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HCCI Engines Offer a Promising Jump in ICE Technology

702 Big Block Chevy Boat Engine

ProCharged 7.3L Ford Godzilla Engine

Moroso Ultra 40 Sleeved Ignition Wire Sets with 135 Degree Spark Plug Boots for GM LS

Sin City Diesel's Compound Turbo 6.7L Cummins Engine

Popular Posts HCCI Engines Offer a Promising Jump in ICE Technology 702 Big Block Chevy Boat Engine ProCharged 7.3L Ford Godzilla Engine Moroso Ultra 40 Sleeved Ignition Wire Sets with 135 Degree Spark Plug Boots for GM LS Sin City Diesel's Compound Turbo 6.7L Cummins Engine Connect with us advertise with us

HCCI Engines Offer a Promising Jump in ICE Technology

702 Big Block Chevy Boat Engine

ProCharged 7.3L Ford Godzilla Engine

Moroso Ultra 40 Sleeved Ignition Wire Sets with 135 Degree Spark Plug Boots for GM LS

Sin City Diesel's Compound Turbo 6.7L Cummins Engine

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Add Your Listing Edit Your Listing By Category Engine Components A/N Fittings/AdaptorsAir Induction SystemsBatteriesBearings (camshaft)Bearings (engine sleeve type)Bearings (main rear main)Bearings (Rod)Belt Tensioner/IdlersBrass FittingsBushingsCam CapsCamshaft Belt DrivesCamshaft KitsCamshaft SealsCamshaft Thrust Plate and PartsCamshaftsCarburetorsChain KitsClampsComplete EnginesConnecting RodsConnecting Rods Nuts BoltsCrankshaft ConversionsCrankshaft KitsCrankshaft Oil SlingersCrankshaft Pulley SleevesCrankshaft Repair SleevesCrankshaft SealsCrankshaftsCylinder Head ComponentsCylinder Heads New: Aluminum BareCylinder Heads New: Aluminum CompleteCylinder Heads New: Cast Iron BareCylinder Heads New: Cast Iron CompleteCylinder Heads Reman: Aluminum BareCylinder Heads Reman: Aluminum CompleteCylinder Heads Reman: Cast Iron BareCylinder Heads Reman: Cast Iron CompleteCylinder Liners (sleeves)Diesel InjectorsDipstick Adapters (Chevy Ford)Dowel PinsEFI ComponentsEngine BlocksEngine Blocks - RemanufacturedEngine KitsEngine Management Systems/ECUsEngine MountsExhaust ComponentsExhaust Components: Complete SystemsExhaust Components: Custom ExhaustsExhaust Components: Leak DetectionExhaust Components: ManifoldsExhaust Components: Tube NotchingExhaust Components: Tube SwagingExhaust Components: Tube/Frame Bending MachinesFilters - AirFilters - FuelFilters - OilFlywheel (ring) GearsFlywheel AssembliesFuel Injection - ElectronicFuel Injection - MechanicalFuel PumpsFuel System ComponentsGasket CementGasketsGear DrivesGovernorsHarmonic Balancer Repair SleevesHarmonic Balancers/DampersHead Bolts/StudsHex ShaftsHydraulic Lash AdjustersIgnition ComponentsInjector TubesInjectors - DieselInjectors - Gasoline DirectInjectors - IndirectIntake ManifoldsIPR ValvesKeysLockwashersMain Caps (4-bolt)Manifold StudsNitrous Oxide Systems, ComponentsNitrous Valves and PlatesNuts and BoltsOil CoolersOil Filter AdaptersOil PansOil Pressure SpringsOil Pump KitsOil Pump ScreensOil Pump ShaftsOil Pump Timing CoversOil PumpsOiling Systems; Dry SumpOverhead Camshaft Repair SleevesPiston Pin BushingsPiston Pin Lock RingsPiston PinsPiston RingsPistonsPlugs - ExpansionPlugs - MagneticPlugs - Oil DrainPlugs - StandardPush RodsRadiator/Oil FansRering KitsRestoration Engine PartsRocker Arm Rebuilding ComponentsRocker Assemblies and KitsRocker Stud GirdlesSealsSerpentine BeltsShimsShort BlocksSpark PlugsSpringsSuperchargers, componentsSwitchesTappetsThread RepairThrust WashersTiming Belt/Chain TensionerTiming Belts/ChainsTiming Chains, Gears, SprocketsTiming ComponentsTiming CoversTransmission