DIAMOND REAMERS

Turbocharger Push Rod Bore

CPU = 1.6¢ per piece

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

  • Material:                      Gray Iron

  • Bore Size:                   0.7880" +/- 0.00035"​​

                                          20.015mm +/- 0.0089mm

  • Machine:                     Makino A70

  • Holder:                        CAT 40

  • Stock Removal:           0.020" / 0.508mm

  • Roundness:                 0.0002" / 0.005mm

  • Straightness:               0.0002" / 0.005mm

  • Coolant:                       Water Soluble

  • Surface Finish:            63 Ra Max / 1.6 Ra Max

Achievement:

  • Roundness:                 < 0.0001" / 0.0025mm

  • Straightness:               < 0.0002" / 0.005mm

  • Surface Finish:            < 28 Ra / 0.7mm Ra

  • Tool Life:                      > 70,000 - 2 bores

  • Cycle Time:                 < 24 seconds         

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

turbocharger pushrod cpk 2.PNG

Process Performance

7% of tolerance

CPU:

1.6¢ per piece

Objective: Replace costly DiHart Carbide Reamer

  • Tool:                         Adjustable Diamond Reamer

  • Machine:                  Heller HMC

  • Material:                   Ductile Iron

  • Stock Removal:        0.015" / 0.38mm

  • Coolant:                   Water soluble

  • Holder:                     HSK-100A

  • Infeed:                      0.025" / 0.635mm per rev

Heavy Duty Differential Case

CPU = 2.1¢ per piece

Achievement:

  • Reduced CPU by a minimum of 125%

  • Diamond tool life outperformed carbide 200/1

  • Cycle Time:    < 20 seconds 

Diesel Engine Crank Bore

CPU = $0.005 per piece

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

  • Tool:                         Adjustable Diamond Reamer

  • Bore Size:                5.2500" / 13.335mm

  • Machine:                  Transfer Line

  • Material:                   Ductile Cap / Gray Iron Block

  • Stock Removal:        0.008" / 0.203mm

  • Coolant:                   Water soluble

  • Holder:                     Special Accu-Cut Floating Holder

Achievement:

  • Roundness:              < 0.0002" / 0.005mm

  • Straightness:            < 0.0003" / 0.008mm

  • Capability is 11% of tolerance

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

V8 Cylinder Bore

CPU = 2.1¢ per 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 / 1.0mm Ra

Achievement:

  • Roundness:              < 0.005mm

  • Straightness:            < 0.005mm

  • Cycle Time:              < 30 seconds 

  • Reduced piston ring wear due to improved straightness

  • Reduced secondary honing cost by at least 75%

  • Capability is 18% of tolerance

Automotive Differential Case

CPU = $0.009 per piece

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

  • Material:                      Ductile Iron

  • Bore Size:                   1.078" / 27.38mm

  • Machine:                     Fuji Milling Machine

  • Stock Removal:           0.002" / 0.05mm

  • Roundness:                 0.0002" / 0.005mm

  • Straightness:               0.0003" / 0.008mm

  • Coolant:                       Water Soluble Synthetic

  • Surface Finish:            < 20 Ra / 0.5mm Ra

Achievement:

  • Roundness:                 < 0.0001" / 0.0025mm

  • Straightness:               < 0.0002" / 0.005mm

  • Surface Finish:            6 - 8 Ra / 0.15 - 0.2mm Ra

  • Cycle Time:                 < 16 seconds 

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

  • Increased tool life by 150x

Power Frame

CPU = 2.8¢ per bore

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

  • Bore:                           Blind Bore w/ 0.625" relief / 15.875mm

  • Material:                      Gray Iron

  • Bore Size:                   5.127" / 130.23mm

  • Machine:                     HMC

  • Stock Removal:           0.010" / 0.25mm

  • Roundness:                 0.0004" / 0.010mm

  • Straightness:               0.0005" / 0.013mm

  • Coolant:                       Water Soluble Synthetic

  • Surface Finish:            63 Ra Max / 1.6mm Ra Max

Achievement:

  • Roundness:                 < 0.0002" / 0.005mm

  • Straightness:               < 0.0002" / 0.005mm

  • Surface Finish:            < 20 Ra / 0.5mm Ra

  • Cycle Time:                 < 18 seconds 

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

Steering Knuckle - Strut Bore 

CPU = 1.8¢ per piece

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

  • Material:                      Ductile Iron

  • Bore Size:                   2.130" / 54.10mm

  • Machine:                     VMC / HMC

  • Holder:                        HSK-100A

  • Stock Removal:           0.016" / .406mm

  • Roundness:                 0.0005" / 0.013mm

  • Straightness:               0.0005" / 0.013mm

  • Coolant:                       Water Soluble

  • Surface Finish:            25 Rz

Achievement:

  • Roundness:                 < 0.0002" / 0.005mm

  • Straightness:               < 0.0002" / 0.005mm

  • Surface Finish:            < 10 Rz

  • Cycle Time:                 < 33 seconds​ 

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

Turbocharger Main Bearing Bore 

CPU = $0.009 per piece

Objective:

  • Material:                     Gray Iron

  • Bore Size:                   0.6252" / 15.88mm

  • Machine:                     Haas VMC

  • Holder:                        CAT 40

  • Stock Removal:           0.002" / 0.05mm

  • Roundness:                 0.0001" / 0.0025mm

  • Straightness:               0.0002" / 0.005mm

  • Coolant:                       Semi Synthetic

  • Surface Finish:            < 16 Ra / 0.4mm Ra

Achievement:

  • Roundness:                 < 0.0001" / 0.0025mm

  • Straightness:               < 0.0001" / 0.0025mm

  • Surface Finish:            < 8 Ra / 0.2mm Ra

  • Cycle Time:                 < 14 seconds 

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

BSM 427 gears.jpg

Machines

button_email.png
button_phone.png