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Our solutions in action
Our aim is to provide you with a tool solution that is perfect for your application. Regardless of the industry you work in. Regardless of the material being processed. See for yourself where our tool solutions are in use.
Helicopter Part
Customer application
This customer previously used an old reverse boring bar which had to be driven into the bore off-center at spindle standstill, causing manufacturing delays. The tool also caused inconsistent results and quality problems which resulted in high quality control costs.
| Workpiece | Aviation component |
| Material | Stahl 35NCD16 |
| Parts per year | 150 |
Solution
The SOLO tool, with indexable insert, produces consistent results all within tolerance. It can be driven into the bore centric at low rpm resulting in faster production cycles.
Customer Benefit
- Machining of each bore from one side in one single pass
- Increased reliability and quality reducing QC efforts substantially
- Blade life time: 300 Counterbores
- Average time savings of 30 min per part / 75 hours per year
Turbine Rotating Part
Customer application
The customer was looking for an automated solution to machine chamfers to bores front & back in one operation. The goal was to minimise tool changes and process time as well as eliminate manual deburring.
| Workpiece | Aviation component |
| Material | 17-4 PH Steel |
| Parts per year | 50 parts (1’000 bores) |
Solution
HEULE recommended a SNAP tool for front and back bore chamfering. It allowed chamfering front and back with one tool. Manual deburring was eliminated. HEULE helped to reduce process time to an absolute minimum.
Customer benefit
- Machining of bores from one side, eliminating the need to turn the part
- Consistent deburring quality
- Elimination of manual handling
- Blade life time of 2’500 bores
- Estimated machine time savings of 90 min per part / 75 hours per year
333 hours saved by combined deburring
BURAG AG has been active in metal and tube machining for 80 years. The highly specialised company in Eschlikon, Switzerland, processes steel tubes into tube fittings and tube formed parts. Threads are rolled, moulded and cut. Tube ends are drawn, expanded, rolled and profiled and where necessary, the tubes are also drilled.
BURAG AG’s customers include leading companies in sanitary and fastening technology, the machine industry, heating and combustion manufacturing as well as agricultural machinery. The highest levels of precision, quality and flexibility are required. Efficient manufacturing processes are developed for customers in the production halls and wherever possible, the processes are fully automated. The goal is to implement processes that run without human intervention.
Combined drilling and deburring as a solution
This type of automated production was also required to produce connecting pipes for a machine in the agriculture industry. The aim was to produce 25,000 workpieces per year as efficiently and reliably as possible. The engineers at BURAG AG developed a customised production strategy and produced the first series of tubes for the customer to their complete satisfaction. However, the BURAG AG team was not satisfied with the process for the four bores in the pipe. Due to an unreliable drilling operation, a lot of time had to be invested in monitoring the drilling result. In addition, the process time was very long, as a second tool was used for deburring the front and back bore edges after drilling. All in all, it was an unstable process that repeatedly pulled on the nerves of the people in charge.
As HEULE tools were already in use at BURAG AG, the Swiss deburring specialist was contacted again to find a solution. During an initial on-site visit by Eisenbart GmbH, the HEULE sales partner for Switzerland, various options were discussed and passed on to HEULE for a feasibility study. The result was an application-specific drilling combination tool that combines drilling with deburring on both sides of the bore in one operation and promises a reliable deburring result even with uneven bore edges.
Aircraft Component
Customer application
The customer previously had to drill and chamfer the bores in three steps. He was looking for a solution to produce bores in one operation without a tool-change to minimize machine-time and eliminate manual deburring.
| Workpiece | Aircraft workpiece |
| Material | Thin Aluminium Profile |
Solution
The solution from HEULE is a VEX-S tool which is designed for combined drilling and deburring in one operation.
Customer Benefit
- Significant time savings by combining three process steps in a single pass
- One tool-change eliminated
- Manual deburring eliminated
- Higher process reliability
- Process time decreased by 50%
Gearbox housing
Customer application
The customer, a manufacturer of gearbox housings, was looking for a more efficient solution for applying back spotfacings.
| Workpiece | Gearbox housing |
| Bore diameter | Ø22.5 mm |
| Diameter back spotfacing | Ø41.0 mm |
| Material | GG25 |
| Machine | Horizontal Machining Centre HELLER MCH250 |
Solution
HEULE recommended the following BSF counterboring tool.
| Tool | BSF-OG-2100/4100/070-HB |
| Blade | BSF-MG-0975/1000/1A |
Customer benefit
Thanks to BSF, machining is faster and more reliable, i.e. without needing to stop the machine nor re-clamp the workpiece. The customer benefits from reduced cycle times and improved process reliability.
