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| Systems Approach |
Advancements
Manufacturers are continually pushing the envelope in regards to what can be accomplished with the singlepass process. Improved tool, fixture, and machine designs have allowed for increased production rates as well as improved bore precision. The following are some of the latest advancements that have been made.
Automation and Automatic Tool Adjustment:
Various automation, autogaging, and autotool size compensation systems have been developed for the singlepass process, each designed to further reduce labor costs. Case history #8 illustrates one particular application in which the component manufacturer desired to have each finishing cell completely automated so that one operator could oversee a couple of cells at a time. Included in each cell are one singlepass bore finishing system; one O.D. grinding machine; one O.D. crowning machine; one automatic gage; and one robotic automation package. The automatic gage is set up to inspect bore size; O.D. size; face runout to the bore; and O.D. to bore concentricity. Information from these measurements is used to automatically adjust the grinding and bore finishing sizes when necessary. To automatically adjust the singlepass, bore finishing tooling, the robot first automatically changes its end of arm tooling and then proceeds to turn the front adjusting nut on each individual tool as needed. The robot then changes the end of arm tooling back to the grippers, loads a new part, and continues on with the automatic cycle.
Other forms of automatically adjusting the singlepass tooling include using a draw bar through each spindle to move the tapered mandrel in relationship to the sleeve.
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| Case History #8: (Diesel Roller) |
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| Diameter: |
20.048mm |
Length: |
165mm |
| Material: |
Silicon Nitride |
Hardness: |
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| Bore Type: |
Thru |
Stock Removal: |
0.85mm |
| Tool Pass #1: |
19.452mm |
Diamond Size: |
40/45 |
| Tool Pass #2: |
19.702mm |
Diamond Size: |
40/45 |
| Tool Pass #3: |
19.952mm |
Diamond Size: |
40/45 |
| Tool Pass #4: |
20.027mm |
Diamond Size: |
60/80 |
| Tool Pass #5: |
20.041mm |
Diamond Size: |
200/230 |
| Tool Pass #6: |
20.048mm |
Diamond Size: |
320/400 |
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| Bore Quality |
Required |
Achieved |
| Size: |
.005mm |
0.003mm |
| Roundness: |
.005mm |
.003mm |
| Surface Finish: |
0.2Ra |
0.1Ra |
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| Machine Type: |
Engis Model # 0318-1UM6 (6 Spindle Machine) |
| Coolant: |
Water Based |
| Production: |
80 Parts Per Hour |
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