rené gerber ag maschinenbau visit us march 15, 2018 on our ...€¦ · affecting the workpiece...

GrindTec Forum in Augsburg – March 15, 2018

René Gerber AG Maschinenbau

DEBURRINGHONINGPOLISHING

Visit uson our GrindTec-booth:

Hall 1 / booth 1017

www.gerber-maschinen.ch

GRINDTEC FORUM AUGSBURG – MARCH 15, 2018

René Gerber AG - Maschinenbau 1

«The production of symmetrical and asymmetrical cutting edge radii

with the diamond brushing technology and defined deburring and

polishing of fine machined parts»

Marc Schori

President & CEO, René Gerber AG

THAT IS THE COMPANY «RENÉ GERBER AG»

DeburringEXPO 10-12 October 2017, www.gerber-maschinen.ch

As a technology leader in process development and the construction of brush deburring, edge preparation and polishing systems, we have the solution for our customers over more than 60 years.

Technology company and long-term supplierin the tool-, automotive-, watch- and medical industry

With 3 technology center's in Germany, Switzerland and the USA as well of worldwide representations

Technology leader in brush deburring and edge preparation

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GERBER BRUSHING-PROCESS

Gerber brushing process Most different workpieces

Various materials

deburring

Rounding

polishing

René Gerber AG - www.gerber-maschinen.ch

Tools

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WHAT IS BRUSHING AND DEBURRING


The process allows a brush, which is coated with an abrasive or

which consists of bristles with incorporated abrasive grains, to slide

over a sharp-edged workpiece, to get a perfect edge honing result.

There is no secondary burr during rounding / deburring with brushes

The result is absolutely reproducible by means of the setting parameters

Edge preparation through the brushing process

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During deburring, the tips in the surface are smoothed without

affecting the workpiece thickness. This means that the surface is

polished simultaneously during edge preparation.

Reduction of roughness by polishing

Optical surface improvement

There is no influence on the workpiece thickness

DeburringEXPO 10-12 October 2017, www.gerber-maschinen.ch 5

Surface smoothing through the brushing process

Source: Feintool AG; CH-Lyss



Smallest radius Burr root thickness

Complete burr removing

Exact radius

Exact edge honing – exact radius

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Clearly defined techniques are needed to ensure that the results are reproducible and reliable.The company René Gerber AG has developed and develops solutions for defined deburring, rounding and polishing of precision parts by means of brush technology.

Reproducible and process-safe rounding

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Uniformly processed

Aligned 360° brushing

Uniform rounding

Regular polishing

Process-safe reproducibility



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4. Revolving head




1. Oscillating table 2. Tilting spindle 3. Planetary table

5. Planetary brushing head with/without turning station 6. Several planet heads in series

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THE PROCESS

1. To increase the service life of cutting elements such as…., the cutting contour is carefully prepared

2. This result in a 30%-500%-improvement in the lifetime / cutting performance

No only defined radii are produced in the 0.01mm range, but also the cutting edge surface is reduced by a factor of 3 and cutting faces / grooves are polished.


Cutting edge preparation

Edge to be rounded10

APPLICATIONS

Cutting edge preparation Cutting edge preparation of inserts

Profile cutting inserts

Drilling and milling tools

punch

dies

and othertools

Deburring Precision deburring in medical technology

René Gerber AG - www.gerber-maschinen.ch 11

Brushing-Polishing machines



Edge preparation

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K-Faktor < 1 K-Faktor 1 K-Faktor >1

Waterfall Exact radius Trumpet shape

NEW TERMINOLOGY, DEFINITIONS

Expressed differently K>1 = trumpet form / Flat

K=1 = Full Radius

K<1 = Waterfall

Depending on the application of the cutting edge, the K factor is decisive for the service life and the surface quality.


INCREASED TOOL LIFE OF MILLING, TURNING, DRILLING


By the brush polishing, not only the edge preparation is done at the

cutting edge but also the surface is smoothed. This means that the

surface is polished simultaneously during edge preparation.

