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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 finishing of transmission gears has traditionally been performed with I.D. grinding or conventional honing processes. More and more manufacturers are now switching over to the singlepass process for this operation and realizing costs savings as much as 50%. In the following application perishable tool cost is less than $0.01 per part with the singlepass process verses over $0.02 per part with conventional honing. Additional savings are also achieved by having a greater up time due to less frequent tool changes.
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| Gears being finished with single-pass process. |
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| Diameter: |
20.013mm |
Length/Clearance: |
15mm |
| Material: |
SCM420H |
Hardness: |
HRC 58-64 |
| Bore Type: |
Thru |
Stock Removal: |
0.050mm |
| Tool Pass #1: |
19.998mm |
Diamond Size: |
20/30 |
| Tool Pass #2: |
20.008mm |
Diamond Size: |
20/30 |
| Tool Pass #3: |
20.013mm |
Diamond Size: |
20/30 |
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| Bore Quality |
Required |
Achieved |
| Size: |
±0.009mm |
0.007mm |
| Taper: |
0.008mm |
<.004mm |
| Surface Finish: |
0.8Ra |
0.4/0.6Ra |
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| Machine Type: |
Engis Model # 0318-16 (6 Spindle Machine) |
| Coolant: |
Water Based |
| Production: |
480 Parts Per Hour/>2Cpk |
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