In automotive engineering, components must leave the production line without defects. Otherwise, for example, the autonomous braking system could fail at crucial moments. This is where component deburring plays a crucial role - electrochemical metal processing (ECM) ensures the required surface perfection. Many planners are currently looking for lean production systems to replace conventional deburring processes.

The first glance at complex components such as pump housings makes it clear just how challenging deburring is: these components often have a veritable network of holes through which the hydraulic oil or fuel, for example, later flows at high pressure. It is not easy to remove the existing burrs, especially if there are several bore intersections inside such a housing. Sometimes a lengthy manual process is required, which can take an hour or more for large hydraulic bodies for the aviation or commercial vehicle industry and is therefore cost-intensive. "In addition, manual processing naturally involves a risk of error," emphasizes Richard Keller, member of the management team at Emag ECM. "If employees overlook a burr, it can come loose during subsequent use and obstruct the flow. This is unacceptable in view of the high safety requirements in aircraft or automobile construction."

It therefore comes as no surprise that electrochemical deburring has become established for many components in recent years. Errors are largely eliminated here and the processing speed is rapid: During electrochemical metalworking, an electrolyte solution flows between the workpiece (the positive anode) and the tool (the negative cathode). This causes metal ions to detach from the workpiece. The shape of the cathode or the tool with the active, current-conducting areas is selected in such a way that the material removal from the workpiece leads to the desired component contour. This not only leads to surfaces with maximum quality - without thermal damage to the material structure - but also to completely consistent and reproducible results.

View of the new CI machine: Users benefit from compact technology with high-quality components and a favorable price-performance ratio. (Image: Emag ECM)

The ECM specialists at Emag, based in Gaildorf near Schwäbisch Hall, are constantly developing the process with a view to new materials, component geometries and quality requirements. For the new CI machine series available since spring 2017, the engineers have, among other things, revised the basic frame of the CI system and optimized the size of the control cabinet and the electrolyte management system in order to save expensive working space in their customers' production facilities. "It is obvious that, in view of technological developments, deburring and ECM clearing, for example when a component is already hardened, are becoming increasingly important. We wanted to develop a solution for this that, on the one hand, fully guarantees users the outstanding benefits of electrochemical metalworking and ensures reliable processes and, on the other hand, can be offered at an extremely attractive price-performance ratio."

Users then benefit from flexible technology with high-quality components throughout. The cycle time can be changed precisely using scalable devices, several components can be processed simultaneously during one process step depending on requirements, and upgrading to full automation is no problem with the CI machine. All parameters during the ECM process are fully and reproducibly monitored and documented. Last but not least, the CI machine only requires a footprint of around 7.5 square meters including filtration.

E-mobility is also moving into focus

The new CI machine is already in use at a North American aerospace supplier and an Italian commercial vehicle supplier. In both cases, deburring is carried out on very complex housings. Despite a large number of holes on the component, the cycle times are less than 60 seconds - a quantum leap in view of the lengthy manual processes previously carried out. "These examples show that we are on the right track with our development approach: We were able to prevail against national and international competitors because the CI machine has outstanding performance values, while at the same time being cost-effective. The enormous cost pressure among users calls for effective mechanical engineering, such as we offer with the CI machine," explains Keller.

There is much to suggest that this cost-benefit argument will gain even more attention from users in the future, as many components in electric and hybrid engines also require ECM broaching, drilling and deburring processes. In addition, there is another argument that should not be underestimated in view of the current discussion about the_{CO2 footprint} in automotive production: Compared to many alternative processes, electrochemical metal processing takes place much faster. This saves many tons of carbon dioxide. as