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Off-Highway

Surface Finishing for Off-Highway Applications

Off-Highway Excavator

In the off-highway industry, equipment is often placed under severe loads in hostile environments. Heavy equipment demands high torque applications.  The stop-and-go conditions typical of its operation, grind on interacting metal components create shock loads on the power transmission components (gears, bearings, etc.). Furthermore, maintenance is often not performed as scheduled and break-in procedures are seldom followed, leading to premature wear that may result in catastrophic failures. These failures along with the high fuel and lubricant consumption combine to increase operating costs.

REM’s­ ISF®­ Process, an isotropic superfinishing process capable of polishing the surfaces of power transmission gears and other metal to metal contact components is able to improve the performance of off-highway equipment through its range of component benefits. The ISF Process helps keep industrial equipment running by reducing friction among intermeshed parts, increasing mean time between equipment overhaul by reducing contact fatigue and wear.  ISF®­ Surface generated by the ISF Process is proven to significantly improve load distribution in gear applications thereby increasing power density allowable and offering design upgrades through increases to input power or component downsizing.

The ISF Process is capable of processing extremely large components with weights in excess of 10,000 lbs./4,500 kgs, and is able to be a cost effective solution for high volume part applications. Lastly, the ISF Process is an effective repair technology for the removal of surface damage and surface deposits/contamination from operation.

With applications on a wide range of earth-moving, construction and agricultural equipment including backhoes, cement trucks, mining equipment, tractors, and bulldozers, REM’s ISF Process is the optimal surface finishing solution for any Off-Highway components suffering from premature failure, in need of extended service life, or that require a design upgrade.

Assorted Off-Highway Gears-Before and After ISF

Assorted Gears-Before and After ISF

Common Off-Highway Applications for the ISF Process:

  • Torque Converter Components
  • Transmission Gears and Assorted Components
  • Driveshaft Couplings and Universal Joints
  • Camshafts, Tappets, Valve Springs, Rocker Arms

Component Benefits for Off-Highway Applications:

  • Reduced Friction/Roughness
  • Increased Resistance to Micropitting
  • Increased Resistance to Scuffing
  • Increased Resistance to Contact and Bending Fatigue
  • Increased Part Durability/Reduced Wear
  • Reduced Lubricant/System Operating Temperatures
  • Reduced Vibration and Noise
  • Increased Power Density Allowable/Component Load Carrying Capacity
  • Reduced Lubrication Requirements and Cost (anti-wear additives, etc.)
  • Increased Lubricant Lambda Ratio
  • Increased Fuel Efficiency/Operating Efficiency
  • Increased Average Time Between Maintenance
  • Eliminated Break-in/Run-in Requirement
  • Reduced Metal Debris Generation
  • Reduced Warranty Maintenance Costs
  • Potential to Refurbish Used Gears

Production Benefits for Off-Highway Applications:

  • Potential to Eliminate Surface Coating Requirements
  • Potential to Reduce Grinding Surface Finish Requirements
  • Potential to Reduce or Optimize Deburring and Chamfering Operations

Common Off-Highway Alloys that REM can Assist with:

  • Standard Gear and Nitriding Steels (ex. SAE 8620, 9310, 4140, 4340, DIN 34CrNiMo6, Pryowear® 53, Nitralloys™)
  • Specialty Steels (ex. M50/M50 NIL, 440C, SAE 4122-MOD)
  • Bearing Steels (ex. AISI 52100/DIN 100Cr6)

Common Off-Highway Component Forming Methods the ISF Process can Improve:

  • Ground (Machined)
  • Milled
  • Turned
  • Forged
  • Hobbed

Interested in learning more, ready to start a project, or have an application that you don’t see listed here?  Contact us today to see how we can help solve your surface finishing/polishing needs.

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