The world's largest automotive supplier relies on Kennametal Extrude Hone for its finishing solutions

KENNAMETAL

The world's largest automotive supplier relies on Kennametal Extrude Hone for its finishing solutions
Wednesday, July 9, 2014Description :
Manufacturers and quality professionals in sectors such as automotive, aerospace, energy, medical and other industries requiring high-precision components are well aware that the removal of particles remaining at the Ensuring that there is no micro-contamination is a quality problem that can not be overlooked.

The machining of valves, gears and complex sprockets, of thousands of parts, is a matter of a few seconds but their complete finishing can take several minutes. As a result, inter alia: production bottlenecks, increased manufacturing costs and extended delays in placing on the market.

Kennametal Extrude Hone is a global leader dedicated to providing high-precision surface solutions for uncompromising quality components. Patented techniques such as TEM (Heat Treatment Machining) address the increasingly complex finishing challenges faced by manufacturers around the world.

Delphi-TVS is a joint venture between Delphi Corp. (Troy, Michigan, USA) and T.V. Sundaram Iyengar & Sons (Kancheepuram, India). Delphi is the world's largest automotive supplier and Delphi-TVS is India's largest manufacturer of automotive systems.

"As a global company, we have a great responsibility in maintaining world-class quality standards for our products," says T.N. Umasankar, Head of the Delphi-TVS manufacturing engineering department. "We manufacture diesel injection parts, high-volume components. The main problem is the deburring of the transverse holes resulting from the previous machining operations.

Delphi-TVS was faced with many problems: the large volume of components close to one million per year made manual deburring unaffordable and the high-precision nature of Diesel injectors made the TEM solution a necessity.

After much research, the company chose Kennametal Extrude Hone's TEM solution (thermal energy method). A pressure gas mixture of fuel gas and oxygen is injected at a pressure of about 5 to 10 bar in a confinement chamber whose size is determined by both the amount of material to be removed and the volume of parts in the chamber .

An ignition device ignites the gas mixture, thereby releasing the thermal energy resulting from the oxidation of the fuel into a high-speed wave in 20 milliseconds. Due to their areas of raised surfaces and their thin section, even internal burrs and flashes are immediately destroyed. The gas mixture submerging the entire part, all internal and external surfaces, is exposed to the combustion of the mixture. The transverse internal holes and the intersecting edges, which are difficult or impossible to access, are instantly processed.

"Hundreds of installations have been completed, along with the continuous optimization of our TEM equipment and process," explains Bruno Boutantin, Global Marketing Director of Kennametal Extrude Hone. "One factor remains constant: TEM is a high, fast and economical production process capable of processing one million or more parts per year with a single machine."

"The TEM process is particularly suitable for high volume applications where traditional deburring departments are struggling to keep pace," says T.N. Umasankar. "It instantly cleans a large number of intersecting holes, threads and hard-to-reach areas, literally in 20 milliseconds. Its ability to process ignite several components at the same time greatly increases its possibilities and profitability. No other process, even with high pressure water jet, is likely to bring such added value. "

Kennametal Extrude Hone, with its vast experience of more than five decades and international application know-how, offers proven solutions to many companies operating in the most demanding environments. The Technical Centers and Centers of Excellence guarantee close cooperation with customers at all critical stages, from the initial design phases through the production of small batches of components for prototyping, up to the support of the ascent phase In charge of our commercial workshops before the final delivery of advanced equipment.

In India, Kennametal Extrude Hone is an integral part of Kennametal India Ltd. Located in Bangalore, the Kennametal Extrude Hone Technical Center is well equipped to support the special needs of guests.

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