Industry-first - New modular, 3-axis servo honing system produces constant crosshatch, with automated bore-geometry correction and industry's highest dimensional accuracy
March 2008 - Sunnen's new SV-500 vertical CNC honing system is the world's first to offer three-axis servo control of spindle rotation, stroke and tool feed, allowing the machine to produce a whole-bore, constant crosshatch angle to meet the latest requirements for diesel/gasoline engines, cylinder liners, mud pump liners, hydraulic blocks, and similar large parts or MilSpec programs. Unique in the industry, the SV-500's patent-pending, synchronized servo axes allow the operator to set the desired crosshatch angle through the Windows®-based control, or change it mid-cycle, eliminating the "flattening" of the crosshatch angle that is inherent at the stroke-reversal points for other honing machines. The SV-500 is a the basic module of "system series" that allows processing solutions to be custom designed, end to end, for a wide range parts, production rates and specific customer needs.

"We have used servo drives and motion control to make constant crosshatch capability - which had been essentially impossible to achieve before - completely transparent to the operator," stated Phil Hanna, Sunnen's Machinery Product Manager. "And as an all-electric drive system, the servo-accurate reversal points do not drift over time, not to mention there is no potential for hydraulic leaks."

Equipped with the fastest, most precise linear tool feed on the market, the SV-500 is a modular "series" machine available in single and multi-spindle configurations. It is designed to automatically correct bore geometry and size, while producing a constant crosshatch angle and surface finish, end-to-end, throughout a bore. Designed for bore diameters of 19-300 mm (0.75" to 12"), the workhorse SV-500 offers faster throughput, tighter process control, and numerous automation options. Its potent 15 kW (20 hp) spindle permits high stock removal rates on tough materials, such as compacted-graphite iron. Standard spindle speed is 0-300 rpm, with options of 0-600 and 0-1200 rpm, and a maximum stroke rate of 160 per minute.

The versatile SV-500 can be configured as a single-spindle, manually loaded machine or as a multi-spindle, fully automated system. Sunnen system-engineers each machine as an optimized processing package, complete with custom guarding, part-handling automation, custom risers and fixturing, tooling, abrasives, gaging and coolants, as required by the application. Part indexing options include in-line shuttles for transfer lines, as well as 2- and 32-position rotary tables or (fourth axis) servo-index table with infinite positioning. The open base of the SV-500 allows easy pass-through of large parts and makes the SV-500 highly adaptable for parallel manufacturing in a lean environment.

Setup is fast and easy, all handled from the front of the machine without raising a cover. Stainless steel guarding all around is maintenance free. Fast changeover maximizes machine uptime and output - most tools can be changed in a few minutes.

To realize highest unmanned processing efficiencies, the SV-500 can be equipped for in-process air gaging with Sunnen's PH hone head - or with post-process air gaging - to provide closed-loop control of bore size and geometry, along with downloadable SPC data. PH tools can hold as many as 12 stones, enabling them to produce the optimum straightness and roundness. PH tools are available in a single-angle configuration to fully support the stone, as well as a double-angle configuration for longest stone life. A plug gauge shutoff is also available for processes that do not require the feed back or precision of air gauging.

An intuitive interface and advanced Windows®-based PC control simplifies the honing process to allow anyone with multi-axis experience to run the machine like an expert. Features include automatic bore geometry correction functions. The machine's auto-dwell feature can automatically correct bore straightness - great for blind bores.

The SV-500 provides great cost, size and flexibility advantages over high-production honing systems of comparable capacities. Vertical design of the SV-500 conserves shop floor space. The machine measures 2210 x 2056 x 2275 mm (87 x 81 x 89.5 in.) without coolant tank. A robust case iron base provides excellent vibration damping and long life.

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