Introduction into

OTEC PULSFINISH

Improvement of the manufacturing of

camshafts components

06.06.2014 2

1. Possible task

2. Machine in use

3. Status Quo

4. Possible improvement

4. 1. Alternative 1

4. 2. Alternative 2

4. 3. Alternative 3

4. 4. Alternative 4

4. 5. Alternative 5

5. Possible potentials (saving in process)

AGENDA

06.06.2014 3

• Smoothing of the contact area (radius of the cam)

• Smoothing of the cam

• Smoothing of the spiral groove

• Deburring/ edge honing of the spiral groove

• Deburring/ edge honing of the toothed camshaft

1. Possible task

06.06.2014 4

• Streamfinishmachine with pulse drive

which is prepared for a fully automatic

operation to integrate into the line

production

Video SF 3/105 with pulse drive

• Possibility of deburring, edge honing,

grinding, smoothing, polishing

2. Machine in use

06.06.2014 5

Turning/ Milling Cleaning of the

internal gear Deburring Hardening

Hardening Grinding

3. Status Quo

Overview of the current production process

Finishing

Bandfinishing

06.06.2014 6

The two working station finishing and bandfinishing can be replaced with

one OTEC PULSFINISH working station.

Turning/ Milling Cleaning of the

internal gear Deburring Hardening

Hardening Grinding

OTEC PULSFINISH for polishing and finishing

4. Possible improvement 4.1. Alternative 1

Finishing Bandfinishing

06.06.2014 7

Definition of measuring points

Measuring

point 2

Measuring

point 1

06.06.2014 8

Analysis of Alternative 1

before after

measuring point 1

[Rz µm] 2,25 0,7

measuring point 2

[Rz µm] 2,53 0,64

Requiered task:

The surface on measuring point 1 and measuring point 2 need to have

Rz-Wert < 1,0 µm

0

0,5

1

1,5

2

2,5

3

Messpunkt 1 [Rz µm] Messpunkt 2 [Rz µm]

unbearbeitet

bearbeitet

06.06.2014 9

The three working station grinding, finishing and bandfinishing can be replaced

with one OTEC PULSFINISH working station.

Turning/ Milling Cleaning of the

internal gear Deburring Hardening

Hardening Grinding

OTEC PULSFINISH for grinding, polishing and finishing

4. Possible improvement 4.2. Alternative 2

Finishing Bandfinishing

06.06.2014 10

The three working station deburring, finishing und bandfinishing can be replaced

with two OTEC PULSFINISH working station .

4. Possible improvement 4.3. Alternative 3

OTEC PULSFINISH for deburring

Turning/ Milling Cleaning of the

internal gear Deburring Hardening

Hardening Grinding

OTEC PULSFINISH for polishing and finishing

Finishing Bandfinishing

06.06.2014 11

The four working station deburring, grinding, finishing and bandfinishing can be

replace with two OTEC PULSFINISH working station.

4. Possible improvement 4.4. Alternative 4

Turning/ Milling

(opimized prozess) Cleaning of the

internal gear Deburring Hardening

Hardening Grinding

OTEC PULSFINISH for deburring OTEC PULSFINISH

for grinding, polishing and finishing

Finishing Bandfinishing

06.06.2014 12

The four working station deburring, grinding, finishing and bandfinishing can be

replace with one OTEC PULSFINISH working station.

4. Possible improvement 4.5. Alternative 5

OTEC PULSFINISH for deburring, grinding, polishing and finishing

(1 station directly after turning/ milling)

Turning/ Milling Cleaning of the

internal gear Deburring Hardening

Hardening Grinding

Finishing Bandfinishing

06.06.2014 13

Definition of measuring points

Measuring

point 3

Measuring

point 1

Measuring

point 2

Measuring

point 4

06.06.2014 14

Analysis of Alternative 5

• Work piece were deburred, grinded, and a

rounding was created

• Smoothing of the work piece below Ra 0,1 µm

Optimizing of the Turning/ Milling process can

result to achive the requirements in a single-

step process

roughness Ra

measuring

point 1

measuring

point 2

measuring

point 3

measuring

point 4

before 0,341 0,427 0,336 0,388

BP1 0,0591 0,0538 0,0649 0,0608

BP2 0,0434 0,0568 0,0377 0,0708

BP3 0,0708 0,0497 0,0632 0,0902

BP4 0,085 0,0585 0,0828 0,0728

0

0,1

0,2

0,3

0,4

0,5

Rau

tie

fe R

a

Mess-punkt 1

Mess-punkt 2

Mess-punkt 5

Mess-punkt 6

06.06.2014 15

5. Possible potentials (saving in process):

Alternative 1 Alternative 2 Alternative 3 Alternative 4 Alternative 5

Potential Replacement

of finishing and

bandfinishing

Replacement of

grinding, finishing

and bandfinishing

Replacement of

deburring,

finishing and

bandfinishing

Replacement of

deburring,

grinding, finishing

and bandfinishing

Replacement of

deburring,

grinding, finishing

and bandfinishing

Quantity of

working

station

1 1 2 2 1

Achievable yes yes yes yes yes

Thank you for your attention!

16 Juni 2013