Technology

We can provide all the assistance and all the knowledge you do need for the followings:

  • Production of Hard Chrome Plating plants for Bars and Tubes
  • Production of Skiving and Roller Burnishing or honed Tubes
  • Production of Grinded and Polished Round Bars
  • Any other machine equipment and tooling related to the Hydraulic Component production

IESHP can provide a ‘turn key plant’ for producing Hard Chrome Plated Bars and Tubes or a tailor made solution for Nickel-Chrome piston rods or any other component. We can also develop tailor made solutions for the automotive industry for plating any kind of components from plastic to steel parts any other alloy or micro-alloy steel.

We can supply: Peeling and Reeling machines, Grinding Machines, Induction Hardening Machines, Continuous Chrome Plating Lines, Polishing Machines, Packaging and Cutting Machines. Furthermore for processing the Cold Drawn Tubes inside as Skiving and Roller Burnishing or Honing we can supply the complete machine including the tooling.

IESHP can offer all what you need to produce in-house the two main components for producing Hydraulic or Pneumatic Cylinders.

Improve your efficiency and reduce your costs

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Peeling and Reeling machines

Centerless Grinders are designed and manufactured in Romania from the ground up to provide optimum quality, efficiency, and reliability. The heavily ribbed mechanize castings are combined with the standard outboard supports for both the grinding and regulating wheel spindles to insure maximum rigidity and stability.

Add to that, the hydrostatic type spindles, the automatic lube system, and a wide variety of available grinding accessories, and you have one very versatile, reliable, and efficient center less grinder.

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Continuous Chrome Plating line

COMPARISON BETWEEN CONTINUOUS AND CONVENTIONAL PROCESS

Here follow the main differences between Traditional Plating and the new technology of Continuous Plating Line.

The conventional horizontal Rack Plating or the vertical Dip Plating, which are the most common plating technologies adopted in the Hard Chrome Plating field around the world, can be described as a step-by-step batch treatment requiring considerable human intervention. In the conventional plating methods, the chromium plating operation takes place on stationary bars; the dipping rack carrying the bars deep into the bath, horizontally or vertically, for a period of time.
The bars are mechanically and electrically fixed to the rack which is connected to the cathode. The anodes are placed on the long side of the tank, there is no way to create an electric field concentric to the bars and this leads to thickness variations in the chromium overlay. In Conventional Plating, especially when the chromium-plated bars are pulled out from the tanks, a big deal of harmful fumes escapes into the working rooms. Labor as well as the risks from human exposition to hazardous substances are the most relevant problems related to this technology, not mentioning the problems related to Current Distribution and consequently uneven thickness on the work piece.

disegno-1Continuous Chrome Plating line:

The Continuous Plating process is an innovative but well tested method for the production of high quality chrome plated bars and tubes for pistons rod and linear shaft. In the continuous chrome plating process, the grinded bars to be plated run longitudinally through a plating device one after the other continuously.

The Continuous Chrome Plating is an evolution of the traditional galvanic Chromium Plating in terms of management, productivity and efficiency. The grinded bars, depending on size, are moving at different speeds according to the chrome layer we desire to achieve.

The continuous chrome plating process is able to put a multiple-chrome-layer, depending on the number of chrome tanks in line, with the result of increasing the corrosion resistance.

The Continuous chromium plating process is done with many circular anodes, and the bar advances through the anodes, so that a completely homogeneous chrome layer is guaranteed.

NO environment pollution

In the Continuos Chromium Plating Lines the baths are closed the vapors are continuously collected and treated with both dry and wet scrubbers. There’s NO pollution on the environment or is practically reduced to zero. There is no risk of leaks of Chromic Acid, all tanks are made in Titanium

NO solid wastes

There’re only some solid wastes resulting from the process. The mud generated from the treatment of the waters is very small and easy to collect and dispose one a year.

LESS chromium solution volume

Our Continuous Plating Lines requires a low chromium solution volume (approx. one tenth of the conventional bath plating system) we’ve installed an automatic refilling of the Chroming Solution for each thank to ensure that the chemical content is controlled and in the right percentage of Chrome to ensure a constant plating performance both in terms of quality of the product and constant efficiency of the line.

