New SH-5000 horizontal honing machine is automation-ready for high-volume processing of smaller parts

Two-step honing capability ensures rapid metal removal with precise finish control. Horizontal configuration minimizes fixturing cost and enhances operator ergonomics.

Sunnen's new SH-5000 horizontal honing machine is a low-cost, automation-ready system for high-volume processing of smaller parts, such as gears, turbocharger bushings, valve components and pistol barrels. It handles parts with bore diameters from 1.5 to 101.6 mm (0.060" – 4.0"), and is capable of processing a wide variety of part sizes, configurations, and materials. The machine's 225-mm (9-inch) touchscreen control features infinite part program storage and intuitive setup and run screens to allow inexperienced operators to run the machine as efficiently as a veteran. "Saved" setups in the control ensure fast changeover and high productivity. An easy-to-change stroker fixture plate allows the machine to accept legacy Sunnen ML/EC style fixtures, and additional plates can be ordered to mount customer fixtures for quick changeover. A standard fixture air line control simplifies automation. In addition, generous free space is provided in the electrical enclosure for integrating automation components.

The SH-5000 is factory-equipped with cycle-time control to prevent glazing of the abrasives, and automatic size control to minimize cycle time. Its horizontal layout facilitates part loading and use of inexpensive gimbal-type fixtures, making the machine highly cost-effective for processing large lots of smaller parts. A clear adjustable guard/light curtain allows fast operator-friendly setups. Side access to the workzone enhances operator ergonomics during setup and facilitates integration with part-handling automation. High cutting pressure capability and two-step honing deliver fast stock removal coupled with a precise finish step, all in one operation. The machine's true-running ABEC seven-bearing spindle with direct collet connection allows quick changeover when using high-production MMT tooling. An easy-setup, runout-adjustable adapter enables use of standard Sunnen mandrels as well.

The SH-5000 has a 4.1-kW (5.5 hp) spindle drive and 2.5-kW (3.4 hp) stroker drive. Spindle speed is infinitely adjustable from 200 to 3,000 rpm, with stroke rates of 10 to 550 SPM. The machine's servo ballscrew stroker delivers extreme precision and repeatability for honing in blind bores, while a longer stroke length of 400 mm (15.75") allows the SH-5000 to take on deeper bores. For fastest setup, the machine's stroking system can be positioned with a joystick on the operator station.

The machine utilizes a Siemens touchscreen PLC and digital-servo drives with a patent pending servo-hybrid tool feed system for exceptional repeatability. Digital-servo tool feed and cutting pressure control produce consistent, predictable performance throughout the pressure range. Cutting pressure can be adjusted in 4.5 N (1 lbf) increments to a maximum of 2,224 N (500 lbf). The digital system provides superior feed control at low pressures for improved honing results with small-diameter parts. The control's new digital honing indicator is user-configurable. Other standard control features include zero shutoff, stone wear compensation, feed speed regulation (stone saver), spindle reverse, speed changes while in cycle, inch/metric selectable units, system diagnostics, cycle dwell, in-process short stroking and 13 operator languages.

The SH-5000 easily adapts to floor space limitations with an electrical cabinet that can be specified on the rear or either side of the machine. The machine complies with U.S. and European safety requirements.

For additional information on Sunnen honing systems, tools and abrasives, contact: Sunnen Products Company at sales@sunnen.com.