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1. 13 SPINDLE SPEED say SPINDLE SPEED STROKER SPEED EXTRA STROKES 000 7 7 7 7 14 STROKER SPEED STROKER 12 EXTRA STROKES SZECONTROL umara 42 AUTO 10 SIZE CONTROL ED 6 COOLANT 11 STROKING 9 EMERGENCY STOP 8 FEED 5 CYCLE START 4 CYCLE STOP 2 POWER ON 3 STROKER JOG 7 ASC PROBE 1 POWER OFF FIGURE 2 2 Operator Control Non CE Machines SUNNEN X O MIN ML 2 000 7 2 PRECISION HONING MACHINE FIGURE 2 3a Operator Controls CE Machines 9 SUNNEN X OMIN 14 15 6 4 3 7 2 1 FIGURE 2 3b Operator Controls CE Machines TABLE 2 1 Symbols used on Operator Controls CE Machines SYMBOL DESCRIPTION SYMBOL DESCRIPTION SYMBOL DESCRIPTION 1 POWER OFF 8 FEED 12 EXTRA STROKE H X 2 POWER ON 8 EXPAND 13 SPINDLE TOOL FEED X MIN SPEED 3 STROKER JOG 8 RETRACT 14 STROKER TOOL FEED SPEED CYCLE STOP 9 EMERGENCY WARNING VU STOP gt Hee 62 5 CYCLE START 10 SIZE Xo CONTROL 10 SIZE CONT 6 COOLANT ome SHUT OFF 6 CONSTANT 10 ASC COOLANT AUTO SIZE FLOW CONTROL 6 COOLANT ON DURING 11 STROKING CYCLE ONLY gt 7 ASC PROBE 11 MANUAL STROKING 1 7 MOVES
2. Sg GN OE 35 Workpiece amp Fixture Weight Limits 36 Universal Fixtures sci sae pas SOUS EA 36 Adjusting Finger Fixtures Seki hd Se EL SS US WRG alk 36 Torge SO og Gea Da 36 Hints e ysam sb Se anes adden sek ee ae a 36 Dip Switch Settings eke ees OG au suyus SS Sa OEE ee 36 B General Honing Information Good Honing Practices usa Sos ao eas Seah Sita he aaa 39 echnical Bd eR dC A b EL AC sa 39 Alteration Of Honing Units 2 ease awa Ss ad ak ls 40 Glossary Of Term S u sa eR Gale BOS Gack LR Nae Bead he bey Se dele 42 C Coolant System FLOW Dla SAM BUG ustus BERS 45 D Coolant Troubleshooting wis node ree os ais dvs whale Q ata aed tend Aah tg tata nua Gta 47 E Stroker Carriage Hole Pattern ukan y quy 48 GENERAL INFORMATION amp SPECIFICATIONS Sunnen Power Stroked Honing Machines Model
3. Disconnect Machine from main power supply allow drives to drain before any work is performed inside of Electrical Enclosure Ensure all Guards are in place and are in proper working order DO NOT override safety switches or lockouts Where interlocking systems rely on special actuators or keys DO NOT keep spare master actuators or keys on around or near machine e Use proper lifting procedures when loading unloading the Machine e Keep all non essential persons clear of work area Visitors especially children should not be permitted near the work area DO NOT use machine for other than its intended use Using these Machines for other purposes could result in damage to machine and loss of warranty Be sure to work in a well lit area and to use light supplied to avoid dangerous unseen conditions which may exist otherwise e Use ONLY factory authorized or recommended parts or replacement accessories Using parts or accessories other than those approved by Sunnen could result in damage to machine and loss of warranty Electrostatic discharge can damage the circuitry of the electronic components used in this Machine Use proper electrostatic controls when working with or around electronic components Ground Machine and use wrist strap to reduce the chances of static discharge e Residual Voltage exists for 2 3 minutes after Master ON OFF Switch is turned OFF Before working inside Enclosure wait for
4. sei hes 275591 FORMULAS MULTIPLY INCHES in x FEET ft 25 4 0 3048 7 0000 640625 16 2719 MILLIMETERS mm METERS m SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY Sunnen reserves the right to change revise specifications and product design in connection with any feature of our products contained herein Such changes do not entitle the buyer to corresponding changes improvements additions or replacements for equipment supplies or accessories previously sold Information contained herein is considered to be accurate based on available information at the time of printing Should any discrepancy of information arise Sunnen recommends that user verify discrepancy with Sunnen before proceeding PRINTED IN U S A 0407 whi SUNNEN SUNNEN PRODUCTS COMPANY 7910 Manchester Ave St Louis MO 63143 U S A Phone 314 781 2100 Fax 314 781 2268 U S A Toll Free Sales and Service Automotive 1 800 772 2878 Industrial 1 800 325 3670 International Division Fax 314 781 6128 http www sunnen com e mail MULTIPLY MILLIMETERS mm x METERS m x 1 062500 26 9880 BY 0 03937 3 281 TO GET INCHES in FEET ft SUNNEN PRODUCTS LIMITED No 1 Centro Maxted Road Hemel Hempstead Herts HP2 7EF ENGLAND Phone 44 1442 39 3939 Fax 44 1442 39 12 12 SU
5. sirit raeme tnt a Mowe Sabha os vii SECTION 1 INSTALLATION General 322225555592 92 a E ee ee AAA eee 1 Tools amp Materials saia nau sind pies tee a e eA OE a a eS 1 Installation e WE AA a ee 1 Side eb ceca yay asnu ig Pee ab we aes eos Sa Wanta 2 PNEUMALICS o WE y AAA a a en 3 Transformer Installation u seeds eee ee EIA E ee ed A 3 Electa ur yg qes ah oak dade kw ek a kaa Vsa a a ee ea S 3 Coolant 1 tes weds de ba eke er a Un Og De een bbe Sq 4 Automatic 5126 eae ak eed WIA A ek es De Nae ton 5 Optional Light Cuttam ce eed oe aa Ag sk ea a ein eb eee ete 6 SECTION 2 PREPARING FOR OPERATION Generale atc S Qi Gee OER ae 7 Major Components ze oss Be alsa hi Bind eee eg wataku TOUTS 7 Operator Controls erate eds a eae teas deus oe 8 Satety SYMDOIS sa os tout ss sunsu bode beads deer oes Beste Oe uses uk 13 5 asua Gi aka Udit sake eae i Maes PAG Wee 13 Pon
6. 11 UNLATCH PROBE UP WORKPIECE 7 MOVES 11 AUTOMATIC 7 PROBE DOWN 4 STROKING 10 20 HONING INDICATOR Needle shows feed system position This position corresponds to amount of stock to be removed from bore diameter if Zero Shut Off is size control mode Two scales have different levels of magnification A scale shows stock removal up to 2401 009 and scale shows stock removal up to 480p 018 21 FEED REGULATOR MAXIMUM RATE Feed Regulator is a system to limit maximum rate of feed MAXIMUM RATE dial is turned to set maximum feed rate limit On numbered scale larger numbers indicate faster maximum rates Setting dial to 9 or higher will effectively turn off regulator Note This system is similar to STONE SAVER feature on earlier model Sunnen Honing Machines 22 FEED REGULATOR INITIAL DIAMETER This knob sets feed system position at which Feed Regulator begins to limit maximum feed rate If stone and shoe wear are negligible or properly compensated then this position corresponds to a consistent tool diameter Counterclockwise rotation reduces diameter where Feed Regulator starts longer regulated honing cycle Clockwise rotation increases diameter where Feed Regulator starts shorter regulated honing cycle Turning knob clockwise until it stops will turn off Feed Regulator System 23 FOOT PEDAL Depressing Foot Pedal will start honing cycle if power is ON Feed system wedge travel is controll
7. 031496 0 8000 390625 9 9219 750000 19 0500 035433 0 9000 393701 10 0000 765625 19 4469 039370 1 0000 406250 10 3188 781250 19 8438 3 64 046875 1 1906 421875 10 7156 787402 20 0000 1 16 062500 1 5875 433071 11 0000 796875 20 2406 5 64 078125 1 9844 437500 11 1125 812500 20 6375 078740 2 0000 453125 11 5094 826772 21 0000 3 32 093750 2 3813 468750 11 9063 828125 21 0344 7 64 109375 2 7781 472441 12 0000 843750 21 4313 118110 3 0000 484375 12 3031 859375 21 8281 1 8 125000 3 1750 500000 12 7000 866142 22 0000 9 64 140625 3 5719 5181 13 0000 875000 22 2250 5 32 156250 3 9688 515625 13 0969 890625 22 6219 157480 4 0000 531250 13 4938 905512 23 0000 11 64 171875 4 3656 546875 13 8906 906250 23 0188 3 16 187500 4 7625 551181 14 0000 921875 23 4156 196850 5 0000 562500 14 2875 937500 23 8125 13 64 203125 5 1594 578125 14 6844 944882 24 0000 7 32 218750 5 5563 590551 15 0000 953125 24 2094 15 64 234375 5 9531 593750 15 0813 968750 24 6063 236220 6 0000 609375 15 4781 984252 25 0000 1 4 250000 6 3500 625000 15 8750 984375 25 0031 17 64 265625 6 7469 629921 16 0000 1 000000 25 4000
