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Model 772 Honing Applications
Other
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Jones & Shipman Model 772 Honing Applications Other

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I
Model
HONING
APPLICATIONS
JONES & SHIPMAN
/
HYDRAULIC
&
SUSPENSION
BRAKING
COMPONENT
The functional design produce accuracies
The sectioned insert sleeves are fitted into the aluminium casing of the respective valve assembly,before being mounted on to a floating fixture on the machine.A combination of the specially desi gned honing tool and the machine's inherent features, allow very close tolerances to be achieved.
of
the valves is such that it
of
0,0005mm (0.00002'
1,
is
necessary to
OPERATIONAL
Bore diameter Length of bore Mater
ial
Stock
removal
Ge
ometric accuracy Surface finish Honing time
DETAILS
6,
3mm
(0.2485'1 22,2mm (0.875'1 Hardened Steel 0,015/0,02Smm (0.0006"/0.001'1 0,00075mm (0. 0,075-0,1 µm 70
seconds
00003
'1
(3-4
Micro-inches) Ra
,,
AUTOMOBILE
---
\..
CONNECTING
ROD
- - -
--
~
,
I
I
lf7)
~·
-
+·
app.11CaulOilS
OPERATIONAL DETAILS
Bore diameter Material Stock
removal
Surface finish Tolerances:
Diameter
Geometry Production rate Sizing
Piston Pin bore Crank Pin 20,63mm (0.8125'1 51,35mm (2. Steel forgi 0,064mm (0. 0,
75-1
Micro-inches) 0,010mm (0.
0,005mm (0.
260
Gauge
,0 µm
per
ng
0025
0004
0002j
hour
plug
Steel forging
'1 0,064mm (0.
(30-400,75-1
Ra Micro-inches) Ra
'1
lf7)
u u
bore
,0 µm
0,010mm (0. 0,
005mm 260 Gauge plug
per
(0.0002'1
hour
0)
~
021
1
0025j
(30-40
0004i
The :3ymmetrical cross-hatch pattern produced rotat!ng and reciprocating motion provides_ the ideal supporting surface in an automobile Coni:,ect1~g Rod assembly, for fitting b_eanng. Since the geometric and diameter tolerances are also vitally Important it is essential for reliable honing equi
used.
of
the honing operation, of
the soft metal shell
by
the combined
pment
to
be
STEERING
PUMP
OPERATIONAL
Ma
terial: Previous Operation: Stock
removal:
Surface finish: Tolerances:
Diameter Roundness Taper
Production·
Hone Head withdraw Load/unload
Total Time
component
DETAILS
approach/
per
Cast Iron Gun Ream. 0,013/0,04mm (0. 1,1
µm
(45 Micro-inches) Ra Max.
0,005mm (0.0002'1 0,002mm (0.0001'1
0.002mm (0.0001'1
- 20 seconds
- 4 seconds
-
10
seconds
- 34 seconds 0'
100% efficiency .
0005"
/.0015'1
The close geometric tolerance requirement. together with the blind-end bore condition and irregular casting shape, make this component an ideal application for honing. Using existing reference holes the casting fixture, wh ich 1s free to float laterally.
A rigid honing tool is employed to ensure complete control the diamond abrasives, which extend almost to the end of the tool to accommodate the blind-end condition. and to guarantee parallelism along the bore length. The Model 772's positive reversal mechanism ensures that overrun of the tool bore cannot occur.
1s
clamped
1n
position onto the
of
in
the
r
????~
applications
OP
ERATIONAL DETAILS
Component
Bore
diameter
Mater
ial
Stock
removal
Surface Toler
Production rate
finish
ances Diameter Ro
undness
Taper
:
Slide 14mm (0.55'1 Cast Iron 0,02mm (0. 0,25-0,4µm
0,0075mm (0.0003") 0,0025mm (0.0001'1 0,002mm (0. 20 100% efficiency.
secs
per hour 180
001'1
(10-16
0008
Micro
'1
I
-inch)
bores
at
Ra
COMPRESSOR
SLIDE
The fixture for honing the compressor slide consists floating, universal type fixtu component during the honing plunger is also incorporated component has an unusual bore configuration, if offers problems
to
the honing operation.
