Wash Water Recycling
The Aqua-Save system from MecWash Systems Limited, UK continuously recovers and re-uses the wash water in parts cleaning systems so the need for disposal is significantly reduced. Water quality is maintained throughout production ensuring that parts exit the system in a clean condition, without contamination with oily residues. The only effluent resulting from the Aqua-Save system is a concentrated waste, consisting of the oils, emulsions and soluble waste washed from dirty components, which represents typically less than 5% of the total water volume.
The Aqua-Save system can be added to any aqueous wash system to maintain solution cleanliness and washing performance, to reduce machine downtime, to minimise effluent disposal and to save money.
FEATURES & BENEFITS
- Removal of free and emulsified oils from the wash and rinse solutions
- Continuous recovery and re-use of wash and rinse water
- Significant water, energy, labour and chemical cost savings
- Environmentally friendly, substantial reduction in waste disposal
- Maintains continuous production and eliminates system downtime
- Maintains solution quality and wash performance
- Compact system, requiring minimal floor space
- Fully automatic operation with PLC control
- Can be fitted to all aqueous parts washing systems
- Media- and chemical-free treatment system – no chemical additives or filter membranes required
- Enclosed system
Please contact us for more information on the MecWash Aqua-Save system.
Cost-effective even for Small Batch Production
Paul Horn GmbH is expanding its range of gear cutting products. Horn’s new tool system for milling bevel gear teeth allows the complete machining of bevel gears on universal turn-mill centres. The system was created in cooperation with machine manufacturer INDEX and means that users no longer need any special machines to manufacture gears of this kind. It also allows all functional surfaces to be produced together with the gear teeth in one clamping. This enables high component precision, short lead-times, a very cost-efficient process and short machining times as a result of controlled machining cycles. With a universal turn-mill centre from INDEX, components with bevel gear teeth can be efficiently and flexibly manufactured, including in small quantities. This also makes the process attractive to small and medium-sized companies that would previously have bought in gears or had them manufactured externally.
For the process, Horn relies on its S276 and S279 double-edged indexable inserts, which are screwed on tangentially. This makes it possible to achieve a stable insert seat, which is particularly important during form milling. The tool does not have to be remeasured after the inserts have been turned around or changed because the inserts are precision-ground on the circumference. The milling body can be equipped to allow for different numbers of teeth and outer diameters when cutting gears. The process of developing the complete system (cycle, tool and clamping) called for a great deal of expertise on the part of both the machine manufacturer and the tool manufacturer. To implement the process, various types of INDEX machine with a “bevel gear hobbing” cycle are required. Horn offers the milling cutter bodies with the HSK-T40 and HSK-T63 interfaces. The profiles of the inserts are module-dependent and precision-ground.
Defined Chamfering Deburrs Gear Teeth in Seconds
Paul Horn GmbH has developed a process for precision deburring of gear teeth that represents a further advance in the world of gear production. Although gear teeth can be deburred relatively easily with brushes and discs, higher levels of precision and quality are being demanded, with the result that there is often no longer any scope for undefined chamfers at the tooth edges. So Horn has developed a technology – together with the associated production process – to enable the production of defined chamfers. It can be used, for example, to create a 45-degree chamfer on both sides of a module 1 gear wheel with 25 teeth in less than five seconds. A turn-mill centre with synchronised axes is required for this production process. However, users do not need any special workholding equipment. The solid carbide tools can be clamped in a standard collet, or in shrink-fit or hydraulic chucks.
The process is particularly suitable for machining gears in high volumes. The milling cutters are special tools and have to be individually designed for each gear tooth. Based on the application, Horn engineers will design the appropriate cutting edge geometry for the module, tip diameter and desired chamfer. Horn supplies the process data required for machining together with the cutter. Tool costs are low and quickly pay for themselves thanks to short machining times. The carbide substrate, tool coating and cutting edge geometry are all specially designed for each gear tooth material. As far as the actual machining process is concerned, the material is irrelevant. Chamfers can be milled into various steels, aluminium and plastics within seconds.
Skiving of Large Gear Modules
We present below a Gear Skiving Tool application from HORN for the machining of internal gears from module 3. Featuring interchangeable cutting inserts, the tool system offers high rigidity of the overall system as well as high productivity due to short process times.
Please contact us for more information on Skiving Solutions from Horn.
Applications requiring ultra-precise roundness, concentricity, and cylindricity are well suited for Helical Expanding Cast Iron Laps. Holding tolerances on diameter size and cylindricity to the sub-micron level is routinely achieved. Tools can be made as small as .043 inch (1 mm) up to 6 inches (150 mm) in diameter and as long as 14 inches (355 mm). Tools can be used for a wide range of materials including nonmetallic, non-ferrous, and ceramics.
Helical Lap Company provides tools for precision I.D. and O.D. finishing for major commercial aircraft and defense industry part suppliers. The extensive industry knowledge at Helical Lap supports the demanding requirements for overhaul and repair of components for helicopter and fixed wing aircraft. Helical Lap tools are in use worldwide by commercial airlines, military, OEMs, major MRO repair facilities and sub-contract vendors for lapping a number of high technology components. The following is a list of typical aircraft components which utilize our tools:
- Landing Gear
- Fuel Supply Controls
- Turbine Shafts
- Servo Controls
- Helicopter Rotor Components
Please contact us for further information on solutions from Helical Lap. We can help you choose the right products and provide guidance on the best techniques for your application.