ECOROLL Processing Cylinders Complete Machining with High Pressure Cooling Lubricants

OMEGA System (RDO, RIO) and tool types SK, GZ: Internal machining of hydraulic cylinders and cylinder liners 

ECOROLL's OMEGA system combines skiving and roller burnishing for machining hydraulic cylinders and cylinder liners. While the OMEGA skiving head cuts the cylinder's inner surface to the exact size and form required, the roller head burnishes it. The simultaneous skiving and burnishing process has almost completely replaced honing as the alternative machining process, since it is much more economic and faster. Thanks to its modular design, customized tools can be configured based on pipe quality and machining length. 

Sometimes for various reasons, tubes have to be skived and burnished separately or both processes have to be carried out one after the other. Therefore, all SK skiving heads can be delivered also as separate tools. SK skiving heads are then used in conjunction with GZ roller burnishing tools. In the first pass the SK skiving head peels the cylinder, and in the second pass the GZ tool burnishes it smooth. For cylinders with blind holes or steps, special blind hole skiving heads are available.

For machining short hydraulic cylinders with a length to diameter ratio of L/Ø ≤ 15 ECOROLL's SKOC and GZC tools can be applied directly on the lathe in one setting. The cylinders are premachined by a skiving head. After an automatic tool change the work piece is then finish machined by a separate roller burnishing tool. This process usually requires two toolplaces with one boring bar.

• Complete machining on lathes by combining tools with high pressure internal cooling system and a tool interface for BTA tools for an automatic tool exchange.
• In the first instance, cylinders made of cold drawn tubes are pre-machined by a skiving head, cylinders made of hot-rolled steel tubes are counter bored before skiving process.
• After an automatic tool exchange, the cylinders are finish machined by roller burnishing. The tools are equipped with an internal high pressure cooling lubricant supply in order to ensure intensive cooling and lubrication as well as efficient chip removal and cleaning of the surface.

• Reduces side times and simplifies material flow.
• Machining after all welding work is completed improves quality and geometry.
• Investment costs for a deep hole drilling machine can be eliminated.
• Enables economic manufacturing of small batches.
• For cylinders with through and stepped bores.

• Tool interface (1):
  • Contrary to BTA threads, tools are inserted into the bushing mounted on the boring bar without any rotation. The bushing is then rotated 40° to thighten up the connection. After that the tool is ready to use right away.
  • To disconnect, the bushing is rotated in opposite direction.
  • The tool can be changed manually as well as by an automatic tool change unit or a robot.
  • The interface's passageway can manage all process media, like cooling lubricants with chips or a control hydraulic unit.
  • The interface is suitable for CNC lathes as well as deep hole drilling machines.
• Counter boring tool (2):
  • Coolant splushing of knives through nozzels.
  • High pressure leads to high velocity of cooling lubricant. This results in improved cooling and a more efficient chip removal.
• Skiving tool (3):
  • Coolant splushing same as counter boring tool.
  • Skiving knives switch to working position after activating the cooling lubrication pump.
  • After releasing cooling lubricant pressure, knives retract. There is no need for a separate control hydraulic unit.
• Roller burnishing tool (4):
  • Internal coolant supply through nozzels positioned towards bore wall ensures efficient cleaning of surface before roller burnishing.
• Combined skiving and roller burnishing tool (5):
  • For long cylinders with through bores of larger batches, combined tools with high pressure internal coolant supply and automatic tool control system are available.