ECOROLL Processing Cylinders For Short Cylinders (L/Ø ≤ 15)

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 CNC-lathes or machining centers.
• Skiving and burnishing in one setting before or after machining the cylinder ends. Internal machining on deep hole drilling machine not required.
• GZC Tools: See burnishing tools type G, for this usage equipped with internal washing unit and a special tool holder compatible with boring bar. 
• Accessories: MQL-pump with installation service.

• Reliable, high-precision operation.
• Achieves a diameter tolerance of IT8 or IT9.
• Significantly reduced side-times.
• Transportation of components to a deep hole drilling machine is no longer necessary.
• Tool change on CNC-lathes and machining centers is much quicker than on deep hole drilling machines
• High investment costs for a deep hole drilling machine can be eliminated, which enables small- and middle batch manufacturers to efficiently produce cylinder liners or complete cylinders.
• Separate short tools.
• SKOC skiving head:
  • Achieves surface finish of R_z = 15 – 30 micron.
  • Change of cutting insert and central diameter adjustment without removal of knives.
  • Controlling of knives by MQL pressure (no separate controlling system required).
  • Connection to boring bar with control connection (ECOROLL W connection).
• GZC burnishing tool:
  • Achieves surface finish of R_z < 1 micron.
  • Simple change of wear parts.

• SKOC skiving head:
  • Based on OMEGA system.
  • 3 knives with consecutively arranged cutting inserts.
  • Integrated in tool holder: Control piston equipped with MQL supply. After activating the MQL-supply knives are automatically adjusted to working position. After switch off they retract into the idle position without damaging the peeled surface.
  • MQL nozzles inject cooling lubricants on high speed into the peeling unit which supports chip removal in feed direction.

• GZC burnishing tool:
  • See standard burnishing tool type G.
  • Here equipped with internal washing unit.

• MQL supply:
  • For both tools through boring bar.