Fuel system manufacturers seeking the best fuel performance require flexible high-flow grinding and high-flow test capabilities to achieve finely tuned orifices in numerous design variations.

To this end, Kennametal Precision Surface Solutions® is announcing EXTRUDE HONE MF PROGRESS, the next generation of flow tuning and flow measurement featuring a flow targeting accuracy to +/-1% aimed at orifices 100-350 μm in parts less than 30 mm in diameter and flow rates up to 5 L/min. “Additionally, MF PROGRESS delivers another exclusive added value that we call Flexibility Through Modularity,” says Sharath Shankaregowda, Kennametal Precision Surface Solutions MICROFLOW product manager. “Customers benefit from a self-contained modular construction for each process (grinding, flush, flow testing, etc.) and configurable hardware (manifolds, frequency drives, etc.)”
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Customers are saying adding such advanced process options can help ensure components meet ever more stringent government regulations. From CAFÉ in North America, EURO6 and expected EURO7 in Europe, and PRC standards in Asia, all focused on reducing CO2 emissions, EXTRUDE HONE MF PROGRESS provides the perfect next step in upgraded manufacturing and finishing. In addition, this all takes place in a 25% reduced machine footprint, 50% less tool wear compared to previous-generation equipment, and depending on the application the output can be increased by up to 100%.

MICROFLOW Explained

• MICROFLOW is the real-time monitored flow of abrasive media through small passages, such as fuel-injector spray holes.
• It achieves specific, repeatable processing results, including edge radius, micro-hole size and surface finish. These changes to small-hole geometry improve part function and performance.
• Media flows in one direction, similar to part operation.
• Increased flow is attributed to subtly changing the geometry of the opening entrance (opening exit usually is not affected).
• MICROFLOW processing involves pressure drop, flow rate, geometry, and fluid properties; machine design and dynamics; workpiece characteristics; media properties and processing procedures.
• Exclusive range of standard and customized MICROFLOW media with specific properties perform a step beyond classical hydro erosive liquid.

EXTRUDE HONE MF PROGRESS is available in various inside station layouts: flow tuning, media reclaim, flush module, test module, marking, thanks to the system’s modular design and construction. It is easy to configure and easy to fit into modern production lines ready for robotic or other handling system automation. The machine also comes with expanded on-screen maintenance capabilities and improved filtration to further pump and valve life.

Reliability being at the heart of production control requirements, EXTRUDE HONE MF PROGRESS provides for online monitoring and control of all relevant parameters. The online feature is also beneficial in delivering remote process demonstrations and gathering resulting data.

Manufacturers and quality professionals requiring high-precision components for automotive, aerospace, energy, medical, and other industries know that removing particles from intersected holes and ensuring no micro-contamination is an ongoing challenge. Customized complex valves, gears, pinions, and thousands of other components can be machined in seconds, but require minutes to finish completely. The results are production bottlenecks, increased costs, and longer time to market.

Proprietary technologies such as TEM (thermal energy machining) from Kennametal are solving increasingly complex finishing challenges faced by manufacturers around the world. Danfoss Power Solutions (Ames, Iowa USA) is a global company focused on fulfilling the needs of off-highway vehicle manufacturers with engineered hydraulic and electronic components. “We manufacture hydraulic manifolds for hydrostatic pumps, a high-volume component,” says Lubos Hanulik, Operation Manager, Danfoss Power Solutions. “We use TEM for burr removal on intersected holes, cross-sectional holes from previous machining operations.”

After much investigation, the company chose Kennametal EXTRUDE HONE TEM (thermal energy method) solution. A pressurized mixture of a combustible gas and oxygen is injected at 5 to 10 atmospheres of pressure into a containment chamber sized both by the amount of material to be removed and the volume of parts in the chamber. An ignition system ignites the gas mixture, releasing heat energy from the oxidation of fuel in a 20-millisecond, high-speed energy wave. With their raised surface areas and thin cross-section features, even internal burrs and flashings burn away instantly. Because the gas mixture engulfs the entire workpiece, all internal and external surfaces are exposed to the rapid oxidation. Internal cross-drilled holes and intersecting edges that are difficult or impossible to reach are instantly processed.

“There have been hundreds of installations and continued refinement of our EXTRUDE HONE TEM equipment and process,” says Bruno Boutantin, global marketing manager at Kennametal Precision Surface Solutions. “One factor remains constant: TEM is a rapid, low-cost, high-production process that can process a million or more parts per year by a single machine.”

“If machining process is under control (tool life management is very critical and control of burr size is important too) TEM process with washing will give you the best process reliability and repeatability. High-pressure waterjet did not provide this value,” Hanulik says. “Combining TEM and post washing provided us a more consistent and reliable process, significant improvement of productivity, and increased overall safety. All of this has been achieved with fully automated robotic integration.”

Combining vast experience gathered over more than five decades with worldwide application knowhow, Kennametal Precision Surface Solutions offers proven solutions to many companies working in most demanding environments. Technical Centers and Centers of Excellence ensure close customer association in all critical steps — from the early design phases by producing small batches of components for prototyping through supporting the ramping stage in our contract shops prior to the final delivery of state-of-the-art equipment.