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Diamond Tool & Bore Sizing Systems
Adjustable Diamond Reamers

Reamers

Accu-Cut’s adjustable precision finish reamers outperform carbide reamers for improved statistical capability (2.0+ Cpk), longer tool life (250,000 pcs), and lowest per-piece cost.

Accu-Cut’s precision reamers can achieve well over 2.0 Cpk (process capability) by processing parts using a minimal amount of the allowable tolerances. Our diamond reamers often replace conventional tooling and processes such as carbide reamers and drills, traditional honing, and line boring. Our finish reamers have been proven to improve bore quality while reducing the cost per unit (CPU) by as much as 250% when compared to conventional methods.

turbocharger push rod bore
turbocharger push rod bore

Turbocharger Push Rod Bore

CPU = 1.6¢ per unit

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 / 1.6mm 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!!


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heavy duty differential case
heavy duty differential case

Heavy Duty Differential Case

CPU = 2.1¢ per unit

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

Achievement:

Reduced CPU by a minimum of 125%
Diamond tool life outperformed carbide 200/1
Cycle Time: < 20 seconds
Diesel Engine Crank Bore
Diesel Engine Crank Bore

Diesel Engine Crank Bore

CPU = $0.005 per unit

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 engine block reamer diamond tooling
v8 engine block reamer diamond tooling

V8 Cylinder Bore

CPU = 2.1¢ per unit

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
differential case
differential case

Automotive Differential Case

CPU = $0.009 per unit

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
power frame

Power Frame

CPU = 2.8¢ per unit

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
steering knuckle

Steering Knuckle - Strut Bore

CPU = 1.8¢ per unit

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 reamer
Turbocharger Main Bearing Bore reamer

Turbocharger Main Bearing Bore

CPU = $0.009 per unit

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%.

Want to learn more about our Adjustable Diamond Reamers applications?

CNC turnkey systems

CNC Turnkey Systems

Accu-Cut turnkey systems combine intelligent control, engineered tooling, and automation options to create stable, repeatable processes designed for high-volume manufacturing.

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