Flexible honing on the machining centre

Valve housing EN-GJS-400-15 – Compensator bore / honing

Initial situation at the customer

Request for reduction of ancillary costs
Existing machining centre re-tooled to TOOLTRONIC
Honing for prototype manufacture, as well as small and medium-scale production runs
Requirement for saving the honing process on separate machine

Special features of this solution

A full NC axis incorporated in the machine control system
Shortening of production and lead times
Improved surface quality
Greater contour accuracy

Compensator bore

Fine machining with honing

Significant shortening of production and cycle times
Greater contour accuracy

Honing with TOOLTRONIC
Machining with MAPAL TOOLTRONIC achieves high surface quality and dimensional accuracy with tightest manufacturing tolerances as well as high flexibility in manufacturing. The wear of the honing bars is reliably compensated by a highly sensitive and precise actuating movement (EAT system).

MAPAL TOOLTRONIC: design and advantages

TOOLTRONIC design for machining centres:

Machine connection
Electronics
Motor unit with defined connection point
Modular connection
Stator (stationary unit)

ADVANTAGES OF THIS HONING:

Very tight manufacturing tolerances as well as flexibility in manufacture
High surface quality and dimensional accuracy
Major saving and quality potential for prototypes, small-scale and medium-scale series production
Time-consuming re-tooling is not necessary

Advantages

Tolerances to be achieved: Accuracy of diameter IT 6 and roundness < 5 μm
Turning with a stationary, firmly clamped part
Burr-free, rounded transitions possible
Reduced/low number of custom tools
Low-maintenance system with eccentric actuating tool (EAT system)
Almost all machining centres can be re-tooled to MAPAL TOOLTRONIC technology
Reclamping error due to re-tooling to honing machine no longer applies
Complete process of compensator bore can be mapped by MAPAL (highest economic efficiency & process reliability)