AdaptorsTurbochargers, componentsValve CoversValve Guide LinersValve GuidesValve KeysValve Lifter BallsValve LiftersValve Locks and SealsValve Seat InsertsValve Spring InsertsValve Spring RetainersValve SpringsValve Stem Oil SealsValve Train PartsValvesWater PumpsWater Tubes Engine Equipment & Preparation Adhesive DispensingAir Flow BenchesAir Handling SystemsBalance Shaft Elimination KitBalance Shaft Line Boring EquipmentBalancing AccessoriesBalancing EquipmentBelt SanderBench GrinderBlock Pressure Testing EquipmentBoring Bar InsertsBoring Bar Tool BitsBoring Machines/Connecting RodBoring Machines/CylinderBoring Machines/LineBoring Stand (For Portable Boring Machines)Brass FittingsBroachBushing Bearing & Seal Driver SetsCAD/CAM SoftwareCam Bearing Installation ToolCamshaft Degree Wheel (Digital)Camshaft GrindersCap & Rod GrinderCBN Inserts - NewCBN Inserts - ResurfacedCleaning Specialized EngineCNC Machining CentersCNC Retrofit KitsCompressed Air EquipmentConnecting Rod GaugesCoolant Filter MachinesCore Shift TesterCrack Repair EquipmentCranesCrankshaft Balance WeightsCrankshaft FurnaceCrankshaft GrindersCrankshaft Journal Weld KitsCrankshaft PolisherCrankshaft Polishing BeltsCrankshaft StraightenerCylinder Head Adapter PlatesCylinder Head Assembly/Disassembly Equip.Cylinder Head Chamfering ToolCylinder Head GaugeCylinder Head HoldersCylinder Head PolishingCylinder Head PortingCylinder Head Pressure TesterCylinder Head StraighteningCylinder Hone StopsCylinder Porting ToolsCylinder Sleeve PressDemagnetizersDiamond DressersDiesel Injector Hole Repair ToolsDiesel Injector Sleeve Installation ToolDowel PullersDye Penetrant InspectionDynamometersEngine Adaptor PlatesEngine Cycle AnalyzerExhaust Leak DetectionFeeler GaugesFlexible Honing Tools/Brush HonesFlywheel GrinderFuel Injection Cleaning ServicesGrinder Head StraighteningGrinding CoolantsGrinding WheelsHardness TestersHead/Block Crack Repair KitsHead/Block Resurfacing (Belt/Sanders)Head/Block Resurfacing (Milling)Heat Tabs Temperature SticksHolding FixturesHone Stop FixtureHoning JigsHoning Machines Wrist PinHoning Machines/CylinderHoning Machines/LineHoning Machines/RodHoning Machines/Valve GuideHoning PlatesHoning StonesIgnition System TestersIn-Process Gauges(Cam and Crank Grinders)Inspection GaugesLeak Down TesterLeveling DeviceMagnetic Particle Inspection Crack DetectionMicropolishing EquipmentOHC Line Boring ToolsOil Leak DetectionPCD Inserts - NewPin Fitting & Rod Reconditioning/TestingPin PressPin RemovalPiston KnurlerPiston Ring CompressorsPre-Cup Machining ToolsPush Rod Guide PlatesReplacement Chuck for Valve FacersRocker Arm GrinderRod AlignmentRod Bolt ProtectorsRod FurnaceRod VisesRun-In StandsStandsStud PullersTapsTest EquipmentThickness GaugeThread GaugesThread Repair & Replacement KitTorque PlatesUltrasonic Test EquipmentVacuum TesterValve Grinding BenchValve Guide & Seat Driver SetValve Guide & Seat MachineValve Guide Boring FixtureValve Guide HoneValve Guide KnurlingValve Guide PilotValve Guide ReamerValve Guide ToolValve Refacer (Cutter)Valve Refacer (Grinder)Valve Refacer WheelsValve Seat CuttersValve Seat InserterValve Seat PullersValve Seat ResurfacerValve Seat Runout GaugeValve Seat Tool GrinderValve Seat WheelsValve Spring CompressorValve Spring TestersValve Stem GrinderValve Stem Height MeasuringValve Stem PolisherWater Tube PullerWet Flow Bench Conversions Supplies & Service Chemicals & SolventsCore Cleaning & ProcessingCranes & HoistsHand ToolsLubricantsPressesServicesShippingStorage Racks & BenchesWelding

