By Elliott Tool Technologies, carbide-roll burnishing tools, which produce a mirror-like surface finish while eliminating secondary operations, machining setups, and operator labor and cost, will be featured at IMTS 2016, Booth #W-1292. These cost-effective, easy-to-use carbide rolls from Monaghan Tooling Group improve surface irregularities and tool marks, producing optimum surface finishes of 4 to 20 microinches (0.1 to 0.5 microns). They are ideal for both CNC turning centers and manual lathes for OD and ID/OD burnishing applications. This proven technique can eliminate secondary processes such as grinding, honing, and polishing by automating those processes in the primary CNC machine. Doing so saves setup and processing time and labor costs and enhances machinery utilization and shop floor productivity.
Carbide rolls can be reconditioned several times, yielding economical tool life. Shank sizes are available from 1.5 to 2 inches in diameter, or 40 to 50 millimeters, to process overall length of 9.5 inches (241.3 millimeters) to 18 inches (457.2 millimeters). Roll radius from 0.032 inches (0.787 millimeters) to 0.093 inches (2.36 millimeters) are available.
Spherical surface burnish tools, available in either 1-square-inch or 25-square-millimeter shank size, with a 0.125-inch radius, are excellent for burnishing spherical and contoured surfaces to finishes as low as 2 to 8 Ra microinch. Other sizes and spherical designs are available on request.
Carbide roll burnishing is ideal for a variety of parts and ductile metals under Rc40, including steel, stainless steel, aluminum, and cast iron. A Concord, New Hampshire, job shop recently experienced the benefits of this tooling in a heavy machining horizontal table lathe application. An exceptional finish was needed on the ID of a roughly 6-foot-diameter ring made of a stainless grade with an average hardness of Rc33. The ID had both parallel and tapered walls. Starting with a pre-burnished surface finish of 120 Ra microinch, the job shop was able to obtain a single digit surface finish in a single pass at 450 SFM and 0.035 IPR. This eliminated many hours of fine boring and hand polishing.
Elliott carbide roll tools increase the surface hardness through the cold-working process and compressive forces and increase metal’s resistance to fatigue and failure at stress points while producing a dense and uniform surface.
The burnishing process has been refined and improved for more than 100 years and has a proven track record of success. Monaghan Tooling Group and Elliott Tool Technologies continue this tradition by supplying high-quality burnishing tools.
Monaghan Tooling Group provides engineered tooling and services, including application-related consulting, to solve machining challenges. It has partnered with industry-leading standard and custom-tooling manufacturers including Diatool, UC Tools, RE-AL, MK-Tools, Reamtec, Axis, and Elliot Tool Technologies to address the challenges of precision metal finishing and high-performance cutting.