ON-BOARD POLISHING TOOL

Unmanned Die Polishing Automation of Die Polishing Processing realized on NC Machine Tools

On NC machine tools, such as machining centers, automation of polishing processing was realized by replacing a ball end mill with an on-board polishing tool attached with a special rubber bonded polishing point (Hybrid Rabin) after machining a metal surface with the mill to a desired shape.

The advantage of the On-board Polishing Tool is that the vertical and circumferential tracking functions enables the tip of the polishing point to follow the shape of a pre-machined workpiece, making it possible to polish planes, three-dimensional freely curved surfaces and the vertical walls of dies.

This product consists of ON-BOARD POLISHING TOOL and HYBRID RABIN.

1) ON-BOARD POLISHING TOOL

[Advantage]

ON-BOARD POLISHING TOOL realizes the automation of die polishing processing by attaching it to the spindle chuck of NC machine tools, such as a machining center. It requires no new capital investment, such as purchasing a special-purpose machine, and provides cheap polishing processing in spite of its simple construction.

The largest advantage of the ON-BOARD POLISHING TOOL with a tracking function is the realization of mirror face processing of nano-millimeter (nm) order using only fixed abrasive grains without using separate grains by making the end surface of a polishing point follow the shape of the surface subjected to pre-machining, such as cutting to remove tool marks generated by pre-machining planes, three-dimensional freely curved surfaces and vertical walls after this tool is combined to the later-mentioned HYBRID RABIN.

[Specification]

Three types of the ON-BOARD POLISHING TOOL are available, namely the standard and small size specifications with a vertical tracking function, and the vertical wall-targeted collet chuck specification with vertical and circumferential tracking functions.

(1) In the standard specification, a head can be replaced (polishing point chuck dia. 3 or 6 mm) so that a large diameter polishing point can be attached.

(2) In the small size collet chuck specification, a spring collet restricts runout so that a small diameter polishing point can be rotated at high speed to increase its circumferential speed.

(3) The vertical wall-targeted collet chuck specification provides our epoch-making new products with a circumferential tracking function added to a vertical tracking function capable of polishing even vertical walls.

2) HYBRID RABIN

[Advantage]

Advantage of HYBRID RABIN is to provide even polishing tool marks and improved surface roughness without leaving deep polishing scratches by suitably combining the elastic and flexible rubber characteristics and the diamond abrasive grains. In addition, continuous work is possible without paying attention to clogging, and cutting quality is not deteriorated even after blackening of polishing point surface.

[Specification]

– Polishing point diameter: 1 dia.～30 dia.
– Polishing point number count: #60～#10000
– Rubber hardness: JIS durometer A scale 95
– Diamond abrasive grain: Degree of concentration 100
– Polishing point shaft: Made of stainless steel (can be cut by hacksaw)

Unmanned Tool for Die Polishing Processing

Unmanned tool for die polishing processing ON-BOARD POLISHING TOOL (‘Super’ Craftsmanship Parts Grand Prize “Mechanical Parts Award” 2013 received) is installed to a collet at the tip of the spindle of NC machine tools, such as a machining center to perform polishing processing by the rotating motion of the spindle while pressing HYBRID RUBBING (elastic rubber bonded diamond polishing point) attached to the tip of the ON-BOARD POLISHING TOOL onto a workpiece surface at a constant pressure.

ON-BOARD POLISHING TOOL with a tracking function combined with HYBRID RABIN having elasticity and flexibility realized as far as mirror face processing by making the end surface of a polishing point follow the shape of a die pre-machined by cutting and removing tool marks generated by pre-machining planes, three-dimensional freely curved surfaces and vertical walls.

The introduction effect of this product is as follows:
– Variability of die surface roughness generated by manual polishing is eliminated and quality is stabilized.
– Machining conditions can be digitized and standardized, enabling skill transfer.
– Automatic operation in the night enables to shorten a work period.
– Since the involvement in the outsourcing of polishing work, the education of craftsman and the improvement of skill are not required, cost reduction can be realized.