Hydraulic Tool Maker Turns to Flexible Hone for Deburring/Finishing of Cylinders

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Deburring/Finishing Cylinder Hone Improves Quality for Hydraulic Tool Maker

We us the Flex-Hone Tool to impart a better finish on the cylinders, remove burrs or improve quality standards of certain parts

To maintain a critically important cylinder surface finish in its products, an international hydraulic tool manufacturer has turned to a versatile deburring and finishing cylinder hone which meets its strict quality standards. The manufacturer, ENERPAC, a division of Applied Power Inc., headquartered in Butler, Wisconsin, produces hydraulic tools; such as, cylinder, pumps, jacks, valves and components for a wide variety of industrial construction applications, including all phases of equipment and machine manufacturing.

According to ENERPAC Senior Manufacturing Engineer William Kadlec, the company’s product line – “any kind of hydraulic lifting device”- consists of a plunger with U-cups and seals which moves up and down under hydraulic pressure within a cylinder. The tools operate under pressures as high as 10,000 psi for such applications as lifting bridges, railroad cars, or any other high force requirement, e.g., pressing, pushing or pulling.

The ENERPAC diversified product line features scores of hydraulic tools, in a variety of cylinder diameters from a half-inch to over 22 inches. In manufacturing these tools, the boring operation is “critical because of the final cylinder finish necessary for quality,” says Kadlec. The company insists on 8-18 micro-inch finish.

“If the finish is too rough, the U-cups and seals wear out. Conversely, if the cylinder surface is to smooth, the seals may leak,” explains Kadec.

To ensure the proper cylinder surface, ENERPAC relies on Flex-Hone, a deburring and finishing tool from Brush Research Manufacturing Co., Inc., Los Angeles, CA. The system consists of a resilient-based hone with abrasive laminated to the ends of high-density nylon filaments.

“We us the Flex-Hone Tool to impart a better finish on the cylinders, remove burrs or improve quality standards of certain parts,” says Kadlec.

The cylinder hone is used directly after the boring operation, during which a cylinder of specified diameter is created in the hydraulic tool through the use of vertical of horizontal CNC machine, turret lathes or CNC lathes. During this process, high tool marks or irregularities can occur on the cylinder surface. The surface finish is measured on a profilometer.

“A normal finish in a bore, if you’re lucky, measures 63,” Kadlec explains. “A 250 finish is rough.”

Occasionally a finish falls into the ENERPAC required range of 8-18 by using diamond tools, but more often, the cylinder must be roller burnished and/or finished by a flexible hone.

Mounted on a spindle drill or hand-held, the Flex-Hone Tool easily and quickly hones and deburrs the cylinder surface at speeds up to 500 rpm. The grit or grain sizes of the cylinder hone used in the process vary according to the finish needed.

On a “too-smooth” cylinder finish, the flexible hone gives a crosshatch finish to bring the cylinder up to the 8-18 range. On a too rough finish, it brings it down to the 8-18 range.

ENERPAC utilizes a variety of honing tool sizes for its extensive product line, and depending on the application, employs the finishing tool on thousands of units a year in a single product line.

“The Flex-Hone is so versatile, a great tool for out stringent standards,” claims Kadlec. “It’s mounted on a flexible shaft; you don’t have to worry about true position. It’s a great tool to maintain finishes or re-work them.”

An added feature of the flexible hone, according to Kadlec, is that it’s used with cylinders in which cross-holes or connecting circuits create burrs around the edge of the holes. By running the honing tool in the cylinder bore, the burrs are easily eliminated.

“The cylinder hone allows us to maintain the stringent quality finish we demand, and our customers demand, for our hydraulic tools,” Kadlec concludes.

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Heather Jones
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