Streamfinishing

process and application

OTEC Präzisionsfinish GmbH

Heinrich-Hertz-Straße 24, 75334 Straubenhardt-Conweiler

www.otec.de/en

June 30, 2016 2

Agenda

• Company information

• Streamfinish process & machines

• Pulsfinish process

• OTEC finishing center

• Automotive applications & benefits for customers

June 30, 2016 3

Company profile • Development and production of mass finishing machines

• Founded in 1996, today approx. 110 employees

• World wide sales and services

June 30, 2016 4

Key markets • Cutting tools

• Automotive

• Textiles

• Medical technology

• Pharmaceutical industry

• Watches

• Jewelry

June 30, 2016 5

Facts & figures

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25

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1996 1998 2000 2002 2004 2006 2008 2010 2012 2014

turnover in mio. €headcount number of employees turnover in mio. €

Export ratio: 63 %

Staff and turnover development since company´s foundation

Turnover 2015 approx. 21m. €

June 30, 2016 6

Technological milestones • First compact disc finishing and drag finishing machine

• Dry process for drag finishing and disc finishing machines

• Zero gap system

• Streamfinish technology

• Fully automatic Streamfinishing machine for in-line production

• Pulsfinish process

• 50 patents and utility models

Technology focused and customer oriented

June 30, 2016 7

Streamfinish (SF) process • Workpieces are clamped in a holder and immersed in a rotating

process container filled with grinding or polishing media

• Abrasion by relative movement between media and workpiece

• Deburring, rounding and

smoothing in one operation

• Very short process times

• Ideal for automated production

• High process reliability

June 30, 2016 8

Streamfinish machines

rotating process container

filled with abrasive media

lift unit

• Allows automatic loading

during process

angle adjustment of holders

rotating holder for workpieces

June 30, 2016 9

Streamfinish machines - properties • With up to 5 holders for workpieces

• Manually or automatic loading and clamping

• Manually or automatic angle

adjustment of holders

• Automated holder change possible

• For dry and wet processing

• Easy change of process container

• Very easy changeover between different products

June 30, 2016 10

SF Machines – in-line production

SF machines with automatic loading for processing of camshafts in automotive industry

June 30, 2016 11

SF • Alternating rotation of workpiece up to +/- 2000 rpm

• High tangential acceleration up to 40G

Intense abrasive effect

Very low process time

• Very low Rpk-values (<0,1µm)

possible in short time

• Finishing of inaccessible

areas

-2000

-1000

0

1000

2000

0 0,5 1 1,5 2 2,5 3 3,5 4 4,5 5 5,5 6

ho

lde

r sp

ee

d [

rpm

]

time [s]

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Workpiece holders • Specially designed holders for workpieces

Grippers, collets, mandrels etc.

• Suited for automatic loading of machines

• Clamping on inner or outer shapes

• Optional: with HSK 63 interface

• Optional: compressed air cleaning

Special clamping device

for automatic loading of

camshaft bushes

June 30, 2016 13

OTEC Finishing Center – basis of success • Well-equipped with measurement technology

• Very experienced and highly qualified staff

• Joint process research with institutes & universities

• Free processing of customer samples

individual customer counselling

detailed documentation

development of individual finishing

process for every customer

June 30, 2016 14

Processing of camshafts

June 30, 2016 15

Racing camshaft • Camshaft for a racing car

• Process time < 2 min

• Huge quality improvement

00,20,40,60,8

11,21,41,6

surface quality development

Edge before (left) and after (right) processing

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Deburring & edge rounding • SF process combines surface finish with

Deburring

Edge rounding

while the shape of the workpiece

is kept intact

Before (left) and after (right) SF Process

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Gear wheels • Smoothing

• Deburring

• Edge rounding

• Surface conditioned for

better lubrication

Flanks of gear wheel before (left) and after (right) SF process

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Complex geometries • Processing of complex geometries

Deburring

Smoothing

Edge rounding

• All over improvement in short process times

June 30, 2016 19

Residual compressive stress • SF Process causes residual

compressive stress

in the workpiece

• Higher resistance against

bending stress

• Longer lifetime Residual stress at

camshafts after SF process

Depth [µm]

Resid

ual str

ess [N

/mm

²]

com

pre

ssio

n

1,82 Gpa

hertzian stress

1,94 Gpa

hertzian stress

Co

eff

icie

nt o

f fr

ictio

n

Conventionally

grinded

-30%

Pulsfinish

processed

Testing time [h]

June 30, 2016 20

Decrease in coefficient of friction • Friction measurement on

two-disk test rig (Amsler)

• With droplets of

Mobil SHC 624 oil and

10% slippage

• Coefficient of friction is

reduced by 30 %

June 30, 2016 21

Surface improvement • Elimination of grinding marks

• Significant reduction of roughness

• Granulate impact creates self-contained

micro-cavities to improve lubrication

Surface after Pulsfinish Surface before Pulsfinish

June 30, 2016 22

Customer benefits • Noise reduction (up to 6dB possible e.g. with gear wheels)

• Up to 10% lower heat generation

• Better lubrication of surfaces

• No roughness peaks (Rpk < 0,1 µm)

reduced wear, no run-in necessary, longer lifetime of oil

• Coefficient of friction can be reduced by up to 30%

Higher efficiency, less energy consumption

overall performance improvement

Thank you for your attention!