PERFECT chrome layer

Our continuous chroming line is able to achieve a constant multi-layer chrome over the full length of the bar, automatic monitoring of the characteristics of the chromium bath guarantees the chromium layer is completely homogeneous. "Multi-Layer Chrome Plating Technology", through higher number of chrome layers, grants a guarantee that overlapping substrates create a perfect barrier between the base steel and the external agents. Another advantage is given by the perfectly circular anodes (used in the Continuous Chroming process). Due to this circularity a completely homogeneous and concentric chrome overlay is guaranteed all around, eliminating the need for additional grinding steps.

SAVING ENERGY Less power installed

Our Continuous chroming line require less power installed compared to the traditional Chroming plants process, this technology helps to save energy. Our technology demands about 30% less electrical power than conventional plating.

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Skiving & Roller Burnishing Machines

Machines engineered specifically to perform skiving and roller burnishing operations deliver precise roundness tolerances and quality surface finishes. (Article From: Modern Machine Shop, Derek Korn, Senior Editor)

The machines are designed to use combination skiving/roller burnishing tools to produce geometrically round holes with quality surface finishes for hydraulic cylinders.

Roller burnishing creates a mirror-like surface finish as smooth as Ra 0.05 micron.

For a hydraulic cylinder to operate effectively, the cylinder’s ID must be precisely round and have a mirror-like surface finish to ensure a tight seal between it and the mating internal piston. This is commonly achieved through skiving and subsequent roller burnishing inside a tubular workpiece. Skiving uses a set of three carbide blades positioned around the diameter of a tool to slice away chips and create a geometrically round bore.

Roller burnishing, a cold-working process, uses multiple rollers to compress the peaks of material left behind after skiving to generate an extremely smooth surface finish. Burnishing also introduces a residual stress layer into the cylinder wall, which improves cylinder fatigue life.

These operations are sometimes performed in one pass using a combination skiving/roller burnishing tool on a BTA-style deep-hole drilling machine. However we can supply a machines, tools and automation for deep hole-making applications, has recently designed machines engineered specifically to perform skiving and roller burnishing operations, noting increasing demand in the hydraulics market for such equipment. We’re using a single tool for both operations, achieving roundness tolerances of IT-8 and bore surface finishes as smooth as Ra 0.05 to 0.15 micron in one setup and one tool pass.

  • Work-holding

    The tubes used for hydraulic cylinders are generally Cold Drawn welded (DOM) or Seamless. Care must be taken to secure the tube rigidly enough for the skiving and roller burnishing processes, but not so tightly as to deform it. Therefore, clamping cones are typically used to hold the tubes on both ends instead of three-jaw chucks. This clamping method also facilitates quick workpiece changeovers in automated environments. In addition, extra support must be provided along the length of the tube due to the inherently high length-to-diameter ratio of these workpieces.

  • Power Train

    Thin cuts are taken during skiving. A skiving blade’s radial engagement with the workpiece might be just 3 mm and feeds might be 1 mm per revolution, per blade. However, each tool has two or three skiving blades, which multiples the effective feed rate. Similarly, the cold-working roller burnishing process requires a lot of torque and high spindle speed as it plasticizes and compresses the peaks that skiving leaves behind. As a result a more robust power train with higher horsepower motors and faster spindle speeds than conventional BTA drilling machines.

  • Rotary Union

    A hydraulic circuit inside the skiving and roller burnishing tool expands the skiving blades and burnishing rollers during cutting operations. Therefore, the machine has a rotary union at one end of the tool headstock to provide a hydraulic connection throughout the length of the rotating tool. Once the cutting pass is completed, the blades and rollers are retracted into the tool as it is removed from the tube. The tool continues to rotate as it is removed, but nylon guides on the tool and continuous coolant delivery prevent damage to the cylinder wall. The machines are available in skiving/burnishing diameters ranging from 40,00 to 250 mm inside and lengths up to 12 m (larger machines are available upon request).

We can provide along with the machine all the Skiving & Roller Burnishing Tools enable to produce the most popular sizes of Hydraulic Cylinder Tubes SRB in Tolerance ISO-H8 with ID Roughness Ra=0,12my max.

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Other Machine equipment

To produce inside your plant the right chroming solution instead of buying from the well known multinational companies in the market this mixer all made in Titanium is the right choice that will save you a lot of money.

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