8. 634 15 88 15 62 16 10 5 0630 620 639 16 00 15 75 16 23 5 0641 41 64 631 650 16 27 16 03 16 51 5 0656 21 32 646 665 16 67 16 41 16 89 5 0672 43 64 661 680 17 00 16 79 17 27 5 0688 11 16 678 697 17 46 17 22 17 70 ASC 0703 45 64 697 716 18 00 17 70 18 19 5 0719 23 32 709 728 18 26 18 01 18 49 5 0734 47 64 724 743 18 65 18 39 18 87 5 0750 3 4 740 759 19 00 18 80 19 28 5 0766 49 64 756 775 19 45 19 20 19 69 ASC 0781 25 32 775 794 20 00 19 69 20 17 5 0797 51 64 787 806 20 24 19 99 20 47 5 0812 13 16 802 821 20 64 20 37 20 85 ASC 0828 53 64 818 837 21 00 20 78 21 26 5 0844 27 37 834 853 21 43 21 18 21 67 5 0859 53 64 853 872 22 00 21 67 22 15 5 0875 7 8 865 884 22 22 21 97 22 45 5 0891 57 64 881 900 22 62 22 38 22 86 ASC 0906 29 32 896 915 23 00 22 76 23 24 5 0922 54 64 912 931 23 42 23 17 23 65 5 0938 15 16 932 951 24 00 23 67 24 16 ASC 0953 61 64 943 962 24 21 23 95 24 44 ASC 0969 31 32 959 978 24 61 24 36 24 84 ASC 0984 63 64 972 991 25 00 24 69 25 17 5 1000 1 930 1 009 25 40 25 15 25 63 5 1016 1 1 64 1 011 1 030 26 00 25 68 26 16 FIGURE 2 13 Sensing Unit Setting Fixture m 1 2 2 y FIGURE 2 14 Attachment of Sensing Tip 16 workpiece that has already been honed to final size Set adjustment screw so that sensing tip lightly drags on honed bore Then back off adjusting screw about 1 4 turn T
9. FILTER ELEMENT SUNNEN ML 2000 POWER STROKED HONING MACHINE equipped with OPTIONAL PF 150 GRIT GUARD UNIT FILTRATION SYSTEM COOLANT MANIFOLD gt HIGH PRESSURE RELIEF VALVE 40 PSI MAX CANISTER FLOW CONTROL ON OFF VALVE LOW PRESSURE RELIEF VALVE 13 PSI MAX FLUID PUMP DIRTY FLUID SUNNEN ML 2000 POWER STROKED HONING MACHINE FILTER ELEMENT equipped with OPTIONAL ML 3490 COOLANT SYSTEM 46 COOLANT TROUBLESHOOTING IS IS CHECK WIRES PUMP OVERLOAD NO amp CONNECTIONS ROTATING 10L TRIPPED IF REPLACE MOTOR YES DOES RESET PUMP 10L ROTATION CORRESPOND SUPPLY CORD TO MACHINE CHECK WIRES amp CONNECTIONS IF NOT REPLACE COOLANT PUMP NOTE 4FU AND 5FU MUST BE 1 AMP FUSES OLDER MACHINES MAY HAVE SMALLER FUSES BUT MUST BE REPLACED WITH 1 AMP FUSES 47 STROKER CARRTIAGE HOLE PATTERN 98101 803 0 0F00 06E el 981001 803 999 3109 911001 803 9W11001 803 507039075 4 69 227 ASL 0710 n 292 52 7 REH TW 1 J 0 81 H9 0 1 t J A 2070 46 2 550 1140 79 016 9817001 04 12 52705406716 60 016 5
10. Seah Ze MRL a 27 Clean Bis sree ache eh oS RE OR RU ORM Ss 27 e cae ROE ls es eRe ea s P q Bae S gone 27 Routine Maintenance Schedule 1 1 44 14 1 7 2 27 Goolant Sy Stems a ae Aig tat 28 gets 28 bua ma Aaah 29 SECTION 5 TROUBLESHOOTING 2 Hoel dees Tak Eas ee Wt Ra EA aoe 31 Operational Troubleshooting be ae dk eee ea 31 Machine Operation Troubleshooting 1 2 32 Error Messages 32 Problems 8 4 2 7 1 0 32 TABLE OF CONTENTS cont d Page APPENDIXES A Special Topics be set SiGe ay AN AGS AA OS eg Gee 35 paket as E ee 35 ASC Unit Notes uya yuyu
11. ending cycle To prevent this turn Feed Regulator Initial Diameter knob on counterclockwise about 2 1 2 to 3 turns and turn Maximum Rate knob to fastest speed about 9 1 2 This will damp any feed rod vibration without lengthening cycle time and allow even very small amounts of material to be removed accurately PROBLEM Needle on Honing Indicator will not go all way to top of scale when Feed is Retracted SOLUTION Is Indicator Scale Honing Tool selector set to red D2 tool family If so it is normal for needle to rest about three quarters from bottom of scale when retracted This will not interfere with honing when using these tools If selector is not set to red D2 scale then Stone Feed dial has been turned back too far Advance Stone Feed dial counterclockwise until needle goes up past maximum scale reading PROBLEM When using Zero Shut Off when Feed Force is changed final bore size is different from previous workpiece SOLUTION This is normal Components in Feed System compress to a greater degree when feed force is greater This means anytime you reduce feed force needle on honing dial will rise and sub sequently final bore size will be greater than previous part Assuming stonewear is negligible or properly compensated Opposite is true when feed force is increased Therefore to avoid making oversized bores never reduce feed force by more than 0 5 without turning Stone Feed dial back clockwise
12. lt 15 in A 55 X 5 Z Elec a Y Y 0 749 470 lt 95 418511 1219 mm 48 1905 75 in l ML dy L i iL Py p aan 218 as j CLEARANCE 8 bp AREA OUTLINE LAYOUT Scale 1 4 in 1 ft 1 mm 48 mm Weight Installed Approximately 850 kg 1875 Ibs including coolant Floor Loading Less than 770 kg sm 160 lbs sf CENTERLINE OF SPINDLE NOSE 1010 mm 39 75 in y 1168 1118 gt lt 46 2286 44 90 SIDE VIEW FIGURE 1 A Floor Plan Layout System Configuration viii SECTION 1 INSTALLATION GENERAL Consult this section when unpacking inspecting and installing Sunnen ML 2000 Power Stroked Honing Machine see Figure 1 1 Hereafter referred to as the machine TOOLS amp MATERIALS The following tools and materials are required for unpacking and installing of your Machine Knife Hex Wrenches Hammer Open End Wrenches Crow Bar Cleaning Solvent Tin Snips INSTALLATION Read the following instructions carefully and thoroughly before unpacking inspecting and installing the machine All references to right and left in
13. machine verifies that foot pedal cycle start button is not pressed down to prevent any unexpected start up Error 2 Switch Has Changed During a Cycle In order for this error to occur one of the following switches was changed while machine was honing Expand Retract Size Control Mode Stroker Mode Finishing Feed Force Mode or Stroker Enable These switches cannot be moved during a honing cycle Error 3 Spindle or Stroker Speed Set to Zero A speed must be set for both spindle and stroker before machine can start a cycle Error 4 Safety System Was Triggered The safety system determined that an unsafe condition has occurred I e light curtain was broken Error 5 Workpiece Oversized The original workpiece was oversized The ASC probe never stuck workpiece If ASC is not being used this error should be bypassed See Appendix A Dip Switch Settings Error 6 ASC is Not Aligned Properly Extra Strokes count had decrement by three or more when an additional ASC probe hit was detected Error 7 Feed System is Expanded honing cycle cannot be started with feed system expanded Place feed selector switch to Retract Error 8 Stroker Was Unlatched A honing cycle cannot be started with stroker unlatched Place stroker mode selector switch to Auto Error 9 In Manual Honing Mode A honing cycle cannot be started with stroker mode in manual Place stroker mode selector switch to Auto Erro
14. on all other stones Honing dial STONE LOADED Clean stone with ncrease stroking Use a softer stone Use a coarser grit Check oil to be needle moves Stone surface looks LBN 700 dressing pressure one with a lower stone one with a sure you are using too slowly smeared and stick hardness number lower grit number Sunnen Industrial clogged with chips Honing Oil SLOW STOCK REMOVAL Increase spindle speed ncrease cutting Check oil to be Use a softer stone Use a coarser grit stone one with a lower grit number POOR STONE LIFE Honing dial needle moves too fast Decease cutting pressure Use faster spindle speed one with higher hardness number stone one with lower grit number Check oil to be sure you are using Sunnen Industrial Honing Oil shorten stone more if taper persists sleeve use hard tip stone hole BELLMOUTH True stone and shoes Use softer stone If Bore is LONGER Shorten STONE only If bellmouth persists with truing sleeve OK with lower than 2 3 stone length or row of stones shorten stones still If part is short or hardness number slightly on both ends more but do not shorten 022277772 unbalanced shorten shoes any further stroke length If Bore is SHORTER Shorten STONES and CAUTION 222222222 than 2 3 stone length SHOES equally to Overcorrection of 1 1 2 times bore bellmouth will lead length to barrel condition BARREL True stone and shoes Use finer grit stone Use longer stone or
