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Forming: Punching In The Third Dimension

Forming: Punching in the Third Dimension

Fitted with an intelligent punching head and the right tool, your punching machine will also demonstrate its talent for forming. Article by Vincent Tan, TRUMPF.

Your punching machine can do more than just punch. Fitted with an intelligent punching head and the right tool, your machine will also demonstrate its talent for forming. This allows you to fully process a great diversity of sophisticated components on one machine—and even burr-free if required. It is also efficient for small quantities as tool costs are low and setup times are short. 

The ability to produce burr-free sheet-metal parts directly on punching or punch laser machines saves you the time-consuming process of retrospectively removing the punching burr. This considerably reduces the throughput time, in particular for coated sheet metal and formed parts. Furthermore, the improved edge quality lowers the risk of injury when further processing the parts. 

Roller Deburring Tool

The roller deburring tool is mainly used for simple, large-surface contours. The punched edges are thus perfectly rounded off, which is a decisive advantage for visible edges in particular. A high-quality result is obtained with all of the sheet thickness ranges by adapting the roller contour to the modified burr and to the width of the separation gap.

Ball Deburring Tool

You can get an even better edge quality if you use the MultiShear slitting tool in addition. For shapes with contour radii of less than 20 mm, the deburring MultiTool is to be used. The ball deburring tool is suitable for smaller contours, holes and workpiece corners. Specially hardened balls press the punching burr into the base metal. In doing so, a chamfer is produced on the upper side of the part.  Thanks to the tapered punch head, deburring near formed areas is also possible.

Deburring MultiTool

TRUMPF’s deburring MultiTool, with its three embossing inserts in the die, excels on radii of less than 0.8 in in particular. The tool presses burrs flat in a single stroke or in nibbling mode, even in corners and small contours.

The MultiTool makes your machine more productive by integrating up to 10 different punches and dies into one tool. The strengths of the MultiTool are particularly notable in processing sheet metal parts with small punches of different sizes.

Benefits

  • Shorter production times through complete processing on one machine
  • Lower risk of injury
  • Deburring of all geometries, whether simple, complex, small or large.
  • Also for coated sheets and for parts with formed areas

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Schunk Releases Robot Deburring Tool

Schunk Releases Robot Deburring Tool

For the very first time, manual deburring processes can be automated with the robot deburring tool CDB from Schunk, without having to forgo the proven deburring blades. The adjustable-flexibility deburring tool is suitable for robot-assisted deburring of workpieces made of plastic, aluminium, steel, brass, and other materials in a wide variety of geometries.

The CBD can be used for deburring stamped parts, for household and industrial fittings, as well as for plastic or metal components in the automotive or aviation industry. Being able to insert conventional deburring blades that were previously used manually 1:1 into the robot tool makes quick and uncomplicated changeovers from manual to automated operation possible. No change is required to existing know-how when it comes to blades, blade holders and the process.

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The flexible robot tool imitates the manual deburring process, all while maintaining consistently high quality. Positional inaccuracies, workpiece tolerances, and tolerances of the robot are axially compensated by up to 8 mm, and radially by up to ±5.5 deg.

Balancing force can be individually controlled (axially 13–66 N, radially 13–62 N). Therefore, the tool ensures process-reliable deburring results and reduces rejects, and at the same time requires minimum programming effort. The uniform tool mounting ensures short set-up times when exchanging blades, meaning that the deburring tool can be used efficiently for manufacturing small series. Compared to manual deburring, robot-assisted deburring offers a vast range of advantages, including that employees no longer need to endure difficult, dangerous, and lengthy deburring tasks. Moreover, a consistently high quality is also ensured. In automated operations, unmanned deburring is possible around the clock.

 

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Achieving Consistent Quality

Achieving Consistent Quality

Find out how gear manufacturer Katsa Oy was able to achieve consistent quality in its finishing and deburring processes. Article by Renishaw.

Renishaw RMP60 probe confirming finished gear dimensions after deburring

Renishaw RMP60 probe confirming finished gear dimensions after deburring

The Challenge

Gear and gearbox manufacturer Katsa Oy designs and manufactures power transmission components and supplies special gear units tailored to customer’s demands. Deburring gears manually using grinding wheels can be a variable process, resulting in inconsistent finishes across parts in the same batch. Machine-shop operators have to be very skilled to achieve a quality and consistent finish, but even then, variability from one operator to another is unavoidable.

In addition, manual deburring is a dirty and hazardous job, which few operators at Katsa wanted to undertake. As a consequence, finishing and deburring operations became a bottleneck in the company’s manufacturing process, with a knock-on effect often causing significant delays.

Solution

Thinking of automating the gear deburring process, Katsa approached Flexmill Oy, the global renowned for design and build robotised cell, to build an automated cell to finish-machine and deburr gears ranging in size from 50 mm to 1.5 m diameter.  

The bespoke, turnkey cell incorporates an ABB robot, a Renishaw RMP60 probe and a twin pallet system which allows one gear to be machined whilst another is loaded.

To ensure all excess material on the machined gears is removed automatically by the deburring process, the Flexmill software requires the exact geometrical parameters of the gears and the gear teeth. Some of these parameters are known and available for each of the many different gears made by Katsa.

Those parameters that are not known can be measured using the Renishaw RMP60 probe with radio signal transmission. The ABB robot uses the probe for locating parts during set-up, with the resulting positional data used by the control software to generate a complete, automated deburring cycle—with no manual programming required. Once machined, the RMP60 probe is used post-process to confirm finished dimensions.

Flexmill Cell Featuring ABB Robot and Renishaw RMP60 Probe

The RMP60’s proven kinematic resistive probe mechanism, combined with its unique frequency hopping spread spectrum (FHSS) radio transmission ideally suited to this application. This means that communication between the probe and its receiver remains stable even if, for example, ‘line-of-sight’ is lost or if another radio source enters the environment.

Operating in the 2.4 GHz waveband, the RMP60 machine probe is compliant with radio regulations in all major industrial markets. It offers a variety of activation options, an adjustable trigger force and measurement repeatability of ±1 μm 2σ.

 

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Rene Gerber: BS Power Deburring Machine

Rene Gerber: BS Power Deburring Machine

The BS Power from Rene Gerber is able to deburr and polish workpieces up to a diameter of 400 mm or both sides up to 200 mm.

The planetary brush heads have three large plate brushes with a diameter of 260 mm and thus form a flying circle of 570 mm. The machine is used when flat workpieces with throughputs or pockets with high precision are needed to be deburred and defined with narrow tolerances. Applications are seen in metal processing, especially in the punching and fine-cutting of turning, milling and gear parts.

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