Diamond smoothing roller tool High optimization potential in smoothing in series production

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With a simple yet innovative diamond smoothing roller tool from Kempf, Buro GmbH in Winden (Germany) was able to optimize a previously complex processing step in series production.

When it comes to the ‹smoothing› of surfaces, there are various approaches to implementing this inherently simple work step. In series production, however, the wheat is separated from the chaff: "Here, the individual processes must be executed as quickly as possible, i.e., mechanically, and, on the other hand, must be produced in consistent quality over many processing cycles without constantly having to replace or adjust the tool," explains Thomas Welte from Kempf's Technical Field Service in Reichenbach Fils (Germany). "Especially in cases of high specifications for the component's quality, the right tool selection and procedure can often be problematic—and many manufacturers face great challenges."

At the manufacturer and developer of mechatronic components and systems Buro, all machining processes can be implemented thanks to the diverse range of machinery, allowing them to cover a large portion of machining processes themselves and offer a wide spectrum of manufacturing possibilities with the different departments for milling, gear cutting, turning, and grinding. This advantage—combined with high manufacturing quality and delivery reliability—is appreciated by customers, which is why they have been having components manufactured on order in Winden for decades.

Small component, big impact

At Buro, a compact eccentric component is manufactured that is used in pumps or ventilators. The component, with length variations from 20 to 50 mm (approx. 0,79 to 1,97 in) and diameters from 16 to 38 mm (approx. 0,63 to 1,5 in), was until recently made of leaded free-cutting steel. The turning process was already fully automated. However, to achieve the required surface quality, elaborate grinding work was necessary, which consisted of several separate operations. The parts had to be removed from the lathe, inspected, and finally finished in a downstream grinding process. This was followed by a washing process and another (dimensional) inspection, so the complete machining of the eccentric parts was associated with high costs, a higher error rate, and a significant time expenditure.

Optimized complete machining

With the change of material to C45 steel, Buro aimed to optimize complete machining. Tests were initially conducted with different indexable inserts and various radii to maintain the required surface quality of less than 0.4 µm Ra. This seemed to work for a small number of components, but for series production, the tool life was insufficient—the wear on the indexable inserts was too great.

A small, innovative diamond smoothing roller tool is the solution

The solution to this challenge was found by Buro with Kempf: The diamond burnishing tool UDBTM-R-16, which measures just 97 mm (approx. 3,81 in) from the diamond tip to the shaft end, was impressive in initial tests. With the ability to rotate the diamond tip up to 180° from left to right, the tool is very flexible: it not only allows the desired setting angle to the workpiece contour to be adjusted, but it can also be used in turning machines under confined spaces. This enabled the tool to be integrated into the turning process, eliminating the previously required grinding process. Compared to the turning tools used before, wear on the diamond tip is virtually undetectable even after many thousands of parts, significantly increasing both the tool's service life and the quality of the workpiece.

This enables Buro to reliably and fully automate the production of nearly 200,000 eccentric parts per year while guaranteeing the consistency of the surfaces. "Due to the various advantages the UDBTM-R-16 offers in terms of tool life and surface quality, several of these diamond burnishing tools are now in use in various turning machines in Winden," emphasizes Thomas Welte. "After all, these Kempf tools are very versatile and flexible to use, thanks to their design and the ability to change the angle while clamped."

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