Striving For Perfection With Elliott Burnishing Tools
In the fast-paced landscape of modern precision manufacturing, especially deep hole drilling, Mollart Engineering is always striving to find machining solutions and tools that will increase production efficiency, while reducing costs—without sacrificing the precision our customers demand. When it comes to finishing processes, we have found that burnishing is one of the most modern, cost-effective finishing methods available, providing outstanding quality and unrivalled efficiency.
Burnishing For Outstanding Performance
Here at Mollart Engineering we provide a range of burnishing products and services, and as a partner of Elliott Tool Technologies we are confident in the ability of Elliot burnishing tools to outperform traditional finishing methods like, grinding and honing, which have been the industry standard for many years. These outdated methods often involve extra operations, resulting in longer cycle times, lower productivity and inferior quality to burnished products.
What is it about burnishing that makes it superior to more traditional finishing methods?
1. Burnishing Decreases Costs and Increases Productivity
Burnishing tools such as the Elliott Roller Burnishing tools can be integrated directly into existing CNC machines or lathes, eliminating secondary operations entirely and the need for extra machinery. The time saved in this one step process can significantly increase productivity, reduce costs and save on workshop space.
Roller Burnishing and One-Pass Finishing
Traditional finishing is often a multi-step process. A part is machined on a lathe, creating a surface profile of microscopic "peaks and valleys." To smooth these out, the part is typically moved to a secondary station for grinding or polishing—a process that removes material and consumes valuable floor space and labour. By using a specialised roll, a burnishing tool compresses the material’s peaks into its valleys, creating a smooth, hardened surface in just one pass. This single-step process reduces the need for multiple machines and skilled operators, translating to significant savings.
Other cost saving benefits of burnishing include:
- Lower Capital Investment: By doing the finishing ‘in-machine’, you avoid the high cost of dedicated grinding equipment or the logistical nightmare of outsourcing.
- Extended Tool Life: Burnishing tools boast a much longer tool life compared to abrasive methods, which are designed to wear down as they work. This longevity reduces the frequency of tool replacement and the associated costs. The consistency and repeatability of the burnishing process also lead to fewer scrapped parts, as there is less room for error.
- Few Scrapped Parts: Increased repeatability leads to fewer scrapped parts and lower tooling costs over the long haul.
2. Elliott Burnishing Tools Offer Improved Quality
Beyond cost and time, Elliott burnishing tools deliver a level of part quality that traditional cutting methods simply can’t match.
Work-Hardening for Longevity - The process of compressing the material not only creates a smooth finish but also densifies and work-hardens the surface. This process can achieve single-digit finishes, as low as Ra 4µin (micro inches), directly from the machine. The work-hardened surface significantly improves wear resistance, extending the overall life of the part. This is particularly valuable for components subjected to high friction or stress.
Improved Surface Integrity - the lack of microscopic cracks leads to better corrosive resistance in comparison to abrasive methods.
Burnishing is the Game-Changer
In conclusion, burnishing is a game-changer in modern machining. By compressing material rather than removing it, it offers a powerful solution that reduces costs, saves time, and elevates the quality of the finished product. Its ability to integrate into existing workflows makes it an accessible and valuable technology for machine shops looking to optimize their processes and gain a competitive edge.
We have a variety of Elliott Burnishing tools at Mollart Engineering we also provide bespoke subcontract services to our customers. Below are a few examples of the tools we supply, or you can find out more here https://mollart.com/tooling/carbide-roll-burnishing-tools
ID/OD Carbide Roll Burnishing Tool
The Boring Bar Style Internal diameter and Outer Diameter (ID/OD) Tool is used on turning machines to burnish internal and eternal surfaces, creating extremely fine finishes on most ferrous and non-ferrous materials.
Available in standard lenghts of 12" and 18"
ID Multi-Roller Burnishing Tool
The tool consists of a cage, which retains a series of precision tapered rolls rotating around and bearing on an inversely tapered mandrel.
Within the work-piece, the tool is sized so that the roll develops a pressure that exceeds the yield point of the softer work-piece.
The cold working action will improve minor surface irregularities and tool marks resulting in a low microinch surface finish.
Get in Touch
If you would like to know more about implementing burnishing into your finishing process then please get in touch, we have experts on hand to offer advice. Email sales@mollart.co.uk or more details can be found on our contact page https://mollart.com/contact-mollart-chessington