Whether you’re a professional engine builder, machinist or manufacturer, or an automotive enthusiast who likes engines, racing and fast vehicles, Engine Builder offers content aimed at you. Our print magazine offers in-depth tech features on everything you need to know about engine building and its different markets, while our newsletter options keep you up-to-date on the latest news and products, tech info and personalities in the industry. But, you only get all of that if you subscribe. Subscribe now to receive Engine Builder magazine in print and/or digital each month, and our Engine Builder newsletter, Engine of the Week newsletter or Diesel of the Week newsletter directly in your inbox each week. You’ll be covered in horsepower in no time!

Whether you’re a professional engine builder, machinist or manufacturer, or an automotive enthusiast who likes engines, racing and fast vehicles, Engine Builder offers content aimed at you. Our print magazine offers in-depth tech features on everything you need to know about engine building and its different markets, while our newsletter options keep you up-to-date on the latest news and products, tech info and personalities in the industry. But, you only get all of that if you subscribe. Subscribe now to receive Engine Builder magazine in print and/or digital each month, and our Engine Builder newsletter, Engine of the Week newsletter or Diesel of the Week newsletter directly in your inbox each week. You’ll be covered in horsepower in no time!

ByBrush Research Management on Aug 18, 2021

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Machine shops are increasingly turning to abrasive finishing tools that can be easily integrated into CNC machine carousels or tool holding systems.

With new advances in abrasive technology, machining center operators are able to complete surface finishing simultaneously with other machining operations in order to speed cycle times, improve quality and save on off-line finishing time and costs. As a result, machine shops are increasingly turning to abrasive finishing tools that can be easily integrated into CNC machine carousels or tool holding systems.

However, in doing so, questions inevitably arise about the use of abrasive materials in expensive CNC machining centers. The concern is often a generalized impression that abrasives – like sandpaper – release large amounts of grit and debris that could clog coolant lines or damage exposed slides or bearings.

“These are very expensive, very accurate machines,” says Janos Garaczi, president of Delta Machine Company, LLC, a machine shop specializing in complex, tight tolerance parts made of titanium, nickel alloys, stainless steel, aluminum, plastics and other exotic alloys. “I wouldn’t do anything to jeopardize the accuracy or lifespan of the equipment.”

Fortunately, a closer examination of abrasive tools demonstrates that these concerns are largely unfounded. Although abrasives are often all lumped into the same category, a distinction must be made between abrasives used for aggressive material removal and abrasive finishing tools. Finishing tools release little to no abrasive grit during use, and the amount generated is comparable to the metal chips, grinding dust and tool abrasion created during the machining process itself.  

Even if minimal fine solids are produced, the filtration requirements for abrasive tools are not much different than for machining. Any particulate can be easily removed using inexpensive bag or cartridge filtration systems, according to Jeff Brooks of Filtra Systems, a company specializing in industrial filtration systems including for CNC coolant.

“A disposable media vacuum filter or pressure filter is the most cost-effective option for the end user for filtration that will achieve the high clarity levels required,” says Brooks.    

“For fine honing work, I would recommend a 20-micron bag or cartridge filter at minimum to catch any fine solids and adequately protect the tool, the sump pump and keep the coolant ports from clogging,” says Chris Erato, director of sales at Oberlin Filter, another leading manufacturer of separation filtration for CNC coolant systems.

For CNC operators interested in a fully automated pressure filtration system, there are units that eliminate the need to remove bags or clean magnetic separators that maximize production uptime.  

