ATS, Poland - TEM wage deburring center in Tworóg
Poland’s grown industry and the associated increased demand for workpieces require the use of new technologies. Therefore, ATL decided to build up a combined deburring and cleaning center at its Polish subsidiary. The Aparatura Techniczna Śląsk Sp. z o.o. (ATS) is mainly producing parts for the general engineering sector, components for compressors and road-building machines, and is a certified manufacturer of pressure vessels in accordance with AD 2000.
Now, the purchase of an iTEM400 and a cleaning system expands the portfolio by thermal deburring and industrial parts cleaning. This enables ATS to offer combined wage deburring and cleaning. The 5-station iTEM system can be operated with different sized deburring chambers. This variability allows highest workpiece flexibility, whether single components or bulk goods. The subsequent cleaning of the parts assures a low content of residual dirt and usually provides ready-to-install workpieces.
REMOG, Poland - TEM as an aspect of quality
For many years, the Rudolf-Erich Müller GmbH & Co KG (REMOG) counts on the thermal deburring. The increased know-how and the high competence in the fields of aerotechnics, hydraulic, and machine construction convince well-known affiliated groups like DaimlerChrysler, Siemens, Bosch Rexroth, Linde, Liebherr Aerospace, and Embraer.
Starting with security-sensitive flight control components and landing gear control systems up to hydraulic assemblies from the areas of industrial and mobile hydraulics, REMOG delivers highest quality. “TEM offers maximum safety and is also very cost-effective. Furthermore, this procedure is prescribed by some of our customers for quality aspects. To operate more flexible, we decided to use TEM at our site in Poland, too,” says Markus Müller, production manager of Rudolf-Erich Müller GmbH & Co KG and managing director of the Polish REMOG Polska Sp. z o.o.
The choice fell on an iTEM400 HP whereat the HP stands for “high pressure”. The maximum gas filling pressure of 23 bar emphasizes that the marking is meant seriously. Thanks to this high energy, voluminous workpieces made from cast iron and stainless steel can be thermally deburred as this components require a lot more energy than, for example, aluminium parts. The deburring intensity can be exactly adjusted via filling pressure and oxygen excess inside the deburring chamber. The usage of latest control technology guarantees highest process reliability at optimal performance.
Benseler, Germany - larger batches without any compromises
Differently to other mechanical deburring methods, burrs at inaccessible areas can be effectively removed by means of TEM. And even with this process, the contract deburrer Benseler from Marbach reached the limits. This was caused by the size of the deburring chamber with a maximum batch size of Ø 320 mm. But the first machine of the series iTEM400 with a chamber size of Ø 400 mm put things right and enabled Benseler Entgratungen GmbH to extend its component spectrum.
With nine thermal deburring machines in Marbach and 15 systems across the group, Benseler sees itself as biggest contract deburrer in Europe, also because other processes like ECM and high-pressure water jet deburring are applied as well. The customers are from the fields of automotive and machine construction as well as of plastics processing. For these areas, micro-deburred workpieces for hydraulic and pneumatic components are prerequisites.
Due to the new chamber size, new aspects arose with regard to batch size and cost-effectiveness. Both facts make the thermal deburring more attractive for bulk goods. As evidence, Benseler quotes deburring results, which nobody suspected to be feasible with thermal deburring in such a deburring chamber. Even workpieces which would actually not be assigned to thermal deburring have caused a surprise.
In Marbach, where approximately 70 million parts are yearly deburred in a two shift operation, they say that it is a competitive advantage being the first working with this system. Benseler is considered as a specialist for difficult deburring tasks on the market. Due to a gentle treatment of thin-walled parts for fuel injectors, Benseler could establish itself in the automotive industry. The basis for this is the fixture technology, which must be generally tailored to the respective components to reach optimal results.
Lower Franconia, Germany - complete in-house production due to TEM
The Bavarian company, which exclusively produces hydraulic manifolds, already knows the advantages of thermal deburring for a long time. Due to the purchase of an iTEM400/600, the manufacturer is now in the position to completely produce its workpieces in-house.
