Air-gage-equipped, vertical CNC honing system closes loop on automated bore-sizing to submicron accuracy
2007 - Sunnen's SV-1005 series vertical CNC honing system is now available with an integrated air gaging system to provide closed-loop control of tool size, along with downloadable SPC data. Matched with Sunnen's diamond-plated CGT Krossgrinding® tools or MMT TurboHone® multi-stone mandrel, the air-gage-equipped machine can automatically control hole size to accuracies of 0.25µm (0.00001") without operator intervention, working in a size range of 3.65 mm (0.120-2.56") diameter. It is ideal for automated, high-Cpk production of small engines, hydraulic valves/bodies, fuel injectors, gears, compressor parts, turbocharger housings and gun barrels, in medium and high volumes.

According to Tom Dustman, sales manager for Sunnen Products Company, by combining the new air gaging system with the machine's patent-pending tool-feed control, the SV-1005 eliminates the need for an experienced honing operator to tweak the process. The new Etamic air gaging system controls bore diameter and geometry by taking post-process measurements of the parts while they are still fixtured on the machine's rotary table. Feedback from air gage provides the highest possible accuracy for tool-feed control.

The SV-1005 matches an ultra-precise tool feed system with CNC control to allow any CNC-experienced machinist to master honing quickly. Setup is simple with a 3-axis hand wheel for fine tuning the tool feed and the servo-controlled stroke system and rotary-table. The control includes several features that put honing expertise at the fingertips of novices, such as a switchable autocorrect feature for bore shape. Using measurements from the air-gage system, it allows the operator to select from a library of "problem" bore images (taper, barrel, etc.) to match to the part on the machine. The servo-controlled stroke system ensures a consistent crosshatch pattern and can dwell in any part of the bore, end-to-end, selectively removing stock for ultra-precise straightness and roundness.

The vertical design of the SV-1005 conserves shop floor space, requiring just 2400 x 2300 x 2700 mm WxDxH (95 x 91 x 107 in.). A cast polymer base and cast-iron column provide enhance vibration damping for precision honing, while removable stainless steel side doors facilitate integration with automatic part loading systems. The high-torque, belt-driven spindle is rated at 7.5 kW (10 hp) to cover a wide range of sizing and finishing work using Sunnen's MMT TurboHone® multi-stone mandrels, TC precision mandrels, or CGT Krossgrinding tools.

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