Diamond burnishing tool
High-alloy steel is used to burnish a plasticizing cylinder with a diameter of 12 mm in injection molding machines due to the high thermal wear. The required surface quality is achieved with a Baublies diamond burnishing tool for hard surfaces (HRC > 60), equipped with a customized diamond holder, Form-E diamond, and integrated spring suspension.
Task
- Smoothing of a plasticizing unit/cylinder with an inner diameter Ø 12 mm for injection molding machines. This creates a good flow rate of heated plastic.
- Challenge: There is high wear of the surface due to heat
- Material of the component: solid tempered steel
Solution
- Baublies diamond burnishing tool for internal machining with base body suitable for hard surfaces HRC > 60
- With adapted diamond holder
- With smoothing diamonds form E
- With spring in tool body
- Use on turning-milling center
- Machining: soft machining
– Speed VC 100 m/min
– Feed 0.07 mm/rev
Customer Benefit
Quality:
- Hardening of the component, thus fewer wear parts in injection molding
- No change of geometry from the component
Surface quality:
- Constant surface quality Rz < 4 µ
Process:
- Automatic process
- The alternative of hand polishing is eliminated
Flanging tool
Precision that impresses every day.
The delicate stainless steel cap for the Thermomix mixing knife requires high-precision forming—from 45 to 43 mm, absolutely trace-free, lubricant-free, and in a cycle time of just 8 seconds. With 1.5 million units per year, every second counts. What is needed is a low-maintenance tool that delivers maximum performance over the long term.
Task
- The mixing knife in Vorwerk‘s Thermomix combines the support disc and ground blades with the M6 nut screwed on and fixed in place using the tumbling method. A sheet metal cap is to make the design food safe and dishwasher safe.
- The small stainless steel cap must be filigree deformed. The task is to reduce the circumference from around 45 to 43 mm in diameter - without leaving any significant marks. The process is to run in an assembly line that runs at a cycle time of a good 8 seconds.
- The tool should run maintenance-free for some time.
- Batch size 1.5 million pieces per year
- No lubricant is to be used
Solution
- A forming process with a flanging tool from Baublies suitably deforms the sheet metal and fixes the machined parts: The sheet metal cap, which is flanged in two seconds, makes the design food-safe and dishwasher-safe.
- Forming rollers made of heat-treated tool steel
Customer benefit
Time saving:
- Forming process in only 2 seconds
Cost reduction:
- Extremely low tool costs
- Low wear: tool still runs with the original rolls for more than two years
Process:
- Sheet metal is formed to fit
- Low force application
- Process-safe flanging