel, cast iron, brass, zinc,
or aluminum. You can quickly
and reliably remove cutting
burrs produced by turning,
milling, broaching, and
grinding, as well as burrs
resulting from die-casting.
The benefits are clear:
X Enormous time and cost
savings compared with
other methods
X Utmost process reliability
and reproducibility
Ideal for the following industries:
Suitable materials:
X Automotive suppliers
(perfect for non-hardened parts)
X Hydraulics and fluid component
X Steels
manufacturers
X Cast iron
X Fitting manufacturers
X Copper/brass
X Zinc and die-cast manufacturers
X Aluminum
X Zamak
11
System technology
with high process stability
1
2
3
4
5
6
13
7
8
9
10
11
12
▲
1 | Gas valves
2 | Mixing block
(gas mixing and
ignition)
3 | Ignition device
4 | Sound protection
enclosure
5 | Vacuuming
6 | Machine frame
Optimal deburring – with tried and tested
7
8
9
10
| Deburring chamber
| Closure plate
| Rotary indexing table
| Rotary indexing table
drive
11 | Hydraulic closing
system
12 | Hydraulics
13 | Gas metering system
process technology
A cylindrical deburring chamber is fixed in the machine
frame and is operated from a rotary indexing table holding
five closure plates. A hydraulic system lifts one of the closure plates with workpieces and presses it against the
deburring chamber, sealing it so no gas can escape.
The gas and oxygen mixture is forced through a mixing
block into the chamber and then ignited. The workpieces
are loaded and unloaded outside the sound protection
enclosure during the cycle.
12
Innovative control technology
for reliable processes
Standardized technology on a uniform, intuitive platform
The deburring systems use a modern controller based on
state-of-the-art Rexroth technology which carries out all
control functions with an integrated soft PLC:
X The specific process parameters for different
workpieces are stored in a database and can be
accessed immediately when needed.
X The correct gas pressure and metering are set
automatically.
As a result, the deburring process can always be
reproduced in a constant quality – a clear advantage for
process reliability. Thanks to the graphic process
visualization, users always have an overview of the entire
production process.
X Indication of machine production data
X Additional important information, such as the switching
states of the gas valves
X Maintenance interface for remote diagnosis of all
operating states
13
TEM systems from Rexroth –
technology at a glance
TEM-P 350
TEM-P 80
Technical data
TEM-P 80
TEM-P 350
Chamber diameter
120/150 mm
250 or 320 mm
Effective chamber
height
150/250 mm
300/390/450 mm
Chamber filling
pressure
With Ø 120 mm: 5 – 20 bar
With Ø 150 mm: 5 – 16 bar
With Ø 250 mm: 5 – 23 bar
With Ø 320 mm: 5 – 16 bar
TEM-P 80
TEM-P 350
450
Cycle time with 100%
cylinder filling stroke
25 s
45 s
Electrical connection
3x 400 V, 50 Hz/MP
3x 400 V, 50 Hz/MP
Connection power
12 kVA
26 kVA
Combustion gas
Natural gas/methane
Natural gas/methane
System dimensions
LxWxH
Approx. 2.90 x 1.95 x
2.85 m
Approx. 3.65 x 2.05 x
3.35 m
Total weight
Approx. 3,800 kg
Approx. 13,300 kg
250
390
300
150
Ø 120
Ø 250
Ø 150
Ø 320
Deburring chambers
(sizes in mm)
Standard size
Optional size
14
Faster and more efficient
with automated deburring
Fully-automated thermal deburring –
boost efficiency to save costs
To increase production efficiency, Rexroth offers customized
automation solutions from a single source. With our crosstechnology expertise, we can tailor an individual solution
for your specific application. All solutions are characterized
by maximum flexibility for seamless integration into your
production processes.
Optimal long-term reliability as well as adaptability, efficiency, and low operating costs make Rexroth TEM systems
a safe choice for a quick return on investment.
▲ Intelligent, easy-to-operate control system
▲ Pick+place of unprocessed workpieces with robotics
▶ Automatic removal of deburred workpieces
15
Service and spare parts
for increased productivity
Technical support
X Inspection, maintenance, and optimization
of systems
X Troubleshooting, elimination of faults
X Complaint and warranty processing
X Coordination of service calls
Spare parts service
X Exchange parts
X Electronic spare parts data
X Spare parts sales
X Spare parts stocking
Repair service
X Repairs
X Conversion
Responsibility over the entire life cycle –
services that ensure production reliability
Field service
Rexroth is your dependable partner for all-round system
X Set-up and commissioning
consultation and support. Forty years of deburring experi-
X System inspections
ence help us to develop just the right solution for your
X Maintenance work
specific requirements.
X Troubleshooting
We also offer an extensive range of services: from the initial
X Service orders
consultation, to specific maintenance to ensure the safety
X System conversions
of your systems, up to comprehensive customer support –
we are there for you in every phase of the product life
cycle, worldwide, but always nearby.
In-housing training courses
X Training for set-up and commissioning
X Training for service and maintenance
X Training on the optimization of your machine
Bosch Rexroth AG
Postfach 30 20 07
70442 Stuttgart, Germany
www.boschrexroth.com
You can find local contact information at:
www.boschrexroth.com/contact
3 842 528 619 (2013-09)
© Bosch Rexroth AG 2013
Subject to changes!
The data specified serve only to describe the product.
Due to continuous product advancements, no statements concerning a certain
condition or suitability for a certain application can be derived from our
information. The information given does not release the user from the obligation
of own judgment and verification.
It must be remembered that our products are subject to a natural process of
wear and aging.