Up to now, the manifolds made of aluminium and cast were thermally deburred by an external wage deburrer, because the workpieces have burrs and chips that must generally be removed before usage in hydraulic systems. The increased demand of the customers and thus increased production output tipped the scales for incorporating an own thermal deburring machine into the modern machinery.
The machine from ATL’s standard series is equipped with two milled closing plates with 300 mm depth each, which can vary in their size by using different adapters. The height of the deburring chamber is 300 mm and the diameter is 400 mm. All in all, the maximum chamber size is Ø 400 x 600 mm. Owing to the acquirement of the iTEM400/600, the company can react more flexible to customer requests and additionally saves the previous costs for logistics and freight for transportation of the goods to the wage deburrer and back
Germany - thermal deburring of engine components
For a leading company in the automotive industry, the technicians from ATL Anlagentechnik Luhden GmbH not only developed the biggest long chamber machine so far including a semi-automatic handling system. For the factory in the border triangle, the manufacturer extended its machinery by an iTEM400 to thermally deburr further motor components made of aluminium and stainless steel.
The internationally leading organization for engine technology is an accredited systems supplier for leading-name manufacturers. And exactly for this area, the concern counts on TEM machines from Luhden.
The iTEM200/1200 LC (Long Chamber) is especially developed for thermal deburring of shafts for rocker arms (truck engines). The task that is to be performed is both simple and challenging: repeatable removal of detachable burrs.
With a deburring chamber size of Ø 200 x 1,200 mm and a maximum filling pressure of 20 bar, the 1-station-machine automates the process which has been used so far - the manual deburring. Not only the dimensions of the deburring chamber are special for this machine, the handling system, which consists of rotary indexing table and gripper, was especially designed for the customer, too.
The rotary indexing table is equipped with 8 stations, the deburring fixtures and the workpieces are placed on it and hydraulically driven towards the machine. The gripper grabs on fixture at a time, lifts it into the machine, and places it on the closing plate.
On the iTEM400, which is equipped with a deburring chamber of the size Ø 320 x 300 mm and 5 stations, the Saxon company thermally deburrs rocker arms and aluminium bridges in multi-shift operation. This future-oriented enterprise shows that powertrain components, especially from the cylinder head, are optimally suited for thermal deburring.
WEMA, Belgium - effective cleaning of hydraulic components
By the end of 2011, a thermal deburring machine of the iTEM400 series was delivered to the Belgian component supplier WEMA NV.
WEMA is one of the leading subcontractors in series production of high precision mechanical and hydraulic parts. The Belgian company based in Zedelgem provides market-leading manufacturers of earth moving equipment, agriculture machines, and hydraulic and automotive parts worldwide.
The decision to buy a TEM machine from ATL Anlagentechnik Luhden GmbH was made very promptly. Not only because of the substantial optimization of the production processes. “During the discussions it became obvious that our TEM equipment, in addition to the optimization benefit, meets the guidelines of the WEMA environmental management. From then on, nothing prevented the conclusion of the contract,” explains ATL’s CEO Struckmann.
Valeo, France - modernization of the zinc diecasting production
Within the framework of production modernization, the French concern Valeo decided to invest in a thermal deburring system from ATL Anlagentechnik Luhden GmbH. The machine is operated at Valeo Sécurité Habitacle, Business Group “Comfort and Driving Assistance Systems” in Nevers, France.
An iTEM400, equipped with 5 stations, was chosen by Valeo. From now on, workpieces made of zinc diecasting will be thermally deburred. With cycle times of approx. 35 seconds, up to 6,000 kg of workpieces can be deburred daily.
The machine is additionally equipped with a handling system for adaptation to the production line. Upon customer request, the control panel is not installed on the equipment, but is placed separately.
Quality on a new level“ The preparatory, but especially the subsequent cleaning is of great importance for TEM. Impurities larger than a certain size can cause enormous damages, e.g. on hydraulic systems of our customers,” says Jörn Struckmann, managing director of ATL Anlagentechnik Luhden GmbH, “we could not ignore the positive aspects of a common project, thus we jumped at the opportunity.”
