Better deburring in less time
Mayr Metall processes milled and turned parts with the new GARANT vibratory finishing machine GMT35.
With the GARANT GMT35, the Hoffmann Group has launched its first mobile vibratory finishing system in the Assortment. It promises flexibility for small and medium batch sizes. The Mayr Metall GmbH is already using the machine and is not only saving considerably machining time, but also achieves better grinding results.
Since the beginning of 2021, the GARANT GMT35 vibratory finishing system has been at Mayr Metal with success in use.Matthias Herbst selects three settings on the touchscreen: speed, time and Wet machining. Then he presses the start button and the GARANT vibratory finishing machine GMT35 starts to vibrate. When autumn returns after half an hour or hour All components are evenly ground and cleanly deburred. Matthias Herbst is managing partner of the company Mayr Metall GmbH from Waidhofen/Diepoltshofen near Schrobenhausen in Bavaria. Since January 2021, he has had the new The Hoffmann Group's vibratory finishing machine is in operation.
Quality advantage and time savings
The medium-sized company produces with 20 employees on 15 milling and milling machines. Lathes, a wide variety of components for mechanical engineering. Some are round, others angular, and the sizes also vary. Flexibility is therefore a must at Mayr Metall.
Before the Hoffmann Group's mobile vibratory finishing system was used, the parts after milling or turning, deburred and polished by hand – with sandpaper, Abrasive parts and hand grinding machines. Depending on the order situation, one or two Employees are busy with it. The use of the GARANT GMT35 has a significant Improvement, says the managing director: "The result is more uniform and we save an enormous amount of time. This reduces production costs, makes us more competitive and secures jobs. The components are fed into the machine and after half an hour or an hour they are ready". The vibratory finishing system is on two to three days a week.
As soon as the components and the abrasives are in the trough vibrator, the GMT35 start working.Ideal for small and medium-sized components
With the GARANT vibratory finishing machine GMT35, both metal and plastic can be edit. The component dimensions can be from 15 to 500 millimeters. This means that the machine can be used very flexibly: The number of components that can be used simultaneously vary depending on the component geometry and material, from Individual processing up to over 1000 pieces per processing operation. Mayr Metall uses them especially for post-processing of steel. The size of the machined components varies between 20 and 150 millimeters, the batch size per component between 10 and 1,000 Piece.
In view of these quantities, the GARANT GMT35 is ideal for his operation, says Herbst: "There are other vibratory finishing machines on the market, but they are suitable for large Series Paver". When he heard about GMT35, he had the impression that it was the right one for him. Also with the support of his contact person at Hoffmann Group, Florian Meindl, he is very satisfied: "We have been a customer of the Hoffmann Group and appreciate the professional on-site advice provided by experienced sales representatives and application engineers as well as the extensive range of products in the In the field of grinding and polishing," praises Herbst.
By means of a partition wall in the trough vibrator, two work steps can be carried out. at the same time.Deburring and polishing in a single step
The GARANT GMT35 has a trough vibrator that can be divided into a partition. As a result, two work steps are carried out at the same time, for example deburring and polish. However, the machine can also remove groove and milling marks or remove edges round off. At Mayr Metall, it is 90 percent used for deburring and 10 percent for deburring Polishing..
How many components can be machined in one pass depends on their size. Herbst knows from experience: "For components with up to 100 millimeters, 20 to 30 Parts in the trough. At 20 millimeters, I can make up to 300 pieces, depending on the geometry pour it in."
In case of application error, no rejects
At Mayr Metall, ten employees use the new vibratory finishing system. The following were instructed: from the Hoffmann Group's sales representative. "The operation of the machine is total simple. You can also create programs, then the components are always exact processed in the same way. But since almost every component is different, everyone operates them Employees manually," reports Herbst. As mentioned at the beginning, the touchscreen Speed, time and the editing mode set. The Hoffmann Group recommends in principle, the wet operation of the machine, so that the abrasion is removed and the optimum grinding effect is maintained. "Since we wet almost everything and mainly work in the upper speed range of 2,000 rpm, because for us that brings the best results, we don't have to change much when it comes to hiring. We just set the processing time to half an hour to an hour and off we go. If the result doesn't fit, the time is simply extended."
In addition to the great ease of use and the enormous time savings, Herbst, that it is practically impossible to produce rejects. "The worst thing that What can happen is that abrasives get stuck in a borehole because the did not choose abrasives optimally," reports Herbst. "You have to get them back Rinse out. But nothing breaks in the process. We mainly use the triangular ones Ceramic abrasives in all sizes from small to large, as we mainly Carry out deburring work. Which abrasives fit depends on the material and its surface finish." Porcelain abrasives (main application: polishing) or those made of plastic (main application: grinding of non-ferrous metals) come from Mayr Metal is not used.
In order to achieve an optimal result in deburring, the right Ratio of abrasive medium, component and treatment agent suitable for the material (Compound). The managing director reports: "To find out, we used the Trough vibrator filled differently. In our experience, you get the best Result if you use two-thirds abrasives and one-third components"
Changing the abrasives is quick and easy.Change sanding media in no time at all
Larger components can be passed through directly by each employee after milling or turning deburr the vibratory finishing system. In the case of small series, components that are based on the same Way should be post-processed, collected. Do you need to change the abrasives? , it can be done in no time. "In five to ten minutes," says Herbst. On the left On the side of the trough vibrator is the outlet. This will be opened and then the program item "Emptying" selected. As a result, the components are stored in the Separation station collected by a sieve and automatically removed from the abrasive media separately. At Mayr Metall, it is expected that the abrasives will last for a longer period of time. period can be used. "Ours still look like new, but at some point you have to Of course, they have to be renewed, because the sharp edges of the abrasives are rounded off and the deburring process takes longer," says Herbst.
Mobile and silent with less than 80 decibels
Since the vibratory finishing machine has rollers, it can be easily moved to changing locations. can be used. At Mayr Metall, however, it has a permanent place in the factory hall.
The managing director also evaluates the low volume with which the GARANT GMT35 works: less than 80 decibels. "This is extremely important for us, because Due to the 15 lathes and milling machines, there is a lot of high noise level. Any additional source of noise is a problem."
All in all, the experience after the first five months at Mayr Metall is very good. "The system runs reliably and is used by the employees with pleasure. We save us a lot of time and achieve better quality than before. In a year it will then become clear how the long-term application will develop," summarizes Herbst.
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