15. Dip Switch Settings before making any dip switch changes Set EXTRA STROKES to STROKES Desired cycle time 1 5 x Stroker Speed 60 SPM seconds APPENDIX WORKPIECE amp FIXTURE WEIGHT LIMITS On ML 2000 workpiece and fixture is mounted on Stroker Carriage Because all this has to stroke during honing process it is desirable to keep weight of fixture to a minimum If fixture and workpiece weigh too much stroker speed may have to be reduced A general rule of thumb is If combined mass of workpiece and all fixturing mounted to carriage is less than 5 kg 11 Ib then strokes speeds recommended on chart on operator panel will be acceptable If combined mass of fixture and workpiece is greater than 5 kg 11 16 then stroke speed recommendations should be reduced by 10 for every kilogram over 5 kg 5 for every pound over 11 16 NOTE For safety always start heavy setups at 60 strokes per minute then while cycle is running turn stroke speed up slowly to desired speed If at any point stroker begins to knock labor or vibrate excessively then reduce stroke speed to a point that is no more than 80 of that speed UNIVERSAL FIXTURES ML 2000 is equipped with a standard Universal Fixture see Figure A 1 Universal Fixture is com pletely adjustable so that virtually all workpieces can be stroked automatically workpieces are captured axially but not held rigidly so that they can float on tool so t
16. SENSING NOMINAL DIAMETER RANGE NOMINAL DIAMETER RANGE PART NUMBER DIAMETER LOW HIGH DIAMETER LOW HIGH 5 0125 1 8 120 139 3 18 3 05 3 53 ASC 0141 9 64 135 154 3 57 3 42 3 91 5 0415 5 32 150 169 4 00 3 81 4 29 5 0172 11 64 166 185 4 36 4 22 4 70 ASC 0188 3 16 180 199 4 76 4 57 5 05 ASC 0203 13 64 191 210 5 00 4 85 5 33 5 0219 7 32 211 230 5 56 5 36 5 84 5 0234 15 64 226 245 6 00 5 74 6 22 5 0250 1 4 240 259 6 35 6 10 6 58 5 0266 17 64 256 275 6 75 6 50 6 99 5 0281 9 32 269 288 7 00 6 83 7 32 5 0297 19 64 2 7 306 7 54 7 29 7 77 ASC 0312 5 16 1304 323 8 00 7 72 8 20 ASC 0328 21 64 1318 1337 8 33 8 0 8 56 ASC 0344 11 32 334 353 8 73 8 48 8 97 5 0359 23 64 347 1366 9 00 8 81 9 30 5 0375 3 8 365 384 9 53 9 27 9 75 5 0391 25 64 383 402 10 00 9 73 10 21 5 0406 13 32 396 415 10 32 10 06 10 54 ASC 0422 27 64 412 431 10 72 10 47 10 95 ASC 0438 7 16 426 445 11 00 10 82 11 30 ASC 0453 29 64 443 462 11 51 11 25 11 74 5 0469 15 32 461 480 12 00 11 71 12 19 ASC 0484 31 64 474 493 12 30 12 04 12 52 5 0500 1 2 490 509 12 70 12 45 12 93 5 0516 33 64 505 524 13 00 12 83 13 31 5 0531 17 32 521 540 13 50 13 23 13 72 ASC 0547 35 64 540 559 14 00 13 72 14 20 5 0562 9 16 552 571 14 29 14 02 14 50 0578 37 64 568 587 14 68 14 43 14 91 ASC 0594 19 32 583 602 15 00 14 81 15 29 5 0609 39 64 599 618 15 48 15 22 15 70 5 0625 5 8 615
17. Use mandrel with CAUTION with truing sleeve one with higher grit shorten guide shoes longer stone and shoe Overcorrection of number on both ends barrel will lead to bellmouth condition TAPER IN True stone and shoes Change stroke so tight Reverse work on If power stroking make OPEN HOLE with truing sleeve end of bore is stroked mandrel more often sure spindle and stroker over stone further are in alignment TAPER IN Shorten stone and True stone and shoes If hole has insufficient Provide sufficient Provide adequate oil BLIND HOLE shoes to about 3 4 frequently with truing or no relief at bottom relief at bottom of flow at bottom of hole to wash cutting out OUT OF ROUND Make sure honing tool is recommended size for diameter to Thoroughly true stone and shoes to exact hole diameter If thin wall part decrease cutting pressure If stone stops cutting at decreased pressure use stone with lower If power stroking make sure spindle and stroker are in L122 length should be at least 1 1 2 times the length of bore for best bow correction length less overstroke hardness number to avoid part flexing be honed hardness number alignment WAVINESS Use honing tool with sufficient stone length to bridge waviness or lands and ports in bore RAINBOW Use L BL or multi stone mandrel Stone Use shorter stroke Use stone with lower FINISH TOO ROUGH Decrease cutting pressure Use finer grit stone one
18. Warranty does not apply to the following Normal maintenance items subject to wear and tear belts fuses filters etc Damages resulting from but not limited to Shipment to the customer for items delivered to customer or customer s agent Shipping Point gt Incorrect installation including improper lifting dropping and or placement gt Incorrect electric power beyond 10 of rated voltage including intermittent or random voltage spikes or drops gt Incorrect air supply volume and or pressure and or contaminated air supply gt Electromagnetic or radio frequency interference from surrounding equipment EMI RFI gt Storm lightning flood or fire damage gt Failure to perform regular maintenance as outlined in SPC manuals Improper machine setup or operation causing a crash to occur Misapplication of the equipment gt Use of non SPC machines tooling abrasive fixturing coolant repair parts or filtration gt Incorrect software installation and or misuse Non authorized customer installed electronics and or software Customer modifications to SPC software THE LIMITED WARRANTY DESCRIBED HEREIN IS EXPRESSLY IN LIEU OF ALL ANY OTHER WARRANTIES SPC MAKES NO REPRESENTATION OR WARRANTY OF ANY OTHER KIND EXPRESS OR IMPLIED WHETHER AS TO MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE OR ANY OTHER MATTER SPC IS NOT RESPONSIBLE FOR THE IMPROPER USE OF ANY OF ITS PRODUCTS SPC SHALL NOT BE LIABLE FO
19. all fans to stop running to allow drives to drain OPERATING TIPS The ML 2000 can be setup and operated a number of different ways The use of many features is optional Not all features are beneficial in any given application Appendix A explains some of these optional features and outlines some guidelines for determining when they might be beneficial Usually experimentation will be required to find optimum setup Although ML 2000 is intended for production honing manual stroked honing is possible Manual honing should only be used for honing a very small number of workpieces such as for tooling or repairs The ease of setting up stroker and fixture makes it practical to power stroke even as few as five or ten workpieces Power stroking is always more precise more consistent and safer SETUP MANUAL HONING Follow ALL steps for manual honing carefully and in the order listed ALWAYS start with Feed Force set to no more than 1 1 and Spindle Speeds set to no more than 1 2 of recommended speeds The danger of manual hon ing increases as speed or feed force is increased For Models CE amp CD When finished manually honing return Stroker Key Switch to ENABLE and remove Key so that spindle can not start if an operator is in work area 1 Press Emergency Stop to clear any previous setup 2 Turn OFF coolant supply by turning Main Valve on Coolant Manifold fully clockwise 3 If ASC unit is attached to machine loose
20. amp Figure 2 12 NOTE sensing tip is adjustable to any size within its diameter range However once adjusted to a bore size near maximum sensing tip may take a permanent set and not return to minimum sizes Therefore it may be necessary to have more than one sensing tip if you have more than one application with different sizes within same diameter range Also changeover time from one job to next will be minimized if once adjusted a sensing tip is dedicated to one particular application only All four segments of sensing tip or sensing unit must contact taper on adjustment screw If one or more seg ments has been bent away from screw then back out screw and squeeze sensing tip back into shape If final bore size is smaller than 26 mm 1 03 skip steps 3 through 10 and go to step 11 3 If using Sensing Unit back out adjustment screw until it is loose in sensing body Then tighten this screw one full turn after initial contact is made between tapered portion of adjusting screw and sensing body This initial setting of adjustment screw will allow you to increase or decrease sensing unit size when final size adjustment is made 4 Determine proper micrometer setting for ASC 50 Setting Fixture or ASC 50M Metric Setting Fixture by following formula Desired Bore Size 1 25 4mm 2 Set micrometer to this size and lock micrometer spindle 5 Adjust sensing screws in sensing body so that size is somewhat sm