The Johannes Steiner GmbH & Co. KG is a company with a rich tradition. The family business, which was founded in 1903, is characterized by decades of experience, consolidated knowledge and futureoriented action. “We attach special importance to research and development and that is why we invest above-average in this area. All in all our daily output is about 1.2 million compression nuts made of steel and stainless steel for the common rail system as well as 220,000 ferrules and 30,000 sewing machine spools. Quality is always our primary manufacturing objective, absolute precision goes without saying,” emphasizes the executive director Dino Steiner.
A proactively producing company like Steiner is constantly anxious to optimize its manufacturing processes. It is not only about standing out from the competitors, but also to offer the customers “quality on a new level”. The recently installed, fully automated deburring and purification center is fulfilling this claim in any case.
So far, the workpieces could only be subject to a quality control subsequent to the electroplating. This was not only very costly in terms of time and money, but also meant a high rate of rejects. In the case of the compression nuts, for example, manual deburring of the rolled threads constituted an enormous challenge, because the adherent chips are directly pressed on the thread when molding it. Only during the galvanic treatment, the chips sat up again. “We were searching for a method that reduces the expenditure of time and costs on the one hand and minimizes the rejects on the other,” explains the manufacturer from Baden-Württemberg and completes, “we experimented with the chemical deburring for specific nuts. However, the high process costs, but primarily the insufficient environmental compatibility dissuaded us from this method.” Finally, in the course of research Steiner came across the thermal deburring machines of the Lower Saxons.
Flexibility - the key to success
At the ATL test and demonstration center for thermal deburring and specific cleaning tasks it finally became clear that TEM in combination with ultrasonic cleaning is what the businessman was looking for. The idea of a fully automated deburring and purification center was also developed there. The requirements were as follows:
- Processing of workpieces made of steel and stainless steel
- Automated loading/unloading of the TEM system
- Mechanical transport of the deburred goods to the cleaning machine
- Automatic loading/unloading of the cleaning machine
- Effective deburring of single components, small batches, and bulk goods
- Dry workpieces without an oxide layer after cleaning, products made from stainless steel must also be free of stains
- Low content of residual dirt
To meet the requirements of Steiner, the TEM technicians constructed a customized machine on the basis of an iTEM400. The custom-tailored cleaning system fulfilled the demands as well. „The flexibility of the machines was a key point during the contract award process. Furthermore, it was not just about selling something, the main focus was on the project itself,” comments Dino Steiner. “For us, it was a premiere in very many ways. It is the first fully automated TEM machine that we have constructed,” explains Jörn Struckmann, “and in addition, it is the first time that we are working in the field of couplings for the automotive and hydraulic industry. With this project we have shown that the thermal deburring is a versatile process which eclipses other methods. Burr-free components are the prerequisite for high residual dirt requirements. Today’s possibilities of the TEM process manage these in a very efficient manner.”
Contract deburring for everyone
The realization of the project took approximately 12 months, of which 4 months were machine production time. The focus of the globally unique deburring and purification center is on the fully automated subsequent processing of Steiner’s workpieces. On average, 2 - 3 tons of bulk material are daily deburred and washed in one shift. Due to this, the Johannes Steiner GmbH & Co. KG stands out from its competitors and reaches a new level in terms of quality and quantity.
As of now, Steiner additionally acts as a service center for contract deburring and ultrasonic cleaning. No matter whether single components, small batches or bulk goods, inquiries can be submitted to the family business under www.tem-ex.de.
Due to production- and quality-related reasons, a well-known German medical and pharmaceutical company has now decided to invest in an iTEMPlastics. Especially in the field of medical technology, a reliable subsequent processing of the workpieces is of central importance.
The TEM method does not only deburr thermoplastics effectively and repeatable, a significant improvement of the surface roughness is additionally achieved. Because of this effect, further handling expense can be depleted. The operating gases are oxygen and hydrogen. All thermoplastics like PA, PMMA, PUR, PE, PP, and injection molding parts without glass fiber content are processable.
The EuropTec Kft in Zalaegerszeg, Hungary, is one of eight subsidiaries of the Swiss EuropTec AG. The modern site in Hungary is specialized in plastic machining. Special attention is paid to deburring and surface processing, which are particularly required in the fields of medical and laboratory technology. For this, highest precision and a burrfree finish are of paramount importance. Due to its repeatability, reliability, and individual parameter adjustment, thermal deburring fulfills these factors in the best possible way.