re,
which has a latch
cyc
le. A simple spring loaded
to
assist unloading. Although the
of
to
retain the
a fully
no
SAW
CUTTER
OPERATIONAL DETAILS
Bo
re diam
Material Previous Operation
Stock Surface finish
Tolerances:
Production rate
eter
removal
Diameter Roundness
32mm High Speed Steel
Press 0,25/0,30mm (0.010"/0.012'1 per operation 0,75/1,25
0,012mm (0.0005'1 0,005mm (0.0002'1 Per 18 (0. Honing time Index time Total
(5.35
01'1
seconds
µm
(30/50 Micro-inch)
com
ponents with 0,25mm
stock
90
seconds
6 seconds
96
seconds
per
component)
Ra
High production is a feature saw
cutters.Approxlmately 0,75mm (0.030'1 stock is removed from the stack are performed while the components are The third operation being the finishing after the teeth have been cut
The rotary index table enables the operator to unload completed components and load new components during the honing cycle
, thus eliminating loading time.
of
bores in three equal operations. two of which
and
the cutters have been heat treated.
HYDRAULIC
-
--
of
this installation for the honing
in
the soft condition.
VALVE
---
of
- -
~-
app.t1ca
OPERATIONAL DETAILS
Bore Material
Previous operation No. of
Honing Operations
Stock
removal
Toleran
ces
: Diameter Roundness Taper Surface finish
Production
lf:7,?ffv0)
~
;t.
u u
ions
9,5mm x 22.2mm (0.37 4"
long) Meehanite Fine
bore One 0,140mm (0.
0,0075mm (0.
0,0025mm (0.0001'1
0.0025mm (0.0001'1 0,
25-3
40
bores per hour
,3 µm
0055
0003
(10-12
'1
'1
Micro-inch) Ra
~
dia
x 7 /8"
The
efficiency accuracy b~tween the valve block bore and its mating spool. To
9bta1n to~l1ng utilised for controlled su.rface fl_nish. The enables loading dunng the Honing cycle.
of
the hydraulic control equipment relies on the
this a~_curacy Jones&Shipman individually designed
and
P(?S_1t1ve
efflc1e
nt1y
method
of
producing the desired geometry and
expanding the cutting medium. is
two
Station Lateral Indexing Table
OP
ERATIONAL DETAILS
Bore diameter 24mm (0.950'1 Material Cast Iron Stock remo Surface finish 1,6
Tolerances:
Diameter Roundness Taper
Honing time
val
0,050/0,
10mm
µm
(64 Micro-inch)
0,
01mm 0,0025mm (0. 0,0025mm (0. 15
(0.0004'1
seconds
(0.
0001 0001
002"/0
'1 '1
.004'1
Ra
max
WATER
.
The close tolerance requirement of the 24mm diameter bore and an irregular shaped casting, makes the automobile water
pump housing an ideal honing application.
An indexing fixture allows loading of the component during the
honing cycle.
Automatic size control consists of a plug which enters the bore
when the required size is obtained and is instrumental in terminating the honing cycle.
PUMP
HOUSING
~~~
appl1cat1ons )
OPERATIONAL DETAILS
Bore diameter Material No. of
operations
Stock
removal Surface finish Tolerances:
Diameter Roundness
Taper Production rate at 100% efficiency
.
--
22mm (0.866'1 Steel 2 (rough & finish) Roughing 0,07mm (0.003'1 Finishing 0,02mm (0.
0.4 µm
0,007mm (0.0003'1 0,005mm (0.0002'1 0,003mm (0. Roughing­170 Finishing-15 seconds 240 bores
.
---
(16
Micro-inch)
0001
'1
21
bores per hour
seconds
per
hour
001'1
Ra
-
PI_ST
_O_N_A_N_D_S_LI_D_E_A_
This
two component Piston Assembly. The condition extremely exacting, because affects approximately one third
nearly the whole On
majority is finish honed to produce the required tolerances.
-spindle installation is equipped f of
the cut away section which of
of
the bore length.
the first spindle the parts are rough honed to remove the
of
the material, whilst on the second spindle the bore
the bore circumference, for
SS
or
producing the of
this part is
_E_M_
BL
_Y_
MAIN
FRAME
BORE
"Match honing" consists diameter markets, such an able to have to
Since hi this should
The i
ncorporated
mea
of
the mating component. In the high production
ideal
type
jets
surement of the
as
procedure
reduce
the
be
held
gh pressure
of
component, it naturally follows that this system
be use
d in '"match honing"'.
connect
into the precision-honing tool
the Refngerati
to
stock
for
selective assembly.
systems
ed to the air gauging unit are therefore
bor
of
honing the bore to suit the outs
on
introduce because the manufacturer is
of
e di
Compressor industry, this
parts which
are generally used for gauging
ameter
would
normally
to
during the honi
give continuous
ng
cycl
ide
e.
is
OPERATIONAL DETAILS
Bore
diameter Length Material Stock
removal (max.)