21. are worn They can also be used to help compensate for mandrel runout 40 ALTERATION OF HONING UNITS HOW TO ALTER STONES MANDREL AND SHOES When alteration of honing stone is necessary cut through abrasive with an old hacksaw blade and break unwanted section of stone from stoneholder with a pair of pliers Do not cut into die cast stoneholder except as described under blind hole alterations Use a file or bench grinder to shorten guiding surfaces of shoe Both stone and guide shoe should be altered identically and in same relative position ALTERATIONS FOR SHORT OPEN HOLES Always consider possibility of stacking parts with short bores so that they may be honed as one long bore using standard honing units Individual parts if they have at least one flat face with bore lengths of 1 4 diameter or less can also be honed by holding parts flat against face plate of square honing fixture For precision sizing of short open holes STONE AND GUIDE SHOE LENGTH SHOULD BE BETWEEN 2 3 and 1 1 2 TIMES BORE LENGTH to be honed ALTERATION FOR SHORT OPEN HOLES COMPLETED ALTERATION FOR SHORT OPEN HOLES ALTERATION OF HONING STONE WEDGE CONTACTS GUIDE SHOE Z REMOVE STONE AS SHOV w ALTERATION OF INTEGRAL GUIDE SHOE SS REMOVE GUIDE SHOE AS SHOWN ALTERATION OF REPLACEABLE GUIDE SHOE REMOVE GUIDE SHOE AS SHOWN When alteration is necessary both stone and guide shoe must be shortened by same amount Any
22. change these settings unless specified by a Sunnen Representative B3 Stroke Count Honing Turning this switch on tells ML 2000 to hone for number of strokes set in Extra Strokes display This is useful for deburring or polishing operations The machine must be in ASC mode of operation for this switch setting to take effect B4 Ignore ASC Alignment Error In ASC mode if the plunger is struck after 3 misses during extra strokes the machine determines that the ASC is in misalignment Turning this switch on will prevent ML 2000 from reporting Error 6 condition B6 B8 Not used These switches are not currently used by ML 2000 They should be placed in OFF position 5 38 GENERAL HONING INFORMATION GOOD HONING PRACTICES ALWAYS DEBURR A ROUGH HOLE If a bore is rough or has burrs prior to honing a quick deburring operation with a very hard deburring stone prevents damage to stock removal or finishing stone reduces stone costs and speeds up production HONE BEFORE HARDENING When a part is to be hardened always hone first leaving only as little stock as necessary to correct heat treat distortion When needed use a deburring stone to remove heat treat scale prior to sizing and finishing operation AMOUNT OF STOCK FOR HONING Previous operation should leave just enough stock so that tool
23. compounded for honing needs It keeps stone clean and sharp reduces stone wear increases rate of stock removal and is invaluable in producing fine surface finishes A free flow of honing oil should be provided both for Sunnen Honing Machines and for 39 Sunnen Portable Hones Do not dilute cut or change honing oil in any way LONGER STONE LIFE May be obtained by easing stone into bore when starting honing operation When in use feed regulator does this automatically When not using feed regulator stone can be damaged by tramping on pedal especially in a rough bore KEEP STONE CUTTING PRESSURE LIGHT Just heavy enough to get good cutting action Excessive stone pressure will only increase stone wear it will not make stone cut faster UNUSUAL HONING PROBLEMS Can be referred to Sunnen Honing Laboratory Be sure to include all data concerning problem such as tolerances surface finish requirements stock removal type of material material hardness and production quantities REMOVING WORKPIECE FROM MANDREL Never begin removing workpiece from mandrel until spindle stops When pedal is released or automatic shutoff occurs your spindle should also stop HONING DIAL Each number on dial indicator is equal to a certain amount of stone expansion To determine this refer to chart on front of machine HONING STONE Select from Honing Supplies Catalog from stone cabinet or from SMOPS Guide WORN OUT MAND
24. correct size to fit bushing hole size and screw onto stud on Probe Body Center Probe Body in ASC Arm by loosening Probe Clamp Knob repositioning and reclamping Turn ASC PROBE selector switch to UP Loosen Clamp Knob and slide ASC unit forward until Probe meets bushing bore Retighten Clamp Knob Loosen Angle Plate screw and reposition Angle Plate to set Probe at same height as bushing hole Retighten Angle Plate screw To help guide Probe toward work piece loosen Bumper screw slide Bumper to contact Fine Position Rod and retighten screw 5 Set horizontal position of Probe Note distance from center of Probe to center of bushing lu FIGURE 1 13 Light Curtain Loosen Clamp Knob and slide ASC unit toward front of machine to access two Base screws Loosen two Base screws and slide Base along screw slots distance noted Retighten Base screws and slide ASC unit forward to bring Probe in front of bushing Probe should be centered in front of bushing Set this horizontal position so that Clamp Knob will not touch machine frame when ASC Unit is slid along Rail LIGHT CURTAIN Opt CE Machines Only CE machines come with optional Light Curtain and guarding installed Light Curtain alignment is preset at the factory Light Curtain Set consists of a Transmitter and Receiver Unit see Figure 1 13 Indicator Light on bottom of light curtains Transmitter Yellow indicat
25. force STONE FEED DIAL or damage to feed system may result 12 Pull Mandrel Wedge straight back as far as possible 13 If required install Spindle Sleeve LN 570A not supplied with machine on Honing Unit 14 Rotate spindle by hand until large set screw is up 12 o clock position 15 With set screw indentation on honing unit in 9 o clock position insert honing unit as far as it will go Rotate honing unit 1 4 turn clockwise to engage wedge with feed rod then push honing unit all way in until it bottoms 16 Test wedge hookup by pulling honing unit straight out do not rotate If wedge is hooked up it will not allow unit to come out If honing unit comes out repeat step 16 Push honing unit back in until it bottoms 17 Tighten large set screw in spindle 18 Release Emergency Stop and turn power on NOTE Steps 20 through 29 are instructions for truing stone and shoes of honing tool Truing is not always necessary If you don t need to true mandrel then skipping these steps can save considerable time in set up See Appendix A for guidelines on when truing is necessary and when it can be considered optional 19 Set STROKING selector to MANUAL Set STROKER key switch to DISABLE 20 Turn SIZE CONTROL selector to ZERO SHUT OFF 21 Set Feed Force Dial to some low value approxi mately 1 for tools smaller than 6 mm 25 1 2 for larger tools CAUTION When truing always start at a low feed
26. force for safety 22 Reduce Mandrel Runout refer to Section 2 23 Set Spindle Speed for truing Use chart on operator station as a guideline for determining speed WARNING Recommended speeds may not be suitable for all applications For MANUAL HONING and TRUING always start with a speed that is no more than half speed recommended on chart then increase speed in small increments only when job seems to be running safely Never exceed recommended speed when manually honing or truing 22 24 Position Stroker Carriage for manual honing Push Stroker Carriage back until it stops Turn STROKING selector to MANUAL Set STROKER LENGTH to 6 mm 1 4 in Loosen Stroke Position Lock and turn Stroke Position Handwheel to move Stroker Carriage in until it stops Tighten Stroke Position Lock 25 Remove any fixturing components that do not provide adequate clearance for manual honing 26 True mandrel and stone refer to Section2 27 Return Spindle Speed setting to zero for safety 28 Set Feed Force to desired level 29 Eliminate conical and parallel spindle runout refer to Section 2 30 Set stroke length Loosen Stroke Length Lock on front panel 1 4 turn is usually sufficient and turn Stroke Length Handwheel until Stroke Length Indicator is aligned with desired stroke length For most applications set stroke length to a value that is 95 of bore length or abrasive length whichever is longer See St