With its test and demonstration center, ATL acts as wage deburrer for EuropTec Kft. Already since mid- 2012, various workpieces made from thermoplast have regularly been sent from Hungary to Germany and back again. As a result of short cycle and changeover times of the iTEM systems, the machined components are on their way back after a short time (1 - 2 working days). These advantages enable ATL to react to even urgent orders as quickly as possible.
Dansk Afgratningsteknik, Denmark - wind energy industry counts on TEM
For many years, the Danish company Dansk Afgratningsteknik A/S is using the thermal deburring (TEM) to process metal components. With the purchase of an iTEM400/600 from ATL Anlagentechnik Luhden GmbH, the contract deburrer has not only expanded its machinery.
Dansk Afgratningsteknik A/S is a subsidiary of Hydra-Grene A/S, another Danish company which is specialized in trading and production of hydraulic systems for wind turbines.
The requirements concerning “Green Technology” are rising continuously and hence for every workpiece. Especially in the field of hydraulic systems, deburring with high accuracy is of great importance. A small dissolved burr or chip could disable a hydraulic aggregate.
The acquisition of the machine enables Dansk Afgratningsteknik A/S to thermally deburr large hydraulic manifolds up to a maximum component size of 275 x 275 x 580 mm. With regard to cleanliness, nonexistence of chips, and high accuracy concerning the removal of burrs, the machines reaches optimal results.
In addition to large hydraulic manifolds, hydraulic oil-filter housings, which are made of aluminium, can be thermally deburred now, too. Both are workpieces from Hydra-Grene A/S, particularly for use in wind turbines. Previously, the large hydraulic manifolds had to be deburred manually, which was very time-consuming. Now, the thermal deburring process only needs 1 - 2 minutes per component. The maximum gas filling pressure of an iTEM400/600 is - unlike other TEM machines - 16 bar. It is the first machine of this magnitude on the market which is designed for such a pressure. Mass flow meters on the iTEM400/600 enable a very high repeatability of the process. Constant and highquality results can therefore be ensured.
“The continuous expansion of our know-how enables us to meet the growing requirements of our customers concerning the TEM process with competent advice - not only in the field of wind energy”, said Jörn Struckmann, CEO of ATL Anlagentechnik Luhden GmbH.
China - TEM covers industry‘s backlog for efficient deburring
TEM deburring for hydraulic components The thermal deburring is on the advance worldwide. Among other things, ATL was able to place, or rather already successfully realize projects in Asia lately. One of them was an iTEM400 for Jiangsu Guorui Hydraulic Machinery Co., Ltd. The Chinese manufacturer of carbon steel hydraulic components primarily produces parts for industrial and construction machinery, and agriculture.
One key benefit of an iTEM400 is its variability. It allows the operation of different sized deburring chambers with different maximum gas filling pressures. This is a unique advantage which currently does not exist to the same extent. The machine from ATL Anlagentechnik Luhden’s standard range is equipped with 5 stations and a deburring chamber of the size Ø 400 x 300 mm.
The maximum gas filling pressure of this machine is 12 bar, the average cycle time in single shot operation is approximately 45 seconds. Workpieces with a maximum size of Ø 395 x 280 mm can be deburred within this short time.
TEM machine completes DMG production line Another project in Asia has been realized in cooperation with DMG (Deckel Maho Gildemeister). For this project, ATL Anlagentechnik Luhden acted as a subcontractor and completed the new production line of the Gildemeister AG for its Chinese customer Shandong Changlin Machinery Group Co., Ltd. with an iTEM400/600.
Shandong Changlin is a manufacturer of construction and agricultural machines, and diesel engines. For such a product range, the thermal deburring machine from ATL is very versatile. The deburring chamber with a size of Ø 400 x 600 mm allows thermal deburring of large workpieces up to a maximum size of Ø 395 x 580 mm. The iTEM400/600 is equipped with 2 stations (closing plates) and can build up a maximum gas filling pressure of 16 bar.