Sunnen Products Company

Daniel R Cloutier

Russell Jacobsmeyer

Timothy P Hoth

David M Moehn

Gerry R Schnitzler

Mark E Maichel

Wayne W Althen

Michael J Nikrant

James K Davis

John Harte

Terry R Heller

Scott W Alcock

Russell L Jacobsmeyer

An apparatus, system, and method using an elastic biasing element in combination with an encoder arrangement for precise control of force or torque applied to a moving object, is applied for controlling a feed force applied to an abrasive element of a bore finishing tool, to respond to changes in the feed force such as can arise from contact with a workpiece bore surface and variations therein, such as tapers, hourglass shapes, barrel shapes, and the like. The elastic biasing element can include a single or multiple springs in one or more sets, and the feed force can be selected to have a constant value or vary as a function of time, position, or other variables or conditions.

Elastic biasing element and encoder arrangement for precise control of force or torque

An automated bore finishing process particularly adapted for lapping automatically corrects one or more bore parameters, such as diameter, geometry, surface finish, in an iterative manner to reach a final value, controlled by algorithms that process feedback from a measurement process. The process determines bore parameter information and determines an optimum set of values for the process parameters, such as stroke position, stroke length and duration of the next lapping iteration. This optimization is targeted to achieve the desired final bore parameter or parameters within the specified bore size limits, and may be used to alter the stroke profile either for the entire next iteration or in a continuously changing manner, to minimize or eliminate bore defects over one or a succession of iterations.

Automated bore finishing process

A bore finishing tool has an arbor with a tapered outer circumferential surface and a sleeve over the arbor having a tapered inner circumferential surface cooperatively disposed in surface to surface overlaying relation to at least a substantial portion of the tapered outer circumferential surface of the arbor. The sleeve is adjustably movable relative to the arbor for expanding a diametrical extent of the sleeve and has a plurality of internal material relief features at circumferentially spaced locations in the tapered inner circumferential surface extending partially through the sleeve so as to reduce a level of force required for expanding the diametrical extent of the sleeve. Exemplary material relief features include flutes and fractures. The sleeve can also include an external retraction feature enabling application of a retraction force by an external device for reducing the diametrical extent.

Bore finishing tool

A honing tool holder that provides a capability for automatically feeding the honing elements or stones when in the bore of a work piece, and for automatically stopping the feeding when a particular condition such as a bore size, is reached, so as to enable use of an in-process adjustable feed honing tool in a machine tool, machining center, or the like, lacking a feed mechanism or system. The holder can also include apparatus to automatically prevent feed past a limit. Both the feed force and feed limit can be adjustable, including by simple movements of the tool holder by the machine tool.

Honing tool holder with integral in-process feed system

A honing tool holder utilizes pressure of a through-the-spindle coolant delivery system for automatically feeding the honing elements or stones of an attached honing tool when in the bore of a work piece, and for automatically stopping the feeding when a particular condition such as a bore size, is reached, so as to enable use of an in-process adjustable feed honing tool in a machine tool, machining center, or the like, lacking a feed mechanism or system but including a coolant delivery system. The holder can also include apparatus to automatically prevent feed past a limit. Both the feed force and feed limit can be adjustable, at least the latter by simple movements of the tool holder by the machine tool.

Honing tool holder with a feed system powered by through-the-spindle coolant pressure and actuated by spindle rotation

The honing feed system and method utilizes feedback from various sources during rapid feeding of the honing tool while rotating and stroking, to detect initial contact with a bore surface, to slow the feed to a normal honing rate, involving conditioning the feedback signals to eliminate noise factors such as the stroking movement and forces generated to rotate and feed the tool unopposed.

Honing feed system and method employing rapid tool advancement and feed force signal conditioning

The method of the invention provides a capability for accurately and uniformly determining the sizes of bores of workpieces, both pre- and post-process, to improve process control, particularly compensation for tool or stone wear and other factors, and process data collection. The present method makes all required bore measurements, including those in both the workpiece bore and the calibration ring or sample workpiece bore, with the honing tool, under controlled static, non-honing conditions, including expanding the tool in the bores in a predetermined manner, such as at a predetermined rate. The method of the invention has utility for honing multiple workpieces to a finished size with a single tool, and also for multiple spindle applications.

Pre- and post-process bore gaging using a honing feed system equipped with feed force sensing

The feed system for a honing machine provides a capability to dynamically correct in real time errors in bore size inferred arising from variations in feed force, and a method of operation of the same. The system allows a user to select between rate and force controlled honing modes, which provides one or more of the advantages of both modes. The system provides capabilities for automatic rapid automatic bore wall detection, compensation for elasticity of elements of the feed system and honing tool, and automatic tool protection. The system is automatically operable using feed force, feed rate and positional information for honing a work piece to one or more target parameters, such as one or more in-process sizes and a final size.

Method of operating honing feed system having full control of feed force, rate, and position

The feed system () for a honing machine () provides a capability to dynamically correct in real time errors in bore size inferred arising from variations in feed force, and a method of operation of the same. The system () allows a user to select between rate and force controlled honing modes, which provides one or more of the advantages of both modes. The system provides capabilities for automatic rapid automatic bore wall detection, compensation for elasticity of elements of the feed system () and honing tool (), and automatic tool protection. The system is automatically operable using feed force, feed rate and positional information for honing a work piece () to one or more target parameters, such as one or more in-process sizes and a final size.

Honing feed system having full control of feed force, rate, and position and method of operation of the same

A linkage controlled spring powered feed system for maintaining a virtually constant force against a linearly movable member such as the feed member of a honing machine or other device, the system including a lever member having one end which bears against the linearly movable member and an opposite end, the lever member being pivotally mounted at a location between the opposite ends thereof on the machine frame, a linkage assembly bearing against the opposite end of the lever member in a direction to apply force against the linearly movable feed member, the linkage assembly including a first expandable link member having a compression spring for exerting force against the lever member and a second link member for adjusting the position where the linkage assembly engages the lever member as the lever member moves about the pivotal support to change the effectiveness of the compression spring in applying force to the linearly movable member. The present system can optionally include an additional linkage enabling selectively adjusting the level of constant force to be applied against the linearly movable member, and one or more cam members and spring members enabling speed control, counteracting and otherwise affecting the force applied against the linearly movable member.

Linkage controlled spring powered feed system

A floating fixture platen for use on machine tools having a machine support structure and a machine tool portion rotatable about an axis of rotation, the floating fixture platen including a planar member mounted on the machine support structure in a position normal to the axis of rotation of the rotating tool portion, the platen supporting a workpiece to be operated on by the rotating tool, apparatus on the support structure enabling the platen limited relative free movement in a plane substantially normal to the axis of rotation of the tool whereby rotation of the tool will produce torque in the platen and in the workpiece supported thereby, first and second oppositely facing fluid assemblies each having a piston portion engagable with a surface on the platen and positioned to oppose rotation of the platen, the fluid assemblies having pressure generated therein by the movement of the platen, and a fluid connection between the fluid assemblies to equalize the pressures therein.

Floating fixture platen

A computer controlled machine tool such as a honing machine having a work engaging portion and apparatus to control the machine tool including to establish certain machine operating parameters based on the characteristics of the work to be done, including a computer device having an entry device for entering data as to the workpiece to be operated on, a computer storage device containing data pertaining to certain operating conditions and parameters, said computer device producing output data for establishing the operating parameters of the honing machine based on the entered data as to the workpiece, and the stored data, the computer device having outputs at which signals are produced for establishing the operating parameter for the machine tool.

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Clive, IA, United States of America

Daniel R Cloutier