Surface finish
Bore
Geometryffotal Match
Tolerance
Honing time
Bore diameter Length
Material Stock
removal ( Surface finish Bore
Geometry/fotal
Matc
h Tolerance
Hon
ing ti
me
max
.)
A (Piston bore)
30mm
(1.1875'1 31mm (1.230'1 Meehanite
0.03mm (0.0012'1 0,
2-0,25µm (8-10 Micro 0,
0025mm (0.0001'1 0,00125mm (0.00005'1 24
seconds
B (Journal bore) 19mm (0.7517'1 36mm Meehanite 0,
03mm 0,
75 0,
0025mm 0,00125mm (0. 18
seconds
(1.406'1
(0.0012'1
µm (30
-inches)
Micro-inch) Ra
(0.0001'1
00005
Ra
'1
STEERING
----
SLEEVE
--
- -
~·
---'
l&J l&J
+·
u u
65)
~
app.11CaulOilS
OPERATIONAL DETAILS
Bore
diameter
Bore
length Material Stock
removal
Surface
Toleran
I
I
Producti Sizing
finish
ces Diameter Taper Roundness
:
on
22,07mm (0.865'1 31,75mm EN32M 0,05mm (0.002'1 0,3-0.4
0,0075mm (0. 0,0025mm (0.0001'1 0,0025mm (0.0001") 120 Dead
(1'
.'.'1
Case
µm
(12
per
hour (approx.)
stop
.
Hardened
-16 Micro-inches)
0003
'1
700
VPN
Ra
This
(s
~n
examp
spec1ahsed tooling this difficult of
accurac
le of the
y.
pote
ntial
of
the Honing process. Using
bore
is
produced
to
a high d
egree
°W~@
GREEN & HARD.HONING
SPEED
GEARS
ii
applications
OPERATIONAL DETAILS
Component Bore diameter Bore length Ma
terial Stock removal Surface finish
Tolerances:
Diameter
Roundness
Taper
Production rate
(Green Hone) Speed Gear 40
mm 35mm EN352 Soft Steel 0,05/0,10mm 1,0/1
,5
µm
Micro-inches)
(40-60
Ra
0,0075mm 0,0025mm 0,0025mm 72 parts per hour
(Hard Hone)
Speed Gear 40
mm 35mm EN352 Hardened 0,
12
-0,
18
mm
0,Sµm
(20 Micro-inch) Ra 0,0075mm
0.0025mm 0,0025mm
60
parts per hour
Honing gear bores finished tolerances has been an accepted production method for many years , particularly
in
the hard condition to obtain close
In
the automobile industry where
production quantities are high. More recently, 'Green Honing'
- honing proved extremely successful. Advantages are offered manufacturing process that result in a higher standard of finished gear.
The essen tial feature of this operation in the production is that it provides an accurate bore from which to locate all the other metal cutting operations, ensuring that the teeth are cut with reference to the bore centre line.
As the bore is the major bearing surface in operation, it is logical therefore to use it for location throughout the production process, with hard necessary geometry, surface fi
Many of the problems which were previously encountered on cutting the teeth have almost been eliminated and a considerable reduction in the scrap rate has been achieved,
due entirely manufacturing process.
in
the soft condition - prior to cutting the teeth, has
honing,
the
final
operation, providi
nish
and size.
to
the inclusion of green honing into the
ng
to
the
the
of
gears
JONES &
J
&
s
SHIPMAN
Jones
&
Ship,nan
Narborough Road South, Leicest Telephone:
London No
. 5 Abercorn Trading Estate, Manor Farm Road, Alperton, W
Telephone: 01-
Scottish Office:
10
Whin Place, Nerston East, East Kilbride, Gl
Associated and Subsidiary Companies:
Jones Jones Jones
PUBLICATION
0533
896222 Telex: 34645 Telegrams: "CHUCK LEICESTER"
Office:
902
4426
& Shipman & Shipman Inc. New & Shipman SA.R.L. Paris, France.
C421
5M
182
Ce
lada S.
pA.
Yori<
Milan, Italy
U.SA.
er
LE3 2LF, England
asgow
G74
3XT Telephone:
emb
p.l.c.
ley,
Middlese
x, HAO
03552 25431
1BE
Our
endeavour
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any t,mo
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IN
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