Gas Turbine Housing
Customer application
This turbine manufacturer was looking for a cost-efficient, yet reliable, solution for the application of back spotfacings without the need to turn the turbine housing in the machine.
| Workpiece | Aviation component |
| Material | M-152 |
| Parts per year | 150 parts (9`600 bores) |
Solution
HEULE introduced the BSF back spotfacing tool which allowed the machining of large counter bores in one operation with a very high reliability and quality. Turning and re-clamping of the housing was eliminated.
Customer benefit
- Complete finishing of the part on the machine
- Machining from one side without the need to re-align & re-clamp the part
- Higher process reliability
Turbine Component
Customer application
The customer was looking for an automated solution to make the deburring process more reliable and efficient. Previously, three staff members manually deburred the front and back edges of the bores with carbide blades.
| Workpiece | Aircraft component |
| Material | 17-4 PH Steel |
| Parts per year | 225 parts (3’375 bores) |
Solution
HEULE recommended a COFA tool for front and back bore deburring in one single pass. Manual deburring was completely eliminated. Process time was reduced from 90 minutes to 20 minutes per part.
Customer benefit
- Entire machining from one side in one single operation
- Consistent deburring quality
- Elimination of manual handling
- Process time decreased by 70 minutes per part.
Manifold
Customer application
Our customer is a major supplier of different components to the recreational vehicle (RV) industry in the US. They contacted us after researching machine deburring options.
They required assistance with several applications for deburring crossbores on one of their high-volume manifolds, which is manufactured in multiple configurations. In the past, the manifold hole burrs were removed using thermal/explosive deburring as a secondary off-machine process.
The .391-inch Ø bore through the SAE #4 port that intersected the two VC08-2 cavity ports, proved to be the main challenge. These intersections create a 1:1 crossbore ratio.
| Workpiece | Manifold |
| Bore diameter | Ø0.391″ / Ø9.93 mm |
| Material | Aluminium |
| Machine | HAAS Super VF-2 |
Solution
After an initial review, it was determined to use a standard SNAP tool for the Ø.281″ mounting bores and a standard COFA tool for the .250″ through bore in the SAE #4 port.
The analysis by the HEULE technicians revealed that deburring these intersects would be possible with one COFA-X tool that only cuts from the front and another that only cuts from the back. The customer was presented with this solution. They agreed and requested assistance to conduct the initial tests in HEULE’s own test workshop. For this purpose, they provided non-deburred parts for process development.
Customer benefit
The customer has replaced an expensive external secondary machining process (thermal deburring). They anticipate fine-tuning the program as needed and installing additional standard tools for this part process in order for the machine to produce a fully finished part. The initial manual deburring and secondary processing have been eliminated.
The customer reports that the tools perform precisely as desired. From verifying the initial test results to on-site testing at their factory, they appreciate that HEULE has helped them accurately test the process for which they were seeking a solution
Flow meter
Customer application
The manufacturer of a flow meter required a cross bore with a defined back chamfer in their workpiece. The difficulty lies in gaining access to the bore’s back edge.
| Workpiece | flow meter |
| Bore diameter | Ø6.0 mm |
| Chamfer | at the back bore edge: 0.25 mm x 45° |
| Material | SU304 |
| Volume | 3,000 bores per month |
Solution
For this application HEULE chose their VEX Combi Drill Tool (GH-QO-4002 with replaceable drill insert PS-C2-0600-1T), which is also equipped with a SNAP chamfering blade (GH-QM-30106).
| Tool | VEX |
| Cutting speed | 1,500 rpm |
| Working feed for chamfer | 120 mm/min |
| Machine | vertical CNC machin |
Customer benefit
The VEX Combi Drill Tool drills the bore and applies the required chamfer to the back of the bore in a single pass.
