Sunnen Products’ SV-490 hone provides 90" (2,286 mm) vertical stroke and end-to-end dwelling capabilities to machine bores as large as 8" (200 mm) in diameter on large aerospace, energy and hydraulic components. The machine is equipped with a 7.5-kW (1-hp), 5-500-rpm, variable-speed spindle and a 7.5-kW (10-hp) 1-130 strokes-per-minute DC stroker that produces 3,000-lbs (1,360 kg) of thrust. The servo-controlled rotary tool-feed system is said to produce 225 lbf-in (25.4 Nm) of torque for fast, accurate machining with diamond and superabrasive tools. The feed system can be optimized for each application by either operating as a rate system or feeding to a constant spindle load. This capability, coupled with standard features such as sizing, sparkout, crosshatch and two-stage honing, enables users to tailor machine operations to the tooling/abrasive combination best suited to the application. These features compensate for part variation and enable the SV-490 to produce more-consistent surface finishes with better tool life and optimized cycle time, the company says.
The 69.44 square-foot machine is designed to occupy minimal floor space and facilitate coolant flow. The stationary column provides stability required for long-stroke machining on parts as heavy as 2,000 lbs (900 kg), with diameters ranging from 0.75" to 8.0" (19 to 200 mm).
A Windows-based industrial PC control system enables intuitive setup for stroke, crosshatch angle and other parameters, with capability for dwelling the tool in multiple areas to correct part geometry or process blind bores. The machine can be equipped for in-process air gaging with Sunnen’s PH hone head, or with post-process air gaging. A bore profile display indicates bore straightness throughout the cycle, and an optional post-process gaging system with SPC software enables data collection and machine process control to submicron tolerances. A multi-axis hand wheel is designed for fine tuning of vertical stroke and honing tool position.