Advancements in Single-Pass Bore Finishing - Systems Approach (pag. 4 of 10)

Advancements Manufacturers are continually pushing the envelope in regards to what can be accomplished with the singlepass Processo. 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 Levigatura to the singlepass Processo.

Hydraulic timing components and single-pass tooling

The bore geometry for this Applicazioni was relatively open, however with the blind bore condition, combined with distortion from heat treat, economically finishing this part in production with a conventional Levigatura Processo proved to be difficult and expensive. As an alternative the manufacturer switched part of their production over to using the singlepass Processo. 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 Processo 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 Processo.

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

Bore Quality	Required	Achieved
Size:	±0.0076mm	0.004mm
Taper:	0.0076mm	<.003mm
Surface Finish:	1.5Ra	0.7Ra

Machine Type:	Engis Model # 0010-16S (6 Spindle Machine)
Coolant:	Engis SP2240 Levigatura Oil
Production:	480 Parts Per Hour/>2Cpk