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Precision machining and remanufacturing
Vibratory finishing is sustainable
The relative movement between the workpiece and the grinding wheel removes material from the edges and surface during mass finishing. The surface appearance of the workpieces, the resulting roughness and the stock removal and deburring performance can be varied almost at will by selecting the machine parameters and process media (abrasive media and compound).
Today, customer demands on the surface increasingly require the achievement of low roughness values and/or optical smoothing. Despite improved input qualities of the workpieces due to the further development of upstream production processes, the increased requirements for end products mean that superfinishing in mass finishing is required.
When developing an ultra-fine finish for a workpiece, the right choice of abrasive media is of crucial importance. Avatec distinguishes between 100 abrasiveness levels in its entire range, including 25 different qualities in the fine sanding range alone. The interplay between the quality, shape and size of the abrasive media and the choice of machine type determines the result.
Ultra-fine machining plays an important role in remanufacturing, for example. As already described in the brief analysis by Dr. Ulrike Lange entitled “Resource efficiency through remanufacturing - industrial reconditioning of old parts” from 2017 (VDI ZRE publications), there is an explicit recommendation for such processes from an ecological and economic perspective. Energy and material savings of over 50 % can be achieved. The environmental impact can be reduced by up to approx. 40% compared to new production. The surface finishes required in remanufacturing can be achieved economically thanks to ultra-fine machining.
VDI Zentrum Ressourceneffizienz GmbH (VDI ZRE), VDI ZRE publications:
Brief analysis no. 18, “Resource efficiency through remanufacturing - Industrial reconditioning of old parts” by Dr.-Ing. Ulrike Lange
Ultra-fine machining is also becoming increasingly important in the manufacture of components. Surfaces with a low roughness play an increasingly important role in components if the workpiece is to achieve its optimum function and service life (e.g. medical technology, precision mechanics, optics, etc.). The ultra-fine machining of workpiece surfaces can be used to optimize wear behaviour, reduce energy requirements through improved tribology or minimize noise development during component movements. Or simply enable or optimize the feeding of components in automation by deburring and smoothing them.
In addition to the abrasive media, a suitable compound is required in the process water of the mass finishing process. Due to sustainability goals, the focus today is primarily on circulation solutions for the process water. As high surface requirements necessitate consistent process water quality and a standard process that can be carried out reliably, Avatec's special recyclable compounds buffer fluctuations caused by temperature and contamination. Continuous dirt removal (e.g. with cascade, centrifuge) and re-sharpening of the compound as well as the addition of further additives can achieve a long service life with consistent results.
Ultra-fine machining with suitable abrasive media and a coordinated compound in conjunction with easy-to-operate system technology consisting of a mass finishing system with waste water and preparation management enables an economical and sustainable machining process.
Avatec relies on efficient small solutions and functional automatic system technology.