27. in Gate Fixture or other stroking fixture and close fixture so that workpiece is captured for stroking 3 Turn POWER ON 4 Turn COOLANT to CONSTANT to check flow of coolant to tool and workpiece Return selector to CYCLE ONLY if that is desired mode of operation 5 Start cycle by either pressing Cycle Start or stepping on Foot Pedal In general it should be not necessary to use Foot Pedal for operation However by using it on first workpiece you can make feed system engage workpiece slowly to possibly prevent damage from an improper setup NOTE Cycle stop can interrupt any cycle before final size has been reached 6 When cycle stops automatically gage final bore size WARNING To avoid personal injury allow stroker and spindle to come to a complete stop before removing workpiece 24 FIGURE 3 2 Coolant Line 7 If you are using ZERO SHUT OFF for size con trol then move STONE FEED dial to adjust size if size is not correct NOTE STONE FEED dial has some backlash If you must feed down always feed down beyond and then up to point desired CAUTION Advancing STONE FEED dial while machine is running is not recommended 8 If you are using ASC then adjust final bore size by either adjusting screw in sensing tip or by changing number of extra strokes Large adjustments should be made by adjusting sensing tip Small adjustments can be quickly and conveniently made by changing nu
28. is clean and clear of unnecessary materials particularly common plastics Anti static bubble wrap has been included for use at the machine when an ESD safe workstation is not available You are now properly grounded and ready to begin work Following these few simple rules and using a little common sense will go a long way toward helping you and your company in the battle against the hazards of static electricity When you are working with ESD sen sitive devices make sure you GROUND ISOLATE NEUTRALIZE SUNNEN LIMITED PRODUCT WARRANTY Sunnen Products Company and its subsidiaries SPC warrant that all new SPC honing machines gaging equipment tooling and related equipment will be free of defects in material and or workmanship for a period of one year from the date of original shipment from SPC Upon prompt notification of a defect during the one year period SPC will repair replace or refund the purchase price with respect to parts that prove to be defective as defined above Any equipment or tooling which is found to be defective from improper use will be returned at the customer s cost or repaired if possible at customer s request Customer shall be charged current rates for all such repair Prior to returning any SPC product an authorization RMA and shipping instructions must be obtained from the Customer Service Department or items sent to SPC will be returned to the customer Warranty Limitations and Exclusions This
29. marked on pump indicates proper direction for rotation If pump is rotating backwards turn power off and turn off main power supply to machine Reverse any two leads from electrical supply cord coming into machine Do not change any machine or motor wiring or pump may not rotate in right direction if coolant system is moved to another machine 4 Connect Quick Connect Coupling from bottom of Drip Tray to Pump Outlet see Figure 1 10 5 Foot pedal assembly must slide under coolant cart as coolant cart is pushed in First make sure machine power is off of safety latch and replace foot pedal cover When replacing cover reach inside and hold safety latch up Make sure that latch will be held up by brace on inside of foot pedal cover see Figure 1 11 Squeeze lower front corners of cover together to insert pins on cover in holes on foot pedal base plate 9 Push coolant cart into machine Be sure that flexible conduit retracts into opening in machine base as cart is pushed in 10 Place cart in a position where no coolant can escape work area and where operator has comfortable access to front panel and work area Lock casters on coolant cart to keep it from moving during operation 11 Pour coolant into drip tray and let drain down to cart below Watch coolant level gage during filling Do not overfill coolant system Level of reservoir should be below to high mark on fluid level gage or coolant will overflow onto floor W
30. marks can be cleaned up and bore inaccuracies corrected Less stock allowance is needed for Sunnen honing because Sunnen Honing Units are self center ing in bore When going from a stock removal to a surface finishing operation leave only enough stock to remove cross hatch pattern of coarser stone usually only a few ten thousandths of an inch PROVIDE RELIEF IN BLIND HOLES Honing of a blind hole can be greatly assisted by providing relief in bottom corner of bore This allows for at least some overstroking The relief need be only a few thousandths deep and can even blend as hole is honed The ideal length of relief is 1 3 stone length Any length of relief is much better than none PARTS CAN BE STACKED Frequently parts with short bores can be stacked and honed as one long bore Parts must have flat and parallel faces KEEP YOUR HONING TOOLS TRUE Cutting surface of stone and guide surfaces of shoes must be kept straight and parallel to produce accurate work Occasional use of a truing sleeve will assist in keeping tools true USE ONLY PROPER HONING OIL Best honing results are obtained only when proper Sunnen Industrial Honing oil is used Cutting oils coolants and other fluids are generally not satisfactory for honing and may result in excessive stone wear or glazing low stock removal rates and poor surface finish and frequently cause galling or scoring of part Sunnen Industrial Honing Oil is especially
31. or if very fine finish is required bronze guide shoes are recommended Should your particular application require special guide shoes not described in our catalog please contact Customer Service Department Industrial Division in St Louis or your local Field Engineer IMPORTANT Guide shoes of different materials should never be mixed on a multi stone length mandrel When shoes are removed from a mandrel to be used later they should be re assembled in their original position WEDGES Wedges are subject to wear and to assure best performance they should be replaced when they show signs of wear Old wedges should be discarded Wedges supplied with all permanent type mandrels have long life but should be inspected regularly and replaced if showing any wear This is especially important in AK20 BAL20 AL20 and Y32 honing unit groups WEDGE PLATES High and low wedge plates are supplied with Y Keyway mandrels of 35 mm 1 365 size and larger to provide coverage of mandrel diameter range even with worn guide shoes and stones Use low wedge plate e g YS6L W unless stone cannot be expanded far enough to reach diameter to be honed within range of honing unit Use high wedge plate e g YS6H W when necessary to reach diameter to be honed SHIM MANDREL SHIMS Furnished with all P28 honing units They are inserted between mandrel body and guide shoe when necessary to reach maximum diameter especially when guide shoes
