Manifold

Description

Our customer is a main supplier of various components to the US Recreational Vehicule industry. He has approached us after researching options for on-machine deburring to assist him with several cross hole deburring applications on one of their high volume manifold parts, that are produced in several configurations.
Up to now, the burrs of the manifold holes had been removed by thermal / explosive deburring as a secondary operation off the machine.

Application details

Application details

Upon initial review, it was determined to use a standard SNAP tool for the Ø.281” mounting holes (4) as well as a standard COFA tool for the Ø.250” through hole in the SAE #4 port.

The Ø.391” hole through the SAE #4 port that intersected the 2 VC08-2 cavity ports proved to be the main challenge. These intersects create a 1:1 cross hole ratio. This is why we focus here on this application.

  • Bore diameter: Ø 0.391" / Ø9.93 mm
  • Material: Aluminium
  • Machine: HAAS Super VF-2

Solution proposed by HEULE

Solution proposed by HEULE

Upon review with HEULE engineering, it was determined that deburring these intersects would be possible with a front cut only and back cut only COFA-X tool. This solution was presented to the customer, and they were onboard. They had requested assistance of HEULE to complete initial testing at HEULE facilities and provided non-deburred parts for process development.

We tested both the C8X-O-1035 (BCO=Back cutting only) and

C8X-O-1036 (FCO=Front cutting only).
Machine used for testing was a HAAS Super VF-2, which is the standard machine used in production. Cutting parameters used were the same as factory testing (65 SFM, 0.0042 IPR).

Customer benefits

Customer benefits

The customer has replaced a costly external secondary operation (thermal deburring). He is excited to further tweak the program as needed and install additional standard tools on this part process to have a fully complete part coming off the machine, saving initial manual deburring as well as sending out for secondary processing.

The customer stated that the tools did exactly what he wanted them to do and from time of reviewing initial test results performed at HEULE to testing on site at his facility, appreciated us helping him prove out the process he has been searching for a solution to.

Upper image: Resultat of BCO (Back cutting only) tool
Lower image: Resultat of FCO (Front cutting only) tool

60 Years Heule