Challenge Details
- Surface finish of 16Ra microinch (0.4Ra) or better required
- Currently transferring shafts to another machine to grind down material
Objective
Propose a consistent and robust process that would replace the grinding process that has to be done on a separate machine to achieve the required finish on multiple contoured profiles.
Solution
Monaghan Tooling proposed a Single Roll OD Top Hat Burnishing solution with a 0.125” (3.175mm) radius carbide roll. The Top Hat Roll tool was able to follow along the profiles of the part generating an excellent surface finish.
***Elliott Tool# 590010080558M
Overall Results
- 12-14 Ra micro inch (0.30 - 0.35Ra) surface finish achieved
- 30 minutes saved per part
- Replaced secondary grinding operation with burnishing
Benefits Realized
CycleTime Savings
The Top Hat Roll burnishing solution resulted in 30 minutes per part in time savings.
Cost Savings
The solution allowed for the part to be finished on the same machine. This freed up the grinding machine to be used for other operations resulting in cost savings