32. provides valuable information for proper installation operation and maintenance of your equipment Troubleshooting information can also be found within the Instructions If you cannot find what you need call for technical support Where applicable programming information for your Sunnen equipment is also included Most answers can be found in the literature packaged with your equipment Help us help you When ordering parts requesting information or technical assistance about your equipment please have the following information available Have ALL MANUALS hand The Customer Services Representative or Technician will refer to it Have Model Number and Serial Number printed on your equipment Specification Nameplate Where Applicable Have Drive model and all nameplate data Motor type brand and all nameplate data For Troubleshooting additional information may be required Power distribution information type delta power factor correction other major switching devices used voltage fluctuations Installation Wiring separation of power amp control wire wire type class used distance between drive and motor grounding Use of any optional devices equipment between the Drive amp motor output chokes etc For fast service on your orders call Sunnen Automotive Customer Service toll free at 1 800 772 2878 Sunnen Industrial Customer Service toll free at 1 800 325 3670 Customers outside the USA conta
33. switch sets size control mode 2 ZERO SHUT OFF Honing cycle will end when needle on Honing Indicator reaches zero This corresponds to a consistent feed system position If stone and shoe wear are negligible or properly compensated then this position will correspond to a consistent final bore size ASC Automatic Size Control unit will determine when honing cycle is complete by checking workpiece bore size with a plug gage type probe once every stroke 11 STROKING Three position selector switch sets stroking mode lt MANUAL Stroker will not operate in this mode Stroking must be done manually Honing cycle can be started only with Foot Pedal 5 UNLATCH In this mode Stroker Carriage is disengaged from power stroking unit This mode is used only during setup Machine will not run in this mode AUTOMATIC Stroker will operate during honing cycle at speed and stroke length selected Cycle can be started with Foot Pedal or CYCLE START button x 12 EXTRA STROKES After size control device either Zero Shut Off or ASC signals completion of honing cycle honing cycle will continue for number of strokes shown on display before stopping Return to center selector switch changes number of extra strokes up or down to a maximum of 99 If ASC mode of size control is selected but ASC unit is disconnected then honing cycle will be a timed cycle lasting for only number of strokes displayed on counter rom 13 SPINDLE
34. the price evidenced by your receipt Receipt SPC grants to you as Licensee a non exclusive right without right to sub license to use the particular copy of the SPC Software licensed hereunder only on the particular equipment sold with the Software SPC reserves all rights including rights not otherwise expressly granted and retain title and ownership to the Software including all subse quent copies or updates in any media The Software and all accompanying written materials are covered by copyrights owned by SPC If supplied on removable media floppy disk you as Licensee may copy the Software only for back up purposes or you may request that SPC copy the Software for you for the same purposes All other copying of the Software or of the accompanying written materials is expressly forbidden and is in violation of the Agreement The Software and accompanying written materials including the user s manual if any are provided an is condition without warranty of any kind including the implied warranties of merchantability and fitness for a particular purpose even if SPC has been advised of this purpose SPC specifically does not warrant that it will be liable as a result of the operation of the Software for any direct indirect consequential or accidental damages arising out of the use of or inability to use such product even if SPC has been advised of the possibility of such use It is recognized that some states do not allow the exclu si
35. these instructions unless otherwise noted are as seen by operator as one looks at machine or assembly being described refer to Figure 1 1 FRONT NOTE When ordering parts for or requesting information about your Machine include Model and Serial Number printed on Nameplate of your Machine 1 Remove banding straps and shipping crate from around Machine 2 Remove all loose components and boxes packaged with your Machine 3 Inspect Machine and components for dents scratches or damage resulting from improper han dling by carrier If damage is evident immediately file a claim with carrier CAUTION MACHINE IS VERY HEAVY Use care when lifting and moving Machine 4 Lift Machine using a 6 ton forklift see Figure 1 2 NOTE Only qualified riggers familiar with moving and setting of large and heavy machinery should be permitted to handle Machine Machine is a precision machine and should be handled with the utmost care To lift and move ML 2000 fork only from front or rear of machine Place one fork under machine base and one under electrical enclosure but close to machine base Structural steel under electrical enclosure is welded to machine base to prevent actually lifting machine by enclosure FIGURE 1 1 Power Stroked Honing Machine FIGURE 1 2 Fork Lift CAUTION Foot Pedal and its conduit to machine are located loosely in front opening of machine Be careful not
36. to pinch conduit with forks Place Foot Pedal assembly on a fork so that it does not drag when moving machine 5 Move Machine to desired location NOTE Machine should be locate on a leveled concrete floor away from heavy traffic Allow 457 mm 18 in from rear of machine to any adjacent walls and 1 mm 3 ft from right side of machine to any adjacent walls to give the operator room to service Machine There should be an overhead track and chainfall located directly over Machine to aid in head installation If no overhead track is available allow ample space around Machine for use of a portable hoist stand for heavy lifting 6 After machine is placed in desired location it will be necessary to stabilize machine with screw located on bottom of right rear corner of machine base For best results place a small block of steel 5 to 8 mm thick 3 16 to 5 16 under stabilizing screw Adjust screw until machine cannot be made to rock on two corners Then tighten jam nut to lock screw in place 7 Open machine covers use a 4mm hex key wrench to release quarter turn latch near rear corner of each cover Place hood prop securely into bracket on hood to hold it open see Figure 1 3 8 After removing packing material from inside machine close both hoods and make sure hoods are latched securely WARNING Hoods do not need to be opened for setup Never have hoods open when power is on Access to internal systems is only neces
37. with higher grit number Check oil to be sure you are using Sunnen Industrial Honing Thoroughly true shoes to exact hole diameter For extremely fine finishes in soft or exotic material use bronze mandrel or bronze shoes RANDOM SCRATCHES Decrease cutting pressure Use finer grit stone one with higher grit number Use softer stone one with lower hardness number If hard steel mandrel is being used change to soft steel mandrel If soft steel mandrel or shoes are being used change to bronze mandrel or shoes Check oil to be sure you are using Sunnen Industrial Honing Oil Many honing problems such as poor cutting action poor stone life and rough finish are caused by wrong honing oil insufficient honing oil dirty honing oil or contaminated honing oil Use only clean full strength Sunnen Industrial Honing Oil Make sure that honing oil is neither diluted or cut with other oils Keep solvents and cleaning fluids away from honing machine 31 MACHINE OPERATION TROUBLESHOOTING Error Messages ML 2000 has built in error messages that will appear in spindle speed screen to alert operator when machine has stopped due to an error or incorrect setup The following is a list of errors and directions on how to clear them Once problem is resolved pressing Cycle Stop button will clear error from display Error 1 Unexpected Start Signal When power is turned on