According to Tim Urano, Quality Manager at Wolfram Manufacturing, any additional cost for filtration related to the use of abrasive tools is so negligible it is “not really a consideration because filtration systems are already required to remove particulate from the coolant generated during the machining process itself.”

At his shop, that includes scale, grit and rust created by cutting through raw stock. Wolfram Manufacturing is also machining more 3D parts made of Inconel, which can release fine metal powder into the coolant that isn’t fully sintered.

As for abrasive tools, Urano says Wolfram Manufacturing has “never ever experienced any problems caused by abrasives in our cutting fluids.” 

For the past eight years, the machine shop has incorporated the Flex-Hone in all CNC machines for cross-hole deburring and surface finishing. The Flex-Hone is from Los Angeles-based Brush Research Manufacturing (BRM). Characterized by the small, abrasive globules that are permanently mounted to flexible filaments, the product is a flexible, low cost tool utilized for sophisticated surfacing, deburring and edge-blending.  

Removal of burrs and sharp edges in cross-drilled holes and other difficult-to-access areas such as undercuts, grooves, slots, or internal holes is critical. Failing to remove burrs can cause blockages or create turbulence in the flow of fluids, lubricants and gases through critical passages.

“On a given part, we might deploy two to three different size Flex-Hones, depending on the number of cross port intersections and different hole sizes,” explains Urano.

The Flex-Hones are added to the tool carousel and are used daily, usually several times an hour, on some of the shop’s highest volume parts.  

“The volume of abrasives that could even possibly come off of the Flex-Hone is insignificant compared to the rest of the particulate that gets into the coolant,” says Urano. 

At Delta Machine in Gardena, CA, automated cross-hole deburring is also integrated into the CNC machining process.

“When you use the Flex-Hone for deburring, all you are doing is removing the burr,” says Garaczi. “It doesn’t create much dust, so for me, any grit or dust released is zero concern. It is not like we are grinding inside the machine with powder everywhere – this is not the same at all.”

For Eric Sun, founder of Orange Vise Company in Orange County, CA, even cutting tools such as carbide drills and end mills can create debris that must be filtered from the coolant.

“Some machine shops might say, ‘I don’t use any abrasives in my process, therefore, my machine is completely free of all particulate matter,’ but that is not the case,” Sun says. “Even cutting tools can wear down and the carbide can come loose and get into the coolant.” 

Although Orange Vise is a contract manufacturer, the company primarily machines vises and quick-change fixturing components used in CNC machines out of aluminum, steel and cast iron. The company utilizes four Mori Seiki NHX4000 high-speed horizontal machining centers and two vertical machining centers.  

According to Sun, many of the vises are made of cast iron with selectively hardened surfaces. To match the surface finish of the hardened surfaces, Orange Vise uses NamPower abrasive disc brushes from Brush Research.  

Composed of flexible abrasive nylon filaments bonded to a fiber reinforced thermoplastic base, the NamPower abrasive disc brushes contain a unique combination of both ceramic and silicon carbide abrasive. The abrasive filaments work like flexible files, conforming to part contours, wiping and filing across part edges and surfaces to deliver maximum burr removal rates along with an ideal surface finish. Other common uses are edge blending, part cleaning and rust removal.  

The abrasive filaments work like flexible files, conforming to part contours, wiping and filing across part edges and surfaces to deliver maximum burr removal rates along with an ideal surface finish. Other common uses are edge blending, part cleaning and rust removal.  

To complete the surface finishing operation, abrasive nylon brushes are installed in the tool loading system of each CNC machine. Although abrasive grit is involved, Sun says the NamPower brush is a “different type of abrasive” because it is essentially “self-sharpening.” Because of its linear construction, sharp new grains constantly come in contact with the work surface and wear off exposing fresh cutting particles.  

“We have used the NamPower abrasive nylon brushes daily for six years,” Sun says. “During that time, we have had no issues with any sort of particulate or grit getting into any critical surfaces. In our experience, any small amount of grit created is a non-issue.”

If you’ve been concerned about dust and grit messing up your CNC machines, remember, these particulates can be easily removed using inexpensive solutions. EB

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