SIMPLY. PRECISE. BORES ... according to this motto, a processing sequence was defined on a hydraulic control housing on a HELLER H6000, in which each step can be measured separately with an exchangeable air gauge arbor and, depending on the measurement result, an automatic diameter compensation (e.g. via the µ-matik interface) is carried out.

The in-process measuring system for a micron-precise diameter determination can be integrated into most CNC machine controls (SIEMENS, HEIDENHAIN, FANUC) via ProfiBus. As a result, process automation and unmanned production runs are now possible in high-precision bore machining in a machining center.

FDream - Reaming and honing combined

The superabrasive and bore-filling metal bond hones are perfoming the rough honing stage immediately after reaming (with inserts made by URMA) and, at the same time, the tool is guided in a rigid manner, thus ensuring the coaxial reaming process of the following bore sections. With this technique, line marks caused by the reaming blades during the back stroke are avoided, since the bore diameter after FDream processing is approx. 25µm larger than the reamed diameter.

With this combination machining, cylinder bore shape quality less than 2µm and roughness of approx. Rz=6µm can be achieved. In order to further reduce the roughness, one or two more FDhone operations can be carried out so that after the machining sequence a cylindrical bore shape of less than 1µm with Ra<0.2µm is achieved.


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In-process air gauging

In order to be able to use honing tools with in-process air gauging (similar to air gauge arbors) in a standard machining center, the air supply interface is fitted to the spindle nose (e.g. for DMG Mori, HELLER, MAG or GROB machines). This allows to produce bores with the tightest diameter tolerances. The honing process is controlled by a industry PC-System that communicates with the machine's PLC control. An automatic bore shape correction system ensures a perfect cylinder bore shapes without conicity.

More information on honing technology on machining centers.

The DIAHON #-honing cycle

The use of the DIAHON #-honing cycle on e.g. HELLER machining centers creates a constant honing pattern in a defined honing angle in the entire bore. The tribological properties of the surfaces, which can be achieved by using our #-honing cycle (e.g. for oil retention volumes in plateau surfaces or improved friction) as well as the slower accelerations in the stroke reversal points are significant improvements when honing on machining centers.

More information on honing technology on machining centers.

µ-matik® - automatic wear compenstation

The µ-matik® interface in FDhone and coolEXact honing tools allows a highly precise wear compensation by the machine spindle. The µ-matik® adjuster unit - installed in the machine's work area - is approached by the tool. The diameter of the tool is then adjusted by rotating the spindle (to the exact degree).

In combination with a measuring option in the machine, the run of unmanned shifts is possible and tool set-up times are minimized.

coolEX®float - honing with pendulum compensation

The coolEX®float honing tool technology enables classic hydraulically activated honing in a machining center or any turning / milling center with a compensation of radial offset and angular errors without any technical modifications to the machine and with the regular honing kinematics (expansion during machining). The classic honing kinematics creates the desired cross-hatch pattern in a defined honing angle.

More to this in the section: coolEX®float tool system.