38. workpieces then truing should be considered A new stone or a used stone placed in an application with a different bore size will not make full contact with bore until it has worn a radius to match bore Before it does this stonewear will be high and cutting rate may be excessively fast Turn feed force down until stone has worn to where it is making full contact with bore NOTE Truing should NOT be considered optional in following situations Honing bores with keyways or similar interruptions where full contact is required for stones to bridge keyway Very close tolerance work where a high degree of cylindricity is required When stone and shoes have worn grossly out of parallel from continued use of a bad setup ASC Unit Notes 1 Disconnecting and Removing If Automatic Size Control Unit is not necessary for an application it can be removed from machine if it is in way of fixturing Disconnect electrical cable and two air lines where they enter machine to left of spindle Air fittings here are self sealing so there is no need to plug ports Loosen Clamp Screw on ASC unit several turns until unit can be lifted free from its guiding rail 2 Timed honing cycles For applications where some deburring or polishing is required for just a small amount of time ML 2000 can be setup to produce cycles of consistent duration This type of operation is available by placing dip switch B3 in ON position See Appendix A
39. 0 00 1 12 1981100 803 p R IRR 48 APPENDIX 000 52 1 4 k lt 4 11 17 3108 55 8 uwy 0 0 gpro t0 0 5 49 5 50 Like any machinery this equipment may be dangerous if used improperly Be sure to read and follow instructions for operation of equipment 51 FRACTION DECIMAL MILLIMETER EQUIVALENTS CHART NCH DECIMAL 003937 FRACTION INCH MILLIMETER FRACTION 0 1000 DECIMAL 281250 7 1438 MILLIMETER FRACTION NCH DECIMAL 656250 MILLIMETER 16 6688 007874 0 2000 296875 7 5406 669291 17 0000 011811 0 3000 312500 7 9375 671875 17 0656 015625 0 3969 314961 8 0000 687500 17 4625 015748 0 4000 328125 8 3344 703125 17 8594 019685 0 5000 343750 8 7313 708661 18 0000 023622 0 6000 354331 9 0000 718750 18 2563 027559 0 7000 359375 9 1281 734375 18 6531 031250 0 7938 375000 9 5250 748031 19 0000
40. 11 Runout Indictor Gaging Point SENSING SCREW SENSING TIPS FOR DIAMETERS 1 8 to 1 1 64 in 3 18 to 26 mm FIGURE 2 12 Sensing Tip 16 When finished truing return STROKER key switch to ENABLE and remove key RUNOUT CONICAL amp PARALLEL Eliminate conical and parallel spindle runout as follows NOTE Mandrel runout should be adjust and mandrel and stone should be trued before adjusting for conical and parallel runout 1 Select a concentric alignment bushing with a bore size close to final honed bore size see Sunnen Honing Supplies Catalog Place alignment bushing on mandrel so that it is centered on stone and shoe section of mandrel see Figure 2 9 WARNING Do NOT step on foot pedal to lock alignment bushing on mandrel Spindle will turn if foot pedal is depressed 2 Turn FEED selector to EXPAND to lock alignment bushing on mandrel Look to Honing Indicator If needle reads somewhere on scale then alignment bushing is properly locked on If not turn STONE FEED DIAL until there is an indicator reading Turn Dial same direction as you wish needle to move 3 Release stroker carriage and pull it out toward front of work area 4 Attach RUNOUT INDICATOR supplied with machine to threaded stroker drive shaft as shown see Figure 2 10 Position aluminum indicator base so that letters EC are up and facing you with that surface approximately level Move clamp handle
41. ARNING Never remove foot pedal cover with power on Machine cycle will start any time foot pedal is depressed with power on 6 Squeeze lower front corners of foot pedal cover together to disengage it from foot pedal assembly and lift it off Lift safety latch with a finger and depress foot pedal by hand Release safety latch and then release pedal Pedal will be locked in an intermediate position so that whole assembly can slide underneath coolant cart 7 Pull foot pedal assembly under coolant cart so that it is in front of cart 8 Push down on foot pedal Lift foot pedal safety latch and hold it up while releasing foot pedal Let go NOTE Use only Sunnen Industrial Honing Fluids Substituting other cutting fluids or diluting Sunnen Honing Oil can adversely affect workpiece surface finish and stone tool life If using Sunnen Coolant Concentrate dilute with water as specified and check concentration daily 12 Check Turn Power ON Check that valves inside work area Drip Tray closed CAUTION Open Valves slowly Coolant may spray first time coolant flow is turned on eTurn Coolant Selector Switch on operator station to CONSTANT Open valves inside work area to check flow of coolant AUTOMATIC SIZE CONTROL Opt Install optional Automatic Size Control ASC Unit as follows see Figure 1 12 1 Unpack Automatic Size Control ASC Unit Turn Clamp Knob on ASC unit counter clockwise and pivo
42. I ML 200D H SUNNEN Installation Setup and Operation INSTRUCTIONS for SUNNEN POWER STROKED HONING MACHINE Model ML 2000 READ THE FOLLOWING INSTRUCTIONS THOROUGHLY AND CAREFULLY BEFORE UNPACKING INSPECTING OR INSTALLING THE SUNNEN ML 2000 POWER STROKED HONING MACHINE SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY SUNNEN PRODUCTS COMPANY 7910 MANCHESTER AVENUE ST LOUIS MO 63143 U S A e PHONE 314 781 2100 GENERAL INFORMATION The Sunnen equipment has been designed and engineered for a wide variety of parts within the capacity and limitation of the equipment With proper care and maintenance this equipment will give years of service READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND THOROUGHLY BEFORE UNPACKING INSPECTING OR INSTALLING THIS EQUIPMENT IMPORTANT Read any supplemental instructions BEFORE installing this equipment These supplemental instructions give you important information to assist you with the planning and installation of your Sunnen equipment Sunnen Technical Service Department is available to provide telephone assistance for installation programming amp troubleshooting of your Sunnen equipment All support is available during normal business hours 8 00 AM to 4 30 PM Central Time Emergency breakdown support is available on a 24 hour 7 day basis Review all literature provided with your Sunnen equipment This literature
43. ICON CARBIDE Hard and brittle synthetic abrasive for stock removal in soft materials such as brass bronze aluminum cast iron etc and in extremely hard material such as tool steel Silicon Carbide is also used for obtaining fine finishes in all materials It is designated by letter J in Sunnen stone code example K12 J85 44 STACKING Technique for honing short parts Faces of parts must be square with bore prior to honing A holding fixture is necessary for aligning and holding parts on a common center zzzzZZZ TAPER Bore condition where diameter of bore gradually increases from one end of bore to other TRUING SLEEVE Cylinder or workpiece whose purpose is to make guide shoes and stone straight and parallel to each other and radius to approximate diameter to be honed 224 2222 WAVINESS Longitudinal wave series of waves or ripple in a bore surface WEDGE Part of Honing Unit that expands honing stone and applies cutting pressure COOLANT SYSTEM FLOW DIAGRAM SUNNEN ML 2000 POWER STROKED HONING MACHINE FLOW CONTROL ON OFF VALVE SUNNEN ML 2000 POWER STROKED HONING MACHINE equipped with STANDARD DIRTY FLUID ML 3250 RESERVOIR ASSEMBLY 45 APPENDIX FLOW CONTROL ON OFF VALVE COOLANT MANIFOLD PUMP HIGH PRESSURE RELIEF VALVE 40 PSI MAX FILTER CANISTER DIRTY FLUID