- Drilling and chamfering in a single pass
- Higher quality of the results
- No deburring by hand
Aircraft component
Customer application
Previously, because of poor accessibility, the front and back chamfer of the bores had to be performed manually. This caused issues with adhering to the high aviation industry standards and caused long production cycles.
| Workpiece | Aviation component |
| Bore diameter | Ø7,036 mm |
| Material | Inconel 718/718plus |
| Machine | Vertical/Horizontal Machining Centre |
Solution
This solution was accomplished with the DEFA chamfering tool (two-bladed) which assures highest quality and guarantees process-reliability. The parts can now be completed entirely on the CNC machine without the need for further manual chamfering.
| Tool | DEFA 7.0-8.0/34 (GH-SD-5214) |
| Blade | DEFA 7.0-8.0 (GH-SM-3909) |
| Cutting speed | 400 RPM |
| Working feed | 0.08 mm/rev |
Customer benefit
The customer achieved the following improvements:
- Replacement of the manual process
- Reduction of the required production time
- Stabilisation of the process
- Improvement of the chamfer quality
Fork piece
Customer application
A Swiss supplier for the German automotive industry was previously required to manually deburr the fork, used in a steering column. Faced with the problem that manual deburring was too time-consuming and caused a production backlog, the company was looking for a new solution.
| Workpiece | Fork piece |
| Bore Ø | 15.0 mm |
| Deburr size | max. 0.3 mm |
| Material | steel |
| Machine | Hermle Milling Centre |
| Machining | axial |
| Coolant | external coolant, 30 bar pressure |
| Dimensions | d = 15.0 mm, H = 42.0 mm, E = 28.0 mm |
| production volume | 200’000 bores per year |
Solution
Fork piece deburring is a tried and tested application of the COFA tool. Customer requirements to minimise processing cycle time as much as possible led to the development of a unique solution. The 15.0 mm diameter could also be machined using a standard COFA tool. HEULE proposed a double-cassette tool in order to work with a maximum working feed rate. This tool uses two blades.
| Tool | Double cassette toolCOFA C6 |
| Blade | C6-M-0006-T |
| Speed | 1,000 rpm |
| Working feed | 0.8 mm/rev |
Customer benefit
The customer defines the benefit as the elimination of manual rework and the now process-reliable deburring, i.e. the time savings. But the emphasis is on the thrilled machine operator, who no longer has to manually process the parts.
- Elimination of manual rework
- High process-reliability
- Enormous time savings
Common rail
Customer application
Our German customer produces over 1 million Common Rails annually. He was looking for a solution to automate the reverse deburring of the low pressure bore. Previously, our customer deburred common rails with a competitor tool. Blade life was not satisfactory and deburring quality was not reliable, resulting in frequent and expensive quality assurance problems.
| Workpiece | Common Rail |
| Low pressure bore | 2.4 mm |
| Main bore | 9.0 mm |
| max. Deburring diameter | 2.8 mm |
| Material | forged case-hardened steel (1,000-1,300 N/mm²) |
Solution
The solution proposed by HEULE is the simple and economical SNAP tool. The edges of the bore are deburred and chamfered without rotating the workpiece or stopping the spindle.
| Tool | SNAP 2/2.4 |
| working length | 30 mm |
| blade | SNAP blade 2.8 mm diameter made of carbide with a TiAlN coating |
| Working speed | 3,300 rpm |
| Cutting speed | vc 25 m/min |
| Working feed | 0.05 mm/rev |
Customer benefit
The customer is completely satisfied with the high level of process reliability and the deburring quality. Previously, the common rails were deburred with a competitor tool. The blades designed specifically for tough materials have a service life of 2’000 bores. Thanks to the SNAP tool’s reliable deburring, the process costs have been reduced.
- High level of process reliability and deburring quality
- Increased blade life: 2’000 bores
- Quality assurance issues eliminated
Crankshaft
Customer application
This crankshaft’s manufacturer is a supplier to the Chinese automobile industry. These oil bores have been manually deburred until now. Due to customer complaints, they were searching for a more stable process. Because they lacked an automated tool solution for deburring crossbores with a bore diameter ratio of nearly 1:1.
| Workpiece | Crankshaft |
| Bore diameter | Ø8.0 mm intersecting with main bore Ø8.5 mm |
| Material | 42CrMoA |
| editing | horizontal |
| Volume | 1 million bores per year |
| Tool | COFA-X(C6X 8.0S) |
| Blade | C6X-M-0001-T |
| Speed | 500 rpm |
| Working feed | 0.1 mm/rev |
| Machine | Shenyang CNC |
| Machining | horizontal |
Customer benefit
The customer was able to switch from manual to automated processing. The deburring result is now stable and of higher quality. The customer appreciates the simple and safe handling of the tool, which requires no setup.
