Holroyd's Edgetek superabrasive machining technology

Holroyd's Edgetek superabrasive machining technology

Holroyd's Edgetek superabrasive machining technology is drastically reducing the cycle times for producing automotive parts manufactured from sintered metals, in one case from 1 minute 10 seconds per component to just 22 seconds. At the same time, the Edgetek's CBN technology is cutting consumable parts costs, achieving a reduction from $1 US to just 3.3 cents per component. This is the result of the Edgetek machine producing a much larger number of components between tool changes: 15,000 as opposed to the 50 achieved with conventional milling and turning machines.

Sintered metals are used increasingly in the automotive industry, due to the requirement for vehicles to go longer intervals between services. As a result, there is a move away from engine drive technology based on rubber belts and pulleys, to chain drives and sprockets. It is precisely these latter components - and gears - where sintering comes into its own. The technology offers the advantage that it can be tailored to suit all requirements, enabling it to become established as a highly efficient and economical manufacturing process.

Although valued for their homogeneous and stress-free composition, materials that have undergone the sintering process are notoriously difficult to machine and are totally unsuitable for conventional turning. However, the High Efficiency Deep Grinding (HEDG) techniques provided by Holroyd's Edgetek machines are an effective answer to this problem.  Holroyd Sales Director Paul Hannah explains: "The use of an Edgetek SAT (Superabrasive Turning System) has enabled one automotive manufacturer to machine powdered metal timing sprockets and reduce tooling costs by 75% as a result of the ability of Edgetek's ability to perform interrupted cuts successfully".

"In another automotive application a sintered triple drive sprocket was extremely difficult to turn conventionally due to the requirement for interrupted cuts. Previously, our customer was using tooling with CBN inserts costing from 50 to 75 dollars each. These were turning each sprocket groove in 1 minute 10 seconds, but were lasting only a maximum of 50 components, resulting in a consumable parts cost of around $1US. Machining the same component on one of our Edgetek SAT machines has reduced the cycle time from 1 minute 10 seconds to just 22 seconds. Moreover, throughput has been increased greatly to 15,000 components per CBN wheel (costing $500), and set-up and consumable parts costs have been reduced commensurately, the latter to just 3.3 cents per component".

In addition to sintered sprockets and gears, the Holroyd Edgetek machines provide unparalleled levels of productivity in the manufacture of rotors and impellers, medical instruments, hand tools, air foils, nozzle guides, airframe actuation components, ducting supports, mechanical seals and many more. These components are often manufactured from among the most difficult to machine materials available, including Ceramics, Nickel, Tool Steel, Waspalloy, Inconel, Hastelloy and Stellite.

The flexibility of the design and the wide range of configurations available enable the Holroyd Edgetek machines to serve the broadest spectrum of industry types, including power generation, automotive, aerospace, medicals, tools and general engineering. The machines can be tailored by Holroyd to suit specific applications and be supplied as complete turnkey solutions as part of a manufacturing cell. A worldwide service network provides support for the machines, and they also benefit from manufacturer- developed preventative maintenance plans.