12/1/11 – Sunnen launches automated CNC honing system for engine blocks
12 January 2011
Sunnen has launched the SV-410 automated CNC honing system for engine block finishing applications. The company says that the new system will give performance builders and production rebuilders a new level of control for achieving precise cylinder geometry, surface finish and crosshatch parameters for superior ring seal, uniform lubrication, minimal leak down and highest horsepower.
The SV-410 is particularly suitable for high-nickel and CGI blocks, the automated, high-horsepower honing system allows engine builders to deliver customized results quickly, with automated efficiency, for consistent quality, highest performance, and longest engine life. The flexibility of the system allows for in-line 4- and 6-cylinder engines, as well as all V-6/8 blocks.
The SV-410 combines automated operation with a 7.5 kW (10 hp) spindle to drive high-accuracy CBN and diamond tooling for short cycle times and high-quality results with minimal labour. Utilizing two-stage metal-bond diamond tooling, the machine eliminates tool changes and completely finishes the bore surface with a plateaued finish. The fully automated system indexes the tool from bore to bore and (for V-blocks) the servo fixture rolls the block for access to all cylinders, ending with a rollover of the block to dump oil/coolant. The servo fixture adapts to any angle V-block via the setup screen without manual adjustments. A work envelope of 915 mm x 1015 mm (36" x 40") and weight capacity up to 680 kg (1500 lb) combine with convenient front loading for versatility in processing a wide range of in in-line or V-blocks. A 500-pound V-block can be rotated in one second, bank to bank.
An optional tool-guide assembly and variety of bore-diameter gaging systems combine with a servo-controlled X-axis travel of 1143 mm (45") to allow automated honing of multi-bore blocks with high precision. Straightness sensing capability provides a display of the bore profile during the cycle. Combined with a patented, servo stroking system, it allows the SV-410 to auto-dwell in any part of the bore to correct straightness automatically in the shortest cycle time. Crosshatch is controlled and set via the control screen for every ring application. The SV-410 can be used to hone blocks with bore diameters from 19-200 mm (0.75-8.00"), depending on the tool options selected.
Designed for automated processing, the SV-410 features full-height/walk-in access doors and stainless steel enclosure preconfigured for use with automated part loading systems, while the CNC control includes a built-in automation interface. Setup is simplified with a multi-axis hand wheel for fine-tuning vertical stroke, tool feed, column position and optional cradle position. The system easily walks the operator through setup.
The SV-410 incorporates PC-based, colour, touch-screen control features multi-language capability, pull-down menus, unlimited capacity for job setups, and programmable custom tools. In addition to optional in-process air gauging, a variety of optional post-process air-gage systems can integrate with the control for SPC data collection, as well as automatic compensation of size, taper and straightness. The control allows easy programming of multiple bore positions.
The SV-410 is built on a malleable iron base for rigidity and vibration damping. The machine’s servo-controlled, straight-line stroke motion is driven by a servo ballscrew at rates of 1-160 strokes per minute, while a powerful 7.5 kW (10 hp) spindle provides ample torque for fast metal removal with tools outfitted with metal-bond CBN and diamond abrasives or standard aluminum oxide and silicon carbide stones. Oversized, lubricated-for-life guide ways for horizontal and vertical axes provide smooth operation and long, maintenance-free life. An optional manual rollover fixture is available for less demanding applications.
SV-410 machines can be equipped with a wide range of Sunnen tooling, including General Hone, GHSS, GHTS, PH, CV/VK, P20/P28, MPS, HB and the new PH precision multi-stone tool. The PH tool is custom-designed for specific applications and can hold as many stones as possible to produce optimum straightness and roundness. It is available in single or two-stage configurations, along with optional, integral air-gauging for in-process monitoring.