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Innovation Squared

Thermal deburring is a process that hasestablished itself in the industry these past

decades. At present scarcely any hydrauliccontrol blocks are produced in Europe for theautomobile or aircraft industries that do notundergo thermal deburring. The advantagesof this method are too significant. As part ofthis process, the following cleaning methodplays a key role.

The Rudolf-Erich Mller GmbH & Co KG,REMOG for short, has relied on the thermaldeburring technique for many years. Nowthe decision has been made to invest in a

TEM facility from ATL Luhden with a part-cleaning facility by LPW ReinigungssystemeGmbH connected downstream. REMOGhas been providing precision parts all overthe world for over 50 years. The increasingknow-how and the high level of compe-tence in the fields of aviation technology,hydraulics, and machine construction haveimpressed well-known concerns like Daim-lerChrysler, Siemens, Bosch Rexroth, Linde,Liebherr Aerospace, and Embraer.

Starting with safety critical aircraft controlcomponents and landing gear operating sys-tems, and extending to hydraulic assemblies,ready assembled and tested, this companyfrom Mnnerstadt delivers the highest qualityin the fields of industrial and mobile hydrau-lics. For us, quality has the highest priority.Of course we have ISO 9001:2000 andAS9100 certifications, so our clients can relyon our processes a hundred percent, andcan concentrate on their own core competen-cies such as product development and finalassembly, says Markus Mller, company

director of Rudolf-Erich Mller GmbH & CoKG and manager of the Polish REMOGPolska Sp. z o.o.

Thermal deburring and part-cleaning in a class of its own

The benefits of thermal deburring havebeen taken advantage of at REMOG for along time now. This elegant method utili-ses the combustion principle for removing

production-process by-products or burrs fromparts by igniting a gas mixture at tempe-ratures between 2000 and 3500 degreesCelsius (4535 - 6332F. The crucial benefit:at these extreme temperatures all burrs, thatis, even those in difficult-to-reach places,or at intersections of two bore holes insidecomponents, can be reliably removed. Themethod offers a high degree of assuranceand is in addition very efficient. In addition,some of our clients demand thermal debur-ring from quality related considerations,

says Mller.

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Thermal deburring at up to23 bar

With the aid of a new TEM machine fromATL, in connection with an innovativePowerJet part-cleaning facility by the LPWReinigungssysteme, REMOG intends toopen a new chapter in thermal deburring.

The machine used is the thermal deburringmachine ATL iTEM 400 HP. The acronym HPstands for High Pressure. That this descrip-tion has substance is underlined by themaximal gas fill pressure of the machine,depending on the diameter of the debur-ring chamber, up to 23 bar (334 psi). Thebenefit: thanks to the high energy output, thisinnovative machine successfully deburrs bulkparts of die cast and high grade steel, whichrequire far more energy than deburringaluminium parts. The generous dimensions

of the largest combustion chamber, with adiameter of 400 millimetres and a heightlikewise of 400 millimetres accommodatelarger parts. The cycle times vary dependingon the deburring process between 30 and60 seconds. In this way, by using three dif-ferent deburring chambers of 250, 320 and400 millimetres respectively, the flexibility indeburring performance is virtually limitless:From bulk parts to large-volume hydrauliccontrol blocks, parts and components froma variety of metallic raw materials can bequickly, safely and efficiently deburred withiTEM 400 HP, says Jrn Struckmann, mana-ging partner of the ATL GmbH.

The machine is loaded manually by anelectronically operated rotary indexingtable, which transports the components tothe combustion chamber. A newly develo-ped gas dosing system, which has no needfor a high-maintenance gas dosing cylinder,injects a precisely defined gas mixture intothe combustion chamber, where the mixtureis ignited. In the combustion that follows

temperatures between 2500-3500 degreesCelsius (4532 - 6332F) are reached. Theburrs to be removed thus reach ignition tem-perature, and react with the excess oxygenin the combustion chamber. This results incomplete incineration of burrs within a fewmilliseconds. The intensity of deburring canbe precisely set by means of the fill pressureand the excess oxygen inside the debur-ring chamber. The most modern controltechnology in use guarantees the highestlevel of process reliability while maintaining

quality and optimal performance, saysStruckmann.

Particle-free part-cleaning

Following the TEM procedure, the parts are indeed tho-roughly deburred both inside and outside, however, as theburrs incinerate, an oxide coating is generated and depo-sited on the part. In order, on the one hand, to guaranteea preferably low level of residual dirt for precision parts,and on the other hand, to reliably prevent corrosion build-up, the subsequent cleaning process that the parts must

undergo has the highest priority.

REMOG has invested a great deal of time in the selec-ting the suitable cleaning system: We thoroughly testedequipment from different manufacturers, and had specificcleaning tests carried out using thermally deburred seri-al parts. In these cleaning tests, the installation by LPWemerged as a clear favourite. The cleaning results wereconsistently a cut above those of the competitors. Evenfor the smallest blind holes, the LPW system delivers thebest results. That is why the decision was made to chooseLPW, says Markus Mller.

The machine used is the PowerJet 670, an innovati-ve water-based part-cleaning system. Despite its outercompact construction, the system distinguishes itself byhigh performance and process reliability. In our waterbased cleaning system of the PowerJet series hides a vastamount of technical know-how offering solutions that utiliseenvironment-friendly water-based media for even challen-ging cleaning tasks. There is also the fact that the system ismodularly constructed, enabling us to configure individual,client-specific systems according to the clients require-ments, says Gerhard Koblenzer, LPW ReinigungssystemeGmbH manager.

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PowerJet 670: fast, clean,economical

With the 670 PowerJet REMOG to meet highdemands in residual dirt removaleconomically. With a batch size of670 x 480 x 300 millimeters, theequipment achieves a throughput capacity

six to eight batches per hour. The maximumbatch weight is 200 kilogramms. Desplite thehigh performance 670 PowerJet sets thebenchmark for energy efficiency. Oneaspect that is currently in permanentlyrising energy prices, an increasinglyimportent role.

First and foremost, the parts that undergocleaning are steel and cast parts which, oncecleaned, may not have more than very littleresidual dirt. Impurities above a certain par-ticle size would cause enormous damage to

our clients hydraulic systems, so thepart-cleaning following the TEM has a keyrole. Hence, the system must deliver exem-plary cleaning results, and with a hundredpercent process reliability, says Mller.

The cleaning system PowerJet at REMOG,which, if necessary, can be extended to up tofive cleaning-/washing levels, manages withtwo different tanks and two cleaning media.In tank 1, this is a neutral corrosive and rustremover, tank 2 it contains an anti-corrosive.In order to reliably attain the required lowresidual dirt, a powerful pressure-flow facility

with a pressure of 18 bar is employed. Inaddition, the work chamber has an integratedultrasonic system of 6000 Watts to aid thecleaning process

Besides excellent cleaning performance, thethrough-put time of the PowerJet system alsoplays a decisive role for REMOG: The iTEM400 HP has a very high through-put, so thatpart-cleaning must proceed fast, without abottleneck developing in the cleaning facility.Even in this respect, the LPW system hasgreatly impressed us. All parts leave the

washing machine sportlessly clean in therequired cycle time. To that extent, we arecertain that by deciding for ATL and LPW, wehave invested in the perfect combination ofinnovative systems, concludes Markus Mller.

Chief Executive Ofcers Jrn Struckmann from ATL and Gerhard Koblenzer von LPW (from left

to right) can offer to customers a thermal deburring and cleaning solution.

www.lpw-reinigungssysteme.dewww.atl-luhden.dewww.remog.de