Optimal cut edge preparation

Polished surface for chip discharge

Short processing time and absolutely reproducibility

Edge preparation through brushing

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INCREASED TOOL LIFE DURING MILLING, TURNING AND DRILLING

The Company René Gerber AG - GrindTec from March 14-17, 2018 15

Part description Drills

Material Carbide

Industry Automotive Industry

Required operations Edge preparation on drill bits

Machine Gerber BP-Smart with drill fixing

Brush Diaflex diamond, impregnated brush

Workpiece mounting 10 pieces drill fixation

Production 10 pieces in 20 second (2 sec. per piece)

Notice Cycle time 20 sec. to achieve a. 0008 "(0.02mm)

uniform grinding. Repeat accuracy of. 0001

"(0.0025mm). Application for new and reground

drill bits.

Drill bits



With the prepared “drill tip”for optimal life time andclean holes

Edge preparation on carbide drills

Edge preparation, brushedCutting edge untreated……….

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Maximum lifetime in case of defined cutting edge

K factor significantly >1

Optimal preparation for the coating > maximum layer adhesion

Reproducible, defined cutting edge in case of using Gerber brushing-process

Edge preparation through brushing

Indexable insert

Defines rounded cutting edge


THE BP-MX IN OPERATION

FURTHER DEVELOPMENT UNDER THE NAME DIAFLEX

Thanks of the development of a new brush technology based on a cellulose-derived natural material with the addition of diamond, it becomes possible to make the cutting edge-honing process much more efficient.

Clean

Process reliability

Powerful


Innovative diamond filling material based on cellulose


ADVANTAGES OF DIAFLEX DIAMOND

Compared to polishing with paste Thanks to a high diamond grain content in the brush, a significantly more efficient polishing

performance

Higher throughput

Higher production capacity

Compared of other diamond materials High temperature resistance (up to 160°C) prevents deformation of the carrier material

Diamond material can unfold his full power

Homogeneous distribution of the diamond grain gives a very high polishing performance

Due to the low heat development, the process reliability is increased

There are a few good reasons


SUMMARY

Innovative brushes, interspersed with diamond, allow easy manipulation of the K-factor

Tactile brush measurement results in high process reliability

Oil cooling with cleaning filter affects the process positively (no residues on the parts, constant temperature)

Diaflex – the natural material with plastic properties

Bürste handeingezogen Segment brushMoulded brush

DIAFLEX BRUSHES


Test the advantages of the new Diaflex brushes

POLISHING


The "Polish" series is able to produce flatnesses on a diameter of 40mm of 0.001mm. A peak value in machining.

Typical applications are:

Technical sapphire glasses and watch glasses

Nozzles for water jet cutting (Ruby)

Glass cylinder for endoscopes

Clock jewels (Ruby)

FinePolish, PowerPolish, DoublePolish

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POLISHING

Polishing of soft to super hard materials

Type: FinePolish Type: PowerPolish Type: DoublePolish

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COMPACTPOLISH – THE INNOVATION OF RENÉ GERBER AG


Applications The CompactPolish face polishing machines are designed to

polish to a certain thickness

Can produce fine polish

Advantages Small parts in the "Haute Horlogerie"

Diverse materials such as stainless steel, brass, ceramic, hard metal, plastics and composite material

COMPACTPOLISH – THE INNOVATION OF RENÉ GERBER AG

Polishing force over the pneumatic cylinder.

Individually controllable polishing power.

Enclosed workspace for clean work.

Four polishing phases are shown in the control.


Different rotor rings in different diameters optimally adapted to the application.

CompactPolish details

GERBER POLISHING PROCESS

Gerber brushing process Most different workpieces

Various materials

Rounding

polishing


Applications, polishing of hard materials

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RANGE OF PARTS


Face polishing with CompactPolish

PRODUCTS AND SERVICES OF «RENE GERBER AG»


Brushing process development

brushing tests

Brushes for cutting element preparation

Brushes for efficient deburring of parts

brushing tools

Service and spare parts

New and demonstration brushing systems

Brushing, honing, deburring

Quelle: Feintool AG; CH-Lyss


REFERENCES

Preparing of tools

For deburring, honing and polishingcontact the company «René Gerber AG»

GrindTec Forum in Augsburg – March 15, 2018

René Gerber AG Maschinenbau

DEBURRINGHONINGPOLISHING

Visit uson our GrindTec-booth:

Hall 1 / booth 1017

www.gerber-maschinen.ch

rené gerber ag maschinenbau visit us march 15, 2018 on our ...€¦ · affecting the workpiece...

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