Carbide Rolls Eliminate Secondary Processes, Produce Mirror-Like Surface Finish

In Booth W-1292, Monaghan Tooling Group (Dayton, OH) will display Carbide-Roll Burnishing Tools by Elliott Tool Technology that produce a mirror-like surface finish while eliminating secondary operations, machining set-ups, and operator labor and cost. These cost-effective, easy-to-use carbide rolls improve surface irregularities and tool marks, producing optimum surface finishes of 4 microinches to 20 microinches (0.1 µm to 0.5µm). 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 set-up and processing time and labor costs and also enhances machinery utilization and shop floor productivity.

Carbide rolls can be reconditioned several times to yield economical tool life. Shank sizes are available from 1.5 in to 2.0 in diameter, or 40 mm to 50 mm, to process overall length of 9.5 in (241.3 mm) to 18 in (457.2 mm). Roll radius from 0.032 in (0.787 mm) to 0.093 in (2.36 mm) are available. Spherical surface burnish tools, available in either 1 in or 25 mm square shank size with a .125 in radius, are excellent for burnishing spherical and contoured surfaces to finishes as low as 2 Ra to 8 Ra microinch. Other sizes and spherical designs available on request.

Carbide roll burnishing is ideal for a wide variety of parts and ductile metals under Rc40, including steel, stainless steel, aluminum and cast iron. A Concord, NH, 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 ft 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, they were 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. “I would estimate we are machining these parts in 1/10th the time we were previously, from 40 hours down to 4 hours,” remarked the company president. “We’re very happy with it!”

Elliott carbide roll tools increase the surface hardness through the cold working process and compressive forces, and increase the 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 over 100 years and has a proven track record of success. Monaghan Tooling Group and Elliott Tool Technologies continue this tradition by supplying the industry’s highest quality burnishing tools.

Also on display will be EasyZERO runout compensation nuts that quickly correct runout errors and misalignment for all round tools using ER collets. These easy-to-use, innovative replacement nuts feature six adjustment screws that allow for up to 0.011 in (0.279 mm) runout to be dialed in easily, allowing for more accurate machining, tighter tolerances and better surface finishes – especially on difficult parts. Concentric cutting means that all cutting edges equally share the chip load, thus increasing tool life and lowering tool costs. Rapidly dialing in the desired runout with complete control ultimately saves time and increases process capability, due to decreased time tapping and resetting tools and collets. ReamTec easyZERO compensation nuts are available in five sizes to fit ER16 to ER40 collets. They are ideal for all round tools where runout may be of concern, including reamers, drills and end mills. Four kits are available which include the easyZERO nut, Hex Key, spanner and ER collet in various combinations.

Monaghan Tooling Group, 30 North Clinton Street, Dayton, OH 45402, 800-732-4565, www.carbiderollburnishing.com, www.MonaghanTooling.com.