Burnishing machine

Types of Burnishing Machine

A burnishing tool often referred to as a refurbishing machine, refers to a finishing tool that smoothens surfaces. It generates a mirror-like finish critical in some machinery and parts. Burnishing tools can be majorly classified into four categories based on their operational mechanism and usage.

By Hand Burnishing Tools

As the name suggests, hand burnishing tools are manually operated. They are portable tools that fix workers' simple burnishing needs in small workshops. They are mostly used to finish small or delicate metal parts and are ideal where precision is paramount. Though manual, these tools require a skilled technician. This is to ensure the pressure is well regulated to achieve an even finish without damage.

Mechanical Burnishing Tools

Mechanical burnishing tools use electric or pneumatic power to rotate the burnishing tip. It provides more efficiency, especially in bulk production. These tools suit smooth and high-precision finish large workpieces. Unlike manual tools, mechanical ones reduce labor and inhabit uniform and rapid finishing.

Internal Burnishing Tools

Internal burnishing tools are used to finish internal diameters of cylindrical parts. These tools usually incorporate expandable heads or rollers that fit within the bore of a workpiece. Internal burnishing is vital in making internal surfaces of a bore smoother. This is especially on hydraulic cylinders or precision shafts.

External Burnishing Tools

External burnishing tools are primarily used to finish external surfaces. They use a similar concept but focus on the outer diameters of cylindrical workpieces. An external burnisher is a tool commonly applied in the tooling and machining industries to provide a mirror finish on turned parts.

Industry Applications of a Burnishing Machine

• Automotive Industry

  A burnishing tool is of much use in the automotive industry. Various engine components like cylinders, pistons, and crankshafts undergo burnishing. This improves the dimensional accuracy while at the same time enhancing surface finish. It reduces friction and retards wear. This extends the lifespan of critical engine components. It also helps in the enhancement of fuel efficiency and overall performance.

• Aerospace Industry

  In the aerospace industry, the application of burnishing machinery is largely in the production of critical components. Such components are like landing gear, turbine shafts, and fuel injectors. These parts require ultra-fine surface finishes to enhance their durability and resist aero.

  In this industry, any slight defect can compromise safety. Burnishing machines help meet stringent quality standards. They provide the necessary finish that aids in stress distribution and reduces fatigue in less critical components.

• Tool and Die Making

  Finishing tools are ideal in the tool and die-making industry. They improve the surface finishes of molds, dies, and cutting tools to be used in other industries. It ensures these tools have the appropriate finish that minimizes friction when in use. This means they will not wear out easily. High-quality burnished tools also produce better quality products. This is because there will be fewer defects on products to be manufactured from these tools.

• Metalworking Industry

  Burnishing tools have broad uses in the metalworking industry to provide better finishes on machined parts. Industries around this industry use burnishing machines to give their products a shiny and smoother finish. Since they are often associated with aesthetic appeal and functional use in the manufacturing field.

• Precision Engineering

  Finishing tools play a critical role in precision engineering where exact measurements and ultra finishes are required. In high-tech industries like robotics, medical devices, and electronics, burnishing machines ensure that the components meet the required quality standards. These form important parts in critical systems.

Product Specifications and Features of a Burnishing Machine

Technical Specifications

• Technical specifications of burnishing machines include:

• Head Types: Either single or multiple head burnishing. The former is ideal for simple operations. Whereas the latter is suitable for high productivity.
• Speed: Usually between 500 to 3000 RPM. It tends to vary depending on the machine model and burnishing required.
• Power source: Could either be electric or pneumatic. Electric machines are preferred for their usage indoors and are easy to use. The latter is ideal for heavy-duty applications.
• Stroke Length: Usually between 50 mm to 200 mm. Long stroke lengths are used for larger workpieces.
• Pressure: Most modern burnishing machines come built-in pressure regulators for precise control. This helps minimize the mental deformation of the workpiece.
• Max Bore Diameter: Internal burnishing machines usually have an expandable mandrel with different diameters. They range from 10 mm to 100 mm.
• Material: Burnishing tools are made of steel or hardened carbide. They are both durable and have great wear resistance.

Key Features

• Key features of burnishing machines include:

• Improved surface finish: The main function of burnishing machines is to enhance their surfaces.
• Tool wear: Advanced burnishing machines are equipped with tough carbide rollers. They offer high wear resistance compared to conventional tools.
• Versatility: Various kinds of burnishing machines are available in the market today. They fit different kinds of industries. From automotive, aerospace, or general engineering.
• High accuracy: Modern burnishing machines have built-in electronic controls. They enhance accuracy and play a vital role in large production.
• Compact design: Recent burnishing machines have a compact design. They allow easy use even in areas with little spaces.

How to Install

• how to install the burnishing machine includes:

• Setting up the machine base: The first step is to ensure the base is level and stable. It needs to be anchored to the floor to avoid any movements during operations. The machine should be leveled using a spirit level. In case of any irregularities, shims should be used to achieve a perfect level.
• Mounting the Burnishing Head: Depending on the design, the burnishing head is attached to the main spindle. A locking mechanism is used to clamp it firmly.
• Loading the Workpiece: The workpiece is securely mounted on the machine to avoid any movements. Vise or clamps are used. Since the safety of the workpiece is vital in the outcome, it needs to be checked often.
• Setting Parameters: Operational parameters like speed and feed have to be set up. The values should be relative to the material to be worked on and the desired finish.
• Connecting Power Sources: If it's electrically operated, the power supply needs to be connected. For pneumatic machines, ensure the air compressor is connected and appropriately set to required pressures.
• Safety Checks: Before running the machine, safety guards should be checked. Operators should also be equipped with safety gloves and glasses to prevent accidents or injuries to their eyes.

