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 even in seri­es production.

Our tech­no­lo­gy has fun­da­men­tal tech­ni­cal and eco­no­mic advan­ta­ges over estab­lis­hed pro­ces­ses such as inter­nal cylind­ri­cal grin­ding and long-stro­ke honing.

Espe­cial­ly for bores smal­ler than Ø 2 mm, whe­re con­ven­tio­nal pro­ces­ses such as honing and inter­nal cylind­ri­cal grin­ding reach their limits due to the sys­tem, our pro­cess deli­vers pre­vious­ly unat­tai­ned results.

With our uni­que inno­va­ti­ve machi­ning tools and the intel­li­gent, for­ce-sen­si­ti­ve con­trol of the machi­ning pro­cess, we offer an easi­ly con­troll­ab­le and robust pro­cess with mini­mum dispersion.

The actu­al machi­ning is car­ri­ed out with tools coated with dia­mond or CBN grit (unde­fi­ned cut­ting edge).

Our sys­tem is sui­ta­ble for through holes.

sonic-honing tech­no­lo­gy: Hig­hest pre­cisi­on AND productivity

MBS_Procedure_4Steps_withLogo

The sonic-honing tech­no­lo­gy is based on the Micro­cut Honing Sys­tem and is sui­ta­ble for spe­ci­fic applications.

We com­bi­ne the adap­ti­ve feed con­trol* of the tool with a fast stro­ke of the work­pie­ce in the sound ran­ge. This enab­les us to achie­ve a mas­si­ve reduc­tion in cycle time, a lon­ger tool life and finer sur­faces with the same grain size.

*Adap­ti­ve feed con­trol: The feed of the tool is con­trol­led depen­ding on the tor­que applied.

The con­trol and eva­lua­ti­on of the pro­cess is mana­ged by a high­ly sen­si­ti­ve for­ce con­trol and can, for examp­le, detect and trig­ger the following

  • Con­di­ti­on raw bore (too lar­ge / too small / none)
  • Tool sta­tus (start / end of tool life)
  • Pro­ces­sing abor­ted if a mea­su­red for­ce is out­side the defi­ned pro­cess window

Work­pie­ce clam­ping tech­no­lo­gy: A key factor

For dif­fi­cult, e.g. thin-wal­led and small com­pon­ents, work­pie­ce clam­ping tech­no­lo­gy is an essen­ti­al suc­cess fac­tor for achie­ving high form qua­li­ty and auto­ma­ti­on. Micro­cut can offer various cor­re­spon­ding systems.

MICROCUT FACTS

>
0
Hz

FAST STROKE FREQUENCY

<
0
mm

FAST STROKE AMPLITUDE

>
0
rpm

TOOL RPM

 

0
mm

TOOL LENGTH (coated)

 

Micro­cut Honing Sys­tem: The most important advantages

Advan­ta­ges

Form:
Hig­hest pre­cisi­on and pro­cess capa­bi­li­ty in terms of shape such as round­ness, par­al­le­lism, strai­ght­ness and cylind­ri­ci­ty, even with inter­rup­ted bores or work­pie­ces with cross bores.

Dia­me­ter:

  • Very high pro­cess capa­bi­li­ty regar­ding dia­me­ter and very high repro­du­ci­bi­li­ty of the diameter
  • No mea­su­re­ment con­trol necessary

Sur­face:
Very good and repro­du­ci­ble sur­faces in the bore

Pro­cess control:

Why

  • Cylind­ri­cal shape is achie­ved by the pro­cess (no mea­su­re­ment con­trol necessa­ry to main­tain the cylind­ri­cal shape)
  • One-pie­ce tool with maxi­mum dia­me­ter rigi­di­ty (steel)
  • No rele­vant ben­ding of the tool shank as with inter­nal grinding
  • For­ce controlled/monitored machi­ning process
  • No dia­me­ter rele­vant infeed move­ment of the tool
  • The­re­fo­re no uncer­tain­ty due to fric­tion, bre­aka­way tor­que and elasticity
  • Mini­mal influ­ence of tem­pe­ra­tu­re fluc­tua­tions (dia­me­ter of the bore)
  • A lot of grit avail­ab­le due to the tool length
  • For­ce con­trol­led feed
  • Tool coa­ting with small grit size possible
  • sonic-honing with axi­al­ly and radi­al­ly super­im­po­sed machi­ning movement
  • No spon­ta­ne­ous chan­ge of the cut­ting coa­ting, as it is gal­va­ni­cal­ly coated in one layer
  • For­ce con­trol­led machi­ning process
  • Detec­tion of faul­ty raw bores
  • Detec­tion of pro­cess irregularities

Advan­ta­ges

Very short pro­ces­sing times

Why

  • The adap­ti­ve feed con­trol ensu­res opti­mum remo­val rate
  • sonic-honing with high-fre­quen­cy work­pie­ce oscil­la­ti­on (>50Hz)
  • High tool speed (>7000 rpm)
  • The tool has full con­ta­ct with the sur­face (high num­ber of grit in use)

Advan­ta­ges

Robust pro­cess even with bore dia­me­ters of less than 1 mm

Why

  • tool is one-pie­ce and high-strength; works even with a dia­me­ter of 0.015 mm
  • For­ce con­trol­led feed

Advan­ta­ges

Mini­mal sys­tem complexity

Why

  • No adjus­t­ment of the cylin­der shape required
  • No adjus­t­ment of the dia­me­ter necessary
  • No mea­su­re­ment con­trol necessary

Advan­ta­ges

Various scala­b­le auto­ma­ti­on opti­ons and easy inte­gra­ti­on with exter­nal auto­ma­ti­on solutions

Why

  • Machi­ne con­cept is desi­gned for automation
  • High fle­xi­bi­li­ty for cus­to­mi­zed solutions

Advan­ta­ges

Low space requirement:
Hig­hest pro­duc­tion capa­ci­ty in the smal­lest space

Low ener­gy consumption:

Why

  • Com­pact design of the machine
  • Ver­ti­cal spind­le arrangement
  • Litt­le moved mass
  • Ener­gy-effi­ci­ent drives

Micro­cut Honing Sys­tem: Achiev­a­ble values

Cri­ter­ion Achiev­a­ble values with the Micro­cut Honing System
Dia­me­ter range from 0.015 mm loo­se grit | from 0.25 mm — 8 mm bond­ed grit
Dia­me­ter tolerance +/- 0.5 µm
Bore length to bore diameter approx. 0.5 to 200 x D
Round­ness < 0.2 µm
Cylind­ri­ci­ty < 0.4 µm
Par­al­le­lism < 0.4 µm
Sur­face quality Rz < 1 µm with bond­ed grit
Cycle time Depen­ding on mate­ri­al, stock remo­val, bore length etc., typi­cal­ly from 10s
Parts Geo­me­tries Rota­tio­nal­ly and non-rota­tio­nal­ly symmetrical
Mate­ri­als PCD, sap­phi­re, cer­a­mics, tungs­ten car­bi­de, steel hard / soft, pow­der metall­ur­gi­cal steel, various metal alloys…

 

 

Check­list for Micro­cut Honing System

With this check­list we can assist you to find the best solu­ti­on for you. We will con­ta­ct you shortly.