Completely removing burrs from intersecting holes is critical to the performance of hydraulic manifolds. TEM gave Danfoss Power Solutions a significant quality and productivity boost.
Proprietary technologies such as thermal energy machining (TEM) from Kennametal are designed to solve complex finishing challenges faced by manufacturers. Danfoss Power Solutions (Ames, IA) is a global company focused on fulfilling the needs of off-highway vehicle manufacturers with engineered hydraulic and electronic components. "We manufacture hydraulic manifolds for hydrostatic pumps, a high-volume component," said Lubos Hanulik, Operation Manager, Danfoss Power Solutions. "We use TEM for burr removal on intersected holes, cross-sectional holes from previous machining operations."
After much investigation, the company chose the Kennametal EXTRUDE HONE TEM. A pressurized mixture of a combustible gas and oxygen is injected at 5 to 10 atmospheres of pressure into a containment chamber sized both by the amount of material to be removed and the volume of parts in the chamber. An ignition system ignites the gas mixture, releasing heat energy from the oxidation of fuel in a 20-millisecond, high-speed energy wave. With their raised surface areas and thin cross-section features, even internal burrs and flashings burn away instantly. 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 to reach are instantly processed.
"There have been hundreds of installations and continued refinement of our EXTRUDE HONE TEM equipment and process," said Bruno Boutantin, Global Marketing Manager at Kennametal Precision Surface Solutions. "One factor remains constant: TEM is a rapid, low-cost, high-production method that can process a million or more parts per year by a single machine."
"If a machining process is under control (both tool life management and control of burr size are important), the TEM process with washing will provide the best process reliability and repeatability," said Hanulik. "Combining TEM and post washing provided us with a more consistent and reliable process, significant improvement of productivity and increased overall safety. All of this has been achieved with fully automated robotic integration."
Kennametal Precision Surface Solutions has Technical Centers and Centers of Excellence to help ensure close customer association in all critical steps - from the early design phases through supporting the ramping stage to the final delivery of equipment.
For more information contact:
Kennametal Inc.
P.O. Box 231
1600 Technology Way
Latrobe, PA 15650
724-539-5000
extrudehone.sales@kennametal.com
www.kennametal.com