Deflashing-Descaling Case Study:  Forged Camshafts  

Camshaft, after forging, has heavy scale deposits. The Challenge

Our customer is a major automobile builder and manufactures its major engine components in-house. These forged camshafts needed to be de-flashed and de-scaled prior to turning.

The method in use at the time was a hand operation using a coated abrasive disc on a hand grinder to knock down the parting line, followed by high pressure blasting with steel shot to remove the iron oxide scale.

This system was difficult to quantify and hard to control, in addition to being very labor intensive. McNeil OLS deburring engineers consulted with our customer and devised a highly productive and predictable solution to their production challenge.

The Solution:  Model 7060 Deflashing - Descaling Machine

We applied our extensive knowledge of brushes to this application, incorporating seven brush heads at five work stations to perform a complete de-flash and de-scaling.

Our customer insisted that all the iron oxide scale be trapped and collected in a container that was safe and easy for operators to empty. A large Torit collection unit mounted to the top of the machine filtered the fine particles and separated the heavier particles into a metal container accessible from the shop floor. OLS developed a new urethane impregnated brush core specifically for this application.
McNeil OLS Model 7060 descaling machine taking shape.
The part is first de-flashed by a massive four-head brush array fitted with the newly developed brush cores, aggressively reducing the parting line.  At the next four stations, a rising and falling single-head wire brush further reduces the parting line and removes the last traces of scale.

Our customer specified a close tolerance for parting line projection, beyond which the turning tools would wear too fast. As you can see from the "after" part picture below, not only was the line knocked down below spec, it was virtually eliminated. Parts are rotated on the holding spindle at each brushing station to ensure uniform de-flashing. An on-site robot loads and unloads parts. 		Internal workings of McNeil OLS Model 7060 deflashing/descaling machine.

The Benefits
The OLS Model 7060 provided our customer with a cost effective de-flashing solution which removed all of the variables inherent in the old system. This led to more predictable and controllable process results, taking the guesswork out of quality control. Turning tool life was greatly extended due to reduced “on-off” shock from the reduced parting line profile. All process debris was safely contained and collected, eliminating the “instant rust” effect of falling iron oxide.

 Based on brush costs, our customer calculated that this OLS machine must produce 200 parts per brush-set to “break even” (that is, to be as cost effective as the old method). After a brief set-up and development phase, the machine actually produces 2,800 parts per brush-set, an enormous cost savings all by itself, but with the added benefits of lower turning costs, reduced handling and greatly improved quality control. Automating the process also reduced repetitive stress injuries among employees. Standing over 17 feet tall, this big machine delivers big productivity.
Camshaft before deflashing-descaling with McNeil OLS Model 7060 machine.
Camshaft before deflashing-descaling.		 Camshaft after deflashing and descaling operations.
Camshaft after deflashing-descaling.