On the surface

Superabrasives specialist Engis UK (01491 411117) has launched a tooling solution that supports honing on standard machining centres. The design overcomes the issues caused by lack of height within many machining centres, and has also removed the need for floating tool holders and adaptors, enabling the bore finishing tools to be held directly in the machining centre tool holders, while still providing the required high accuracy geometry demanded of bore finishing operations – roundness to within 1 micron and surface finish up to 0.2 Ra. Using the new flexible tooling system, the first tool passes through the bore with a single in-and-out stroke and its place is then taken by the following pre-set, single-pass tool. The number of tools used in any given application will vary, depending on the amount of stock to be removed, the surface finish and geometry required and the material being machined. This new solution is suitable for many applications, including the manufacture of hydraulic valve, aerospace and F1 components, as well as opening up further opportunities as companies bring low-volume bore finishing tasks in-house. Image: Engis' tooling solution supports honing on standard machining centres Each of the new Engis pre-set single-pass bore finishing tools is coated in a single layer of diamond, which is permanently plated onto the tool, creating faster cutting/stock removal rates and meaning that tool sizes can be held for long periods without adjustment. NCMT (020 8398 4277) is introducing a new lapping machine, from Japanese grinding machine manufacturer Okamoto, on which it is possible to achieve a mirror finish on any surface, including uneven profiles, in a three- to five-minute cycle. Model YT100 is for components up to 200 by 200 mm, while YT300 can accommodate 300 by 300 mm components. Image: Rapid achievement of mirror finishes is promised with the Okamoto YT100 The system works best on hard materials, such as carbide tools. Form punches, dies, cutting punches and moulds, which until now had to be worked by hand, can today be lapped automatically. Improvement in the life of mills, drills and other cutting tools is reported, and the process is suitable for polishing PVD (physical vapour deposition) and CVD (chemical vapour deposition) coatings. Comparable in appearance to a sand blasting machine and used in a similar way, the AERO LAP is entirely different in its operation. It requires the component to have a good surface finish at the outset, so that a mirror polish can be achieved. RUBBER BALLS The media sees a high speed flow of what are essentially rubber balls, in a variety of sizes from 0.5 to 2.0 mm diameter, directed at the workpiece. Coating the surface of the balls, with the help of a liquid additive, is a diamond powder of 3 to 5 microns in diameter or smaller, according to application. At the end of the process, a consistent finish is achieved on all surfaces, without altering their geometry. The equipment is convenient to use, as it operates using a normal compressed air supply, and there is only limited creation of dust and noise. 3M Abrasives (www.3M.co.uk/ abrasives) has developed a new ceramic aluminium oxide abrasive belt that offers significant advantages in productivity and consistency, as well as longer service life. The 3M Cubitron II 984F abrasive belt is the first in what will be a completely new family of premium belts employing innovative abrasive grain technology. Image: 3M's new ceramic aluminium oxide abrasive belt offers significant advantages in productivity and consistency, it is claimed Jim Arbuckle of 3M's abrasive systems division says: "The product has already been successfully launched in the US, where foundry customers producing castings for the aero engine, medical implant, automotive and gas turbine markets have reported significant cost-down benefits and productivity gains. We anticipate similar success in the UK." Cubitron II 984F Abrasive Belt delivers on average up to 30 per cent faster cutting, even on tough to grind metals such as stainless steel, carbon steel, nickel alloy and cobalt chrome. It is especially suited to foundry and investment casting applications, for tasks such as gate or joint line removal. The unique mineral configuration diverts heat away from the workpiece and belt, and into the swarf, reducing the risk of discoloration and the likelihood of heat-related stress cracks. The faster, sharper cut can lead to faster cycle times on automated equipment and also lessens the amount of pressure the operator needs to apply on manual belt machines, making for lower operator fatigue. First published in Machinery, August 2010