Watch case
Customer application
Our customer previously deburred the watch crown bore with a competitor tool but wasn’t able to achieve the required process-reliability. This resulted in excessive rework and testing costs. The main problem was that the disproportionate height of the burr.
| Workpiece | Watch case |
| Bore diameter | Ø1.5 mm |
| Chamfer diameter | Ø1.8 mm |
| Material | XcrNiMo |
| Secondary burr height | < 5 my |
Solution
The analysis performed by HEULE revealed that this production task can be accomplished by optimising the production sequence (burr reduction) and the DL2 tool. It was crucial that the DL2 uses internal coolant to reliably guide the burrs away from the cutting edge.
| Tool | DL2 |
| Cutting speed | 9,600 rpm |
| Working feed | 0.007 mm/rev |
Customer benefit
The solution co-created with the customer ensured the reliability of series production.
- Process reliability in serial production
- Blade life: 20’000 deburrs
- Significant savings due to elimination of rework and testing efforts
Aircraft Component
Customer application
Our customer previously created 30 back spotfacings by turning the part, re-clamping and machining them from the other side. This process took over six hours. The goal was to simplify the operation and to speed up the process
| Workpiece | Aircraft component |
| Material | Inconel 718 Cast |
| Parts per year | 50 workpieces (1’500 bores) |
Solution
The BSF tool allows reliable operation from one side, eliminating the need to re-clamp the housing. Process time decreased from 6 hours to 35 minutes per part.
Customer benefit
- Complete finishing of the part on the machine
- Machining from one side without the need to re-clamp the part
- Higher process reliability
- Time savings per part ~5.5 hrs
Camshaft
Customer application
Our customer produces about 12 million camshafts per year. The customer is looking for a solution to deburr the front and the back of the oil bore automatically. Previously, the camshafts were deburred manually. This was expensive and a reliable quality could not be achieved. High costs for quality control and reworking were the result.
| Oil bore | Ø2.5 mm |
| Deburr diameter max. | Ø3.2 mm |
| Material | Steel similar to St52 (approx. 700 N/mm2) |
Solution
The solution of HEULE is the simple and efficient SNAP tool. Without any need to turn the workpiece or to stop the spindle, it frees the bore edges from the burr and produces a chamfer.
| Tool | SNAP2/2.5 |
| Working length | 20 mm |
| Speed | 3000 U/min |
| Cutting speed | vc 30 m/min |
| Feed | 0.1 mm/U |
Customer benefit
Up to now, the camshafts have been deburred manually. With the automated deburring, the piece can be machined fully on the machine. On a multi-spindle machine, 5 SNAP2 tools are in use at the same time.
The decision to switch the process to machining with SNAP was based not only on the substantial reduction in personnel costs, but also on the process reliability of the tools and the high chamfer quality. This again resulted in reduced quality control work.
- Elimination of manual work
- Extensive reduction in personnel costs
- Increased process reliability
- Extremely high chamfer quality
- Reduced costs for quality control
- Blade life: 10’000 deburrings
Turbine Housing
Customer application
This turbine manufacturer was looking for a cost-efficient, yet reliable, solution for the application of back spotfacings as well as chamfering bores, all in one clamping without the need to turn the part.
| Workpiece | Aviation component |
| Material | Inconel |
| Parts per year | 450 parts |
Customer benefit
- Complete finishing of the part on the machine
- Machining from one side without the need to re-align and re-clamp the part
- Higher process reliability
- Blade life time | COFA: 300 bores, BSF: 50 counterbores
- Estimated time savings of 45 min per part / 335 hours per year
Bearing bushing
Customer application
This customer has to supply 400’000 bearing bushings per year. Four bores have to be machined into each bushing. The previous solution the customer used to deburr the bores was very slow, inconsistent and resulted in substantial manual rework.
| Workpiece | Bearing bushing |
| Bore diameter | 4 mm |
| Outer Tube Ø | 30 mm |
| Inner Tube Ø | 26 mm |
| Chamfer diam. burr free | max. 0.5 mm |
| Material | Steel / 1.0580 E 355 |
| Production volume | 1’600’000 bores per year |
| Machine | Long turning lathe |
| Processing | Radial processing from the bar |
| Coolant pressure | 30 bars |
Solution
The HEULE COFA deburring tool now used, increased cycle time by 20%, assures highest quality and process-reliability. No manual rework is required anymore.
| Tool | COFA4M/4.0/Z1-OM |
| Blade | GH-CM-0914-T nrs |
| Cutting speed | S = 1,200 rpm / v = 15 m/min |
| Working feed | f = 0.2 mm/rev (F = 240 mm/min) |
Customer benefit
The deburring process is reliable, so the manual reworking is no longer necessary. The cycle time could be optimised, resulting in a minimum 20% improvement. Long-tenured employees with extensive expertise are as much excited about the result as the production manager, who can now rely on a process-safe solution.
