DIAMOND REAMERS

Turbocharger Push Rod Bore

Objective: Improve part geometry by replacing current carbide drill / reamer

  • Material:                      Gray Iron

  • Bore Size:                   0.7880" +/- 0.00035"

  • Machine:                     Makino A70

  • Holder:                        CAT 40

  • Stock Removal:           0.020"

  • Roundness:                 0.0002"

  • Straightness:               0.0002"

  • Coolant:                       Water Soluble

  • Surface Finish:            63 Ra Max

Achievement:

  • Roundness:                 < 0.0001"

  • Straightness:               < 0.0002"

  • Surface Finish:            < 28 Ra

  • Tool Life:                      > 70,000 - 2 bores

Accu-Cut Diamond Microcutting process generated 17.67 Cpk on bore size!!           

Objective: Replace costly DiHart Carbide Reamer

  • Tool:                         Adjustable Diamond Reamer

  • Machine:                  Heller HMC

  • Material:                   Ductile Iron

  • Stock Removal:        0.015"

  • Coolant:                   Water soluble

  • Holder:                     HSK-100A

  • Infeed:                      0.025 per rev

Heavy Duty Differential Case

Achievement:

  • Reduced CPU by a minimum of 125%

  • Diamond tool life outperformed carbide 200/1

Diesel Engine Crank Bore

Objective: Produce improved straightness and roundness over conventional honing and line boring.

  • Tool:                         Adjustable Diamond Reamer

  • Bore Size:                5.2500"

  • Machine:                  Transfer Line

  • Material:                   Ductile Cap / Gray Iron Block

  • Stock Removal:        0.008"

  • Coolant:                   Water soluble

  • Holder:                     Special Accu-Cut Floating Holder

Achievement:

  • Roundness:              < 0.0002"

  • Straightness:            < 0.0003"

  • Capability is 12% of tolerance

Accu-Cut's diamond microcutting process tightened production tolerance by over 800%.

V8 Cylinder Bore

Objective: 

  • Material:                   Gray Iron Block with compacted graphite cylinder liner

  • Bore Size:                 102.925mm +/- 0.025mm w/18mm relief

  • Machine:                   VMC

  • Stock Removal:         1.22mm/diameter

  • Passes:                     Rough, Finish

  • Roundness:               < 0.050mm

  • Straightness:             < 0.075mm

  • Coolant:                     Water Soluble, 1000 psi

  • Surface Finish:          40 Ra

Achievement:

  • Roundness:              < 0.005mm

  • Straightness:            < 0.005mm

  • Reduced piston ring wear due to improved straightness

  • Reduced secondary honing cost by at least 75%

  • Capability is 18% of tolerance

Automotive Differential Case

Objective: Replace costly roller burnishing process and improve surface texture.

  • Material:                      Ductile Iron

  • Bore Size:                   1.078"

  • Machine:                     Fuji Milling Machine

  • Stock Removal:           0.002"

  • Roundness:                 0.0002"

  • Straightness:               0.0003"

  • Coolant:                       Water Soluble Synthetic

  • Surface Finish:            < 20 Ra

Achievement:

  • Roundness:                 < 0.0001"

  • Straightness:               < 0.0002"

  • Surface Finish:            6 - 8 Ra

  • Eliminated costly roller burnishing, reducing CPU by minimum of 250%.

  • Increased tool life by 150x

Power Frame

Objective: Use Accu-Cut diamond reamer to increase tool life over existing carbide inserts.

  • Bore:                           Blind Bore / 0.625" relief

  • Material:                      Gray Iron

  • Bore Size:                   5.127"

  • Machine:                     HMC

  • Stock Removal:           0.010"

  • Roundness:                 0.0004"

  • Straightness:               0.0005"

  • Coolant:                       Water Soluble Synthetic

  • Surface Finish:            63 Ra Max

Achievement:

  • Roundness:                 < 0.0002"

  • Straightness:               < 0.0002"

  • Surface Finish:            < 20 Ra

Accu-Cut's diamond reamers improved tool life by a minimum of 300%, eliminating carbide inserts.

Steering Knuckle - Strut Bore

Objective: Size bore with 0.200" wide slot, top to bottom

  • Material:                      Ductile Iron

  • Bore Size:                   2.130"

  • Machine:                     VMC / HMC

  • Holder:                        HSK-100A

  • Stock Removal:           0.016"

  • Roundness:                 0.0005"

  • Straightness:               0.0005"

  • Coolant:                       Water Soluble

  • Surface Finish:            25 Rz

Achievement:

  • Roundness:                 < 0.0002"

  • Straightness:               < 0.0002"

  • Surface Finish:            < 10 Rz

Accu-Cut Diamond Microcutting tooling overcame slot in bore improving roundness and straightness by > 50%.

Turbocharger Main Bearing Bore

Objective:

  • Material:                     Gray Iron

  • Bore Size:                   0.6252"

  • Machine:                     Haas VMC

  • Holder:                        CAT 40

  • Stock Removal:           0.002"

  • Roundness:                 0.0001"

  • Straightness:               0.0002"

  • Coolant:                       Semi Synthetic

  • Surface Finish:            < 16 Ra

Achievement:

  • Roundness:                 < 0.0001"

  • Straightness:               < 0.0001"

  • Surface Finish:            < 8 Ra

Accu-Cut Diamond Microcutting process replaced carbide reamers on family of lower volume turbo chargers, reducing CPU by a minimum of 200%.

  • Engineered to your specific applications

  • Turnkey automation

  • Easily retooled for new applications

  • Built to last 30+ years

  • It can be yours for as little as 2.5¢ per part

  • Click HERE to learn more about Accu-Cut machines

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Machines

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