How to Use

• How to use the burnishing tool includes:

• Turn on the machine: After parameter input, the machine is turned on. The burnishing head then moves towards the workpiece.
• Adjust Pressure: While the machine is rotating, appropriate burnishing pressure has to be set. This is done using a pressure regulator. High pressure is suitable for hard materials. While on delicate or soft materials, low pressure is ideal.
• Start Burnishing: The burnishing head contacts the workpiece. As it does, the operator has to ensure the feed is activated. This will enable the sliding of the burnishing tools over the workpiece surface. Burnishing continues until the desired surface finish is achieved. Frequent checks aid in monitoring the surface condition.
• Stop the Machine: Once the required surface finish is achieved, the machine is turned off. The burnishing head is retracted from the workpiece. All operational parameters should then be reset for the subsequent use.

Maintenance and Repair

• Maintenance and repair of the burnishing machine include:

• Regular lubrication: This minimizes friction, prevents overheating, and reduces wear on the components. Lubrication needs to be done daily, before or after using it.
• Routine cleaning: Burnishing machines should be regularly cleaned after every use. This makes sure no residues or particles are left on the work area. A clean area reduces damage to the machine and gives accurate results.
• Check and replace worn parts: Often needs to be checked for any signs of wear or damage. Components like bearings, belts, or rollers might need to be replaced so often to avert major failures.
• Calibration: Machines need to be checked frequently to ensure them operate within the required specifications. Misalignment can cause poor surface finishes or even damage to the workpiece.
• Watering and storing: Most of the components in burnishing machines are often made of metal. Take note that exposure to moisture results in rusting. Significant damage is caused by rusting. To avoid such, proper storage and covering of the machine when not in use is vital. Also, using anti-rust sprays can be of importance as a precautionary measure.

Quality Control and Inspection for a Burnishing Machine

The key elements for controlling and inspecting quality in burnishing machines include:

Key Elements

• Surface Finish Measurement:

  Surface finish is the main criterion that holds burnishing machines. Use roughness gages to routinely check the surface finish of the workpieces. This will ensure the machine achieves the required standards. Surface finishes are measured in terms of Ra or Rz values.

• Dimensional Accuracy:

  Burnishing tools are supposed to give fine finishes, not alter the dimensions of the workpieces. Precision calipers and micrometers should be used to measure them often. This will ensure the machine doesn't alter dimensions during burnishing.

• Burnishing Pressure:

  Pressure control is vital in determining the outcome of this tool. Pressure regulators ought to be regularly checked. They help maintain consistent burnishing pressures across this machine. Essential for repeatability and consistency.

• Operational Speed:

  Speed can significantly affect the surface finish. Tachometers need to be used often to check whether the machine runs at the specified speeds. It prevents over-speed, which damages the workpiece and gives poor quality finishes.

• Vibration and Noise Levels:

  Abnormal vibration and noise levels are an indication of issues. They can be attributed to misalignment or wear of components. Regular monitoring of these levels ensures potential problems are addressed promptly. This minimizes any possible negative harm to the machine.

• Component Wear:

  This tool's major roller or burnishing pins are subject to great wear. Wear measurement instruments should be used often to check on these consumables. It allows for timely replacement. Otherwise, worn-out components will lower operational efficiency. They also give poor surface finishes.

Testing Procedures

• Testing procedures include:

• Initial Day Testing: Before the start of work, preliminary inspections are carried out. They include visual checks for possible defects and verification of surface finish.
• Benchmark Testing: A test piece with known dimensions and surface finish is used. It gives standardized results for comparison.
• Documentary Results: All results of inspections and measurements are documented. Regularly test helps with tracking performance over time. This is crucial for making informed quality control decisions.

Q&A

Q1. What exactly do burnishing tools achieve?

A1: Burnishing tools improve surface finishes of machined workpieces. They make them smoother and shinier, enhancing appearance and reducing friction for better performance.

Q2. What kinds of materials are suited for burnishing tools?

A2: Burnishing tools can work perfectly on metals like steel, aluminum, and brass. Softer materials like plastics and wood also get a smoother finish with burnishing.

Q3. What really is the difference between burnishing and polishing?

A3: Burnishing focuses on making surfaces smoother through pressure application. Polishing enhances shine using abrasive materials. Both improve finishes but through distinct methods.

Q4. What are the most common use cases for burnishing tools?

A4: In the automotive industry, they improve engine cylinder finishes. Aerospace uses them for durable aircraft parts. Manufacturing, too, for stronger mechanical components with smoother surfaces.

Q5. How often do burnishing tools require maintenance?

A5: Routine checks keep burnishing tools smooth. Simple cleaning after use and lubrication extend their life. Worn parts should be replaced, too, but deep maintenance waits longer - about 6-12 months, depending on use.