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| Advancements
in Single-Pass Bore Finishing (continued) |
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| Benefits/Capabilities |
The singlepass process can be
tailored to meet the requirements of various applications, and as such,
obtain different results. For example, some applications may require
very critical bore geometry and allow longer cycle times; while others
may have less critical geometry, but require a higher throughput at the
lowest possible cost per piece.
Higher
bore precision:
The key to the singlepass process is to allow the diamond tooling to
follow the existing centerline of the bore to be finished with as
little pressure as possible. This is normally done by allowing the
tool, part, or both to float. Depending on many other variables, bore
geometry to better than 0.2µm (.000008”) is
possible. Since all of the diamond tools are set to specific sizes and
do not require expansion during each cycle, the singlepass process is
able to achieve unsurpassed size control in production (1µm
with near perfect repeatability). These results are very predictable
and repeatable, thus lend perfectly to Statistical Process Control.
Lower
cost:
The diamond portion of the tooling wears very slowly in production
which allows for tool life to exceed 100,000 parts in many
applications. With an average of four singlepass tools used in a set
up, the perishable tool cost is usually under $0.01 per finished part.
The long life of the tooling also contributes to very little down time
due to tool change. Cycle times vary depending upon the particular
application, but in general most systems can produce from 120 to 600
pieces per hour. The simple nature of the process eliminates the need
for highly skilled operators. In fact, with proper automation one
operator could actually oversee multiple systems finishing thousands of
parts per hour. |
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| Multiple
single-pass machines integrated together |
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