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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.
Cost Reductions:
The following case histories are good examples of where component manufacturers were able to improve bore quality and dramatically reduce costs by switching from conventional honing to the singlepass process.
Case History #3: (Hydraulic Timing Component)
The bore geometry for this application was relatively open, however with the blind bore condition, combined with distortion from heat treat, economically finishing this part in production with a conventional honing process proved to be difficult and expensive. As an alternative the manufacturer switched part of their production over to using the singlepass process. The system that was designed included (6) singlepass tools with floating holders, pneumatic part clamping with regulated pressure to minimize distortion, automatic gaging, with robotic automation. The singlepass process produced 480 parts per hour with very little downtime and reduced the perishable tool costs to less than $0.01 per part. Because of these benefits the entire production was eventually switched over to the singlepass process |
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| Hydraulic timing components and single-pass tooling. |
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| Diameter: |
14.05mm |
Length/Clearance: |
35mm |
| Material: |
1215 |
Hardness: |
HR15N 89-92 |
| Bore Type: |
Blind |
Stock Removal: |
0.075mm |
| Tool Pass #1: |
14.010mm |
Diamond Size: |
40/50 |
| Tool Pass #2: |
14.026mm |
Diamond Size: |
40/50 |
| Tool Pass #3: |
14.036mm |
Diamond Size: |
40/50 |
| Tool Pass #4: |
14.041mm |
Diamond Size: |
40/50 |
| Tool Pass #5: |
14.046mm |
Diamond Size: |
40/50 |
| Tool Pass #6: |
14.051mm |
Diamond Size: |
40/50 |
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| Bore Quality |
Required |
Achieved |
| Size: |
±0.0076mm |
0.004mm |
| Taper: |
0.0076mm |
<.003mm |
| Surface Finish: |
1.5Ra |
0.7Ra |
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| Machine Type: |
Engis Model # 0010-16S (6 Spindle Machine) |
| Coolant: |
Engis SP2240 Honing Oil |
| Production: |
480 Parts Per Hour/>2Cpk |
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