Case Study: Burnishing a Shaft Used in the Oil Industry
This customer was manufacturing a shaft used in the oil industry made of Super Duplex stainless steel using a DMG Mori NTX2000 machine. This specific shaft had a diameter of 3.94 inches (100mm), and required a surface finish of 16 Ra microinch (0.4 Ra) or better. Previously, they had been moving the shaft to another machine to grind the part down in order to achieve the surface finish needed. This is time-consuming and costly since this required a whole other operation of moving the parts to another machine.
Here was their turning operation before we got involved:
Speed: 1000rpm – turn with a .031” radius (0.8mm) insert
Here were the results from the burnishing solution:
Speed: 1000 RPM
Cutting Feed: 0.02”/rev (0.5mm/rev)
Radial load: 0.02” (0.5mm)
Finish achieved: 5-8 Ra microinch (0.12-0.20 Ra)
The single roll burnishing tool produced a surface finish of 7 Ra microinch (0.18 Ra) or better. The parts could be made all in-house, eliminating the need for expensive sub-contracting to grind the pistons. The new process only required one set-up, saving our customer lots of time and money.
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