- Elimination of manual deburring and rework
- High quality and process-reliability
- Cycle time improved by 20%
- 235 machining hours saved per year
Brake disc
Customer application
The automotive industry requires a vast quantity of brake discs. Therefore, the production process must be 100% optimised. In this application, two distinct types of bores must be drilled and completed in the shortest possible of time.
| Workpiece | brake disc |
Bore number 1
| Bore | core bore for M8 thread |
| Chamfer | front and back: Ø8.5 mm x 90° |
| Material | cast |
Bore number 2
| Bore | Ø8.6 mm |
| Countersink forward | Ø17.2 mm x 90° |
| Chamfer backward | Ø0.5 mm x 45° |
| Material | cast |
Solution
Bore 1
Core bore is drilled in a single pass with a VEX drill combination tool and chamfered both front and back (Ø8.5 mm x 90°).
| Tool | VEX drill combination tool |
| Drilling working speed | 3,200 rpm. |
| Drilling working feed | 0.25 mm/rev. |
| Chamfering working speed | 1,900 rpm. |
| Chamfering working feed | 0.15 mm/rev. |
| Coolant | dry |
| Service life | > 30,000 bores |
Bore 2
In a single pass, this bore is drilled, then countersunk forward (Ø17.2 mm x 90°), and back chamfered (Ø0.5 mm x 45°). It is made with a special VEX drill and countersink combination tool.
| Tool | VEX drilling and chamfering combination tool |
| Drilling working speed | 2,600 rpm. |
| Drilling working feed | 0.26 mm/rev. |
| Drilling service life | > 30,000 bores |
| Chamfering forward working speed | 1,500 rpm. |
| Chamfering forward working feed | 0.15 mm/rev. |
| Chamfering forward service life | > 15,000 bores |
| Chamfering backwards working speed | 1,500 rpm. |
| Chamfering backwards working feed | 0.15 mm/rev. |
| Chamfering backwards service life | > 30,000 bores |
| Coolant | dry |
Customer benefit
The integration of multiple machining operations in a single tool, combined with proven process capability, ensures the best possible cost efficiency.
- Integration of multiple machining operations in a single tool
- Elimination of tool changes
- Best possible cost efficiency
- Highest process reliability
- Elimination of manual deburring
- Substantial time and cost savings
Fitting / Hydraulic T-Piece
Customer application
A Korean manufacturer of hydraulic components and bolt connections / fittings was looking for a safer and more efficient solution for deburring the crossbore of a ball valve. The aim was to automate the process. Until then, employees were laboriously removing the burrs from the bore edges by hand with a brush.
| Workpiece | Fitting / Hydraulic T-Piece |
| Cross bore | Ø10.4 mm |
| Main bore | Ø10.4 mm |
| Material | SS316 |
| Machine | DOOSAN CNC machine |
Solution
The deburring of crossbores with a 1:1 bore diameter ratio posed a unique challenge for HEULE. The tool solutions that were available so far could not cope with the extreme unevenness of a 1:1 bore. HEULE had to find a completely new approach to the solution. They found it by using both new machine capabilities and by developing a special version of the COFA tool (COFA-X). The combination led to success.
| Tool | COFA-X |
| Speed | 500 RPM |
| Working feed | 0.06 mm/rev |
| Coolant | external coolant |
Customer benefit
The possibility of automating the deburring process and the significantly increased process reliability have resulted in substantial cost savings for the customer. Similar T-Pieces are now being made as a result of the successful pilot project
Steering Knuckle
Customer application
To win a large project this customer was looking for a solution to machine steering knuckles in the most cost-effective way. Relatively large chamfers had to be machined to a number of bores, forward and backwards in a single pass without having to reclamp the workpiece and without manual deburring.
| Workpiece | Steering knuckle |
| Bore diameter | several |
| Counterbore diameter | several |
| Material | cast aluminium |
Solution
The DEFA chamfering tool is chosen for these chamfering applications due to the required chamfer size, dimensional accuracy and the interrupted cut.
| Tool | DEFA |
| Working speed | 1,000 rpm |
| Working feed | 0.06 mm/rev |
| Coolant | emulsion |
Customer benefit
The focus is on the cost-effectiveness of the solution. The cycle / production times without stopping the spindle, spindle direction change, interpolation and workpiece re-clamping was less time-consuming than alternative manufacturing processes.
- Chamfering front & back in One Operation
- No stopping of the spindle
- No spindle direction change
- No workpiece reclamping
- More cost-effective solution than alternative manufacturing processes
