coolEX LM combines DIAHON coolEX honing technology with hydraulic tool expansion and pneumatic diameter measurement using DPMS 3.0. This allows the honing process to be controlled directly on the machining centre based on the actual measured bore diameter.
The system is designed for very tight finished tolerances. Within the coolEX family, coolEX LM provides dimensional control < 3 µm, allows larger machining allowances and can handle processes with greater variation in pre-machining stock.
The honing stones are expanded by coolant pressure supplied through the spindle internal coolant system. Machining uses classic honing kinematics with rotation and axial reciprocation and produces a true cross-hatch surface.
With coolEX LM, the tool function is combined with pneumatic diameter measurement. The measurement signal is made available to the process for finished-size control.
DPMS 3.0 can provide pre- and post-process measurement as well as in-process measurement. This enables micrometre-level monitoring of the bore diameter during the machining sequence and allows the honing process to react to the actual workpiece condition.
Cylindricity deviations can also be corrected by selectively adapting the stroke position of the coolEX LM tool. The measurement can additionally support 100% quality inspection, documentation and monitoring of defined minimum material removal.
For coolEX LM, the machining centre is upgraded with DPMS measurement technology and a machine-specific measuring-air transfer. Coolant is routed through the spindle for hydraulic tool expansion, while the measuring air must also be transferred reliably to the measuring nozzle in the tool.
Depending on the machine, the air transfer can be implemented at the spindle nose, at the tool holder or by means of a rotary distributor on the tool. For HELLER applications with HSK-A63, a combined air/torque support can be used, for example. The supplied images show different engineering solutions from realised machine integrations.
coolEX LM is particularly useful when a bore has to be finished directly on the machining centre to a very tight size and the allowance from pre-machining is not sufficiently consistent. The technology is intended for precision bores where diameter, form and process reliability have to be controlled as one system.
A machine upgrade with DPMS 3.0 is required, together with a suitable design of the tool, measuring-air transfer, coolant supply and CNC process.
| System | Main focus | Dimensional control / process |
|---|---|---|
| coolEX | final surface and cross-hatch | finished size relative to pre-machining; short cycle times |
| coolEXact | defined size control using a stop | < 10 µm; larger allowance possible, allowance should not vary significantly |
| coolEX LM | closed-loop precision honing with air measurement | < 3 µm; larger and more variable allowance possible; DPMS 3.0 required |
