Micro­cut Honing Sys­tem: Hig­hest pre­cisi­on, easy to control

The Micro­cut Honing Sys­tem deve­lo­ped spe­ci­fi­cal­ly for smal­ler bores gua­ran­tees shape accu­ra­cy, sur­face qua­li­ty and dimen­sio­nal accu­ra­cy at the hig­hest level

Bore/pin pai­ring

A recur­ring pro­blem in gene­ral with bore/pin pai­ring or in par­ti­cu­lar with hot run­ner sys­tems with nozzle/needle is the dif­fi­cul­ty of mea­su­ring the machined small bore and the­re­fo­re assigning the appro­pria­te pin/needle.
Due to today’s manu­fac­tu­ring pro­ces­ses and machi­ning methods for small bores, the­re is a rela­tively lar­ge tole­ran­ce field for the dia­me­ter of the bore. This requi­res a cor­re­spon­din­gly lar­ge tole­ran­ce field for the pins, which ulti­mate­ly leads to unde­fi­ned play in the respec­ti­ve pairing.
Up to now, this pai­ring pro­cess has main­ly been done manu­al­ly by repeated­ly try­ing out several pins per bore. In addi­ti­on, if the pai­ring is suc­cess­ful, the actu­al dimen­si­on of the bore and the tole­ran­ces are unknown.
Sin­ce the intro­duc­tion of the Micro­cut Honing Sys­tem, a dif­fe­rent approach has been taken. Due to the pre­cise tool dimen­si­ons and the sta­ble machi­ning pro­cess, the bore is machined to a pre­cise­ly defi­ned and always repro­du­ci­ble dimen­si­on. Thus, the exact bore dimen­si­ons are known and the pin can be pro­du­ced cor­re­spon­din­gly easier.

The advan­ta­ges of the Micro­cut Honing Sys­tem in the nozzle/needle pai­ring are

  1. Immedia­te­ly burr-free work­pie­ce when the injec­tion mould is put into operation
  2. The sta­ble machi­ning pro­cess gua­ran­tees that bore geo­me­try and dia­me­ter tole­ran­ce are high­ly accu­ra­te and repro­du­ci­ble over and over again
  3. The need­les can all be pro­du­ced reli­ab­ly to the same size
  4. Thus the time-con­suming and manu­al pai­ring search is eliminated
  5. The tole­ran­ce of the pai­rings is always constant

The tole­ran­ce of the pai­rings is always constant

With Micro­cut Honing Tech­no­lo­gy, all machi­ning move­ment and for­ce mea­su­re­ments are per­for­med by the tool. This means that even small, very short, step­ped bores can be machined in rela­tively lar­ge inserts. The posi­ti­on of the bore in the work­pie­ce is not changed.
Gate nozz­les are an important app­li­ca­ti­on in injec­tion tool manufacturing.
Here it is important that the need­le seals very pre­cise­ly, which requi­res the best pos­si­ble shape (round­ness, cylind­ri­ci­ty), sur­face and exact dimen­si­on of the bore. In this way a mini­mum of burr for­ma­ti­on on the moul­ded part is achieved.

Injection mould e

Pic­tu­re: Hot run­ner system

Due to the now geo­metri­cal­ly much more pre­cise bore, the dia­me­ter of the need­le can be defi­ned pre­cise­ly, which leads to a mini­mum of clearan­ce. This pre­vents the for­ma­ti­on of burrs on the moul­ded part from the first shot onwards, as the­re is no mate­ri­al bet­ween the wall of the bore and the need­le. Leng­thy com­mis­sio­ning with cor­rec­tions to the mould are no lon­ger necessary.

Pic­tures: Gate nozzle

Pic­tu­re left: Coor­di­na­te ground bore with round­ness 2.31 µm
Pic­tu­re right: After Micro­cut Honing pro­cess with round­ness 0.16 µm

Need­le gui­des in the hot run­ner system

The advan­ta­ges of a very cylind­ri­cal bore with an opti­mi­zed sur­face beco­me par­ti­cu­lar­ly appa­rent with need­le gui­des over the time of the pro­duc­tion pha­se: the hot run­ner sys­tems can be used lon­ger on the machi­ne, sin­ce the wear on the need­le and bore is much less. This leads to hig­her avai­la­bi­li­ty of machi­ne and injec­tion tool and less main­ten­an­ce work on the tool.

Pic­tu­re: Need­le guide

Con­clu­si­on

By using the Micro­cut Honing Tech­no­lo­gy, bores below 8 mm in dia­me­ter can be pro­du­ced with high pre­cisi­on, effi­ci­ent­ly and thus extre­me­ly eco­no­mi­c­al­ly. The Micro­cut Honing Sys­tem offers sys­tem-rela­ted advan­ta­ges even for bores with cross holes or cut-outs. Micro­cut sys­tems can be con­fi­gu­red for all seri­es sizes. Des­pi­te the addi­tio­nal pro­ces­sing step, a clear cus­to­mer bene­fit is gene­ra­ted and will pay off several times over due to the incre­a­sed per­for­mance of the hot run­ner system.
Alrea­dy today, com­pa­nies world­wi­de bene­fit from this offer: They send us small to medi­um seri­es of their work­pie­ces so that we can signi­fi­cant­ly impro­ve the shape accu­ra­cy, dimen­sio­nal accu­ra­cy and sur­face rough­ness of the bore by app­ly­ing Micro­cut Honing System.