44. ING selector on AUTOMATIC For Models ML 2000CE and ML 2000CD only Is STROKER key switch set to ENABLE Is green LED on Light Curtain lit If red LED is lit then something is blocking a light beam If yellow LED is lit then light curtain needs to do its startup self check routine Put your hand through light beam path and then pull it out again to trigger self check routine PROBLEM Stroke Length slowly changes over time SOLUTION Check Stroke Length Clamp Handle for tightness If handle is already tight then stroking load is exceeding capacity of stroking mechanism Reduce stroking load by one or more of following Reduce Stroker Speed Reduce Feed Force Reduce weight of fixturing Also check Stroker Pivot Assembly free play With power OFF open right hood Move large stroker pulley by hand until Crossbeam is vertical see Figure 5 1 Lift end of Pivot Assembly lightly with a finger and let go It should drop between 4 and 10 mm Measured at nut If drop is greater than 10 loosen jam nut and then loosen nut slightly and retighten jam nut against it Recheck freeplay PROBLEM Stroker knocks at one or both ends of stroke SOLUTIONS Is anything in work area being struck by carriage or fixture Press STROKER JOG to check Is stroke length set to a point above 170mm Is Stroke Position Lock tightened If so try turn ing Stroke Position Handwheel If it turns easily see solution to ne
45. ML 2000 Diameter Range I D Manual Stroking Power Stroking Range of Standard Probes for Automatic Sizing Stroke Length Spindle Speeds Stroke Rate Spindle Motor Stroker Motor Feed System Type Size Control Opt Coolant System Roll Out Coolant Cart Coolant Filtration Opt Pump Motor Coolant Pump Coolant Capacity Coolant Requirements Floor Space Color Machine Weight Less Coolant Cart Pneumatic Requirements Power Requirements Noise Emission 1 5 165 mm 060 6 5 in 1 5 101 6 mm 060 4 0 in 3 1 51 125 2 0 in 6 170 mm 236 6 7 in 200 3000 rpm Variable in fine increments 60 350 strokes min Variable in fine increments 2 2 KW 3 HP 0 75 KW 1 HP Variable Maximum Feed Rate Regulator Zero Shut Off or Automatic Size Control ASC Pump and Sediment Tray Filtration PF 150 Grit Guard Unit 0 23 KW 1 3 HP 11 2 L Min 3 GPM 105 L 28 Gal Sunnen Industrial Honing Fluids 1625 6D x 1219 2W x 1905H mm 64 x 48 x 75 in w covers open Pearl Gray Pewter Gray Black Trim 725 kg 1600 105 5 5 Bar 80 PSI See Machine Nameplate or Electrical Specification Plate Less than 72 db A continuous Less than 74 db A peak load max noise condition in a typical factory environment Stroke length diameter range and workpiece weight are contingent on machine configuration workpiece and application INTRODUCTION This Instruction
46. Manual provides information required to install operate and maintain Sunnen ML 2000 Power Stroked Honing Machine When ordering parts for or requesting information about your Machine include model and serial numbers located on Electrical Enclosure of your Machine In this book symbol indicates steps or information that are only for CE version of this machine The CE version is constructed to meet highest level of safety standards as required by European Machinery Directive Required for European market this CE version is available for any customer The regular version of this machine is quite safe for any operator exercising a normal degree of caution associated with machine tool use The CE version provides an extra level of protection by minimizing risks of operator carelessness READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND THOROUGHLY BEFORE UNPACKING INSPECTING OR INSTALLING THE SUNNEN ML 2000 POWER STROKED HONING MACHINE The ML 2000 Production Honing Machine is to be used for finishing bores in small workpieces In finishing bores this machine can achieve any or all of following results fast stock removal consistent final size a high degree of cylindricity fine surface finish To achieve best results and ensure safe operation ONLY Sunnen Tools and Abrasives are to be used in ML 2000 vii 1626 mm 64 1372 mm 1702 mm 1118 mm 1168 mm 46 in TOP VIEW 381 gt gt
47. NNEN AG Fabrikstrasse 1 8586 Ennetaach Erlen Switzerland Phone 41 71 649 3333 Fax 41 71 649 34 34 SHANGHAI SUNNEN MECHANICAL LTD 889 Kang Qiao East Road PuDong Shanghai 201319 P R China Phone 86 21 5 813 3322 SUNNEN ITALIA S R L Viale Stelvio 12 15 20021 Ospiate di Bollate Italy Phone 39 02 3834171 Fax 39 02 383 417 50 Fax 86 21 5 813 2299 COPYRIGHT SUNNEN PRODUCTS COMPANY 2004 ALL RIGHTS RESERVED
48. R DIRECT INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OF USE REVENUE OR PROFIT SPC ASSUMES NO LIABILITY FOR PURCHASED ITEMS PRODUCED BY OTHER MANUFACTURERS WHO EXTEND SEPARATE WARRANTIES REGARDLESS OF ANY RIGHTS AFFORDED BY LAW TO BUYER SPC s LIABILITY IF ANY FOR ANY AND ALL CLAIMS FOR LOSS OR DAMAGES WITH RESPECT TO THE PRODUCTS AND BUYER S SOLE AND EXCLUSIVE REMEDY THEREFORE SHALL IN ALL EVENTS BE LIMITED IN AMOUNT TO THE PURCHASE PRICE OF THAT PORTION OF THE PRODUCTS WITH RESPECT TO WHICH A VALID CLAIM IS MADE Shipping Damages Except in the case of F 0 B Buyer s destination shipments SPC will not be liable for any settlement claims for obvious and or concealed shipping damages The customer bears the responsibility to unpack all shipments immediately and inspect for damage When obvious and or concealed damage is found the customer must immediately notify the carrier s agent to make an inspection and file a claim The customer should retain the shipping container and packing material SUNNEN SOFTWARE LICENSE AGREEMENT This document is a Legal Agreement between you as user and licensee Licensee and Sunnen Products Company SPC with respect to preprogrammed software Software provided by SPC for use on SPC Equipment By using the Software you as Licensee agree to become bound by the terms of this Agreement In consideration of payment of the license fee License Fee which is part of
49. RELS When truing sleeve or workpiece makes contact with any part of mandrel other then shoe replace mandrel or guide shoes TECHNICAL DATA GUIDE SHOES INTEGRAL SHOE MANDRELS Soft shoe mandrels are recommended for all general honing operations Mandrels with hardened steel shoes can be used for honing carbide ceramic or glass for extremely rough holes and for some long production jobs Where extremely fine finishes are required and a 600 grit stone is used solid bronze mandrels with integral shoes are required Occasionally unusual specifications do not permit use of honing oils that contain sulfur and it may be necessary to use bronze mandrels to prevent galling GUIDE SHOES REPLACEABLE SHOE MAN DRELS General purpose guide shoes are supplied as original equipment on mandrels with replaceable shoes Guide shoes of other materials are available and can frequently be beneficial in certain specific applications While it is desirable to provide guide shoes of material with long wearing qualities they must be soft enough to be trued in for any particular job Sunnen general purpose shoes meet these requirements APPENDIX When work being honed is unusually rough or out of round or has burs or wire edges hardened steel guide shoes are usually more economical Hardened shoes are also more economical when CBN Borazon or diamond honing stones are being used When material being honed is very soft or subject to galling
50. SPEED Return to center selector switch changes spindle speed setting displayed above switch Chart below recommends spindle speed in RPM based on workpiece bore diameter 14 STROKER SPEED Return to center selector switch changes stroker speed setting displayed above switch Chart below recommends stroker speed in SPM strokes per minute based on stroke length 15 STROKE LENGTH INDICATOR amp LOCK Index mark on clear piece indicates stroke length setting Tightening handle locks stroke length in place Loosening handle frees stroker for setting a different stroke length with STROKE LENGTH Handwheel 16 STROKE LENGTH Handwheel changes stroke length as indicated by index piece when handle is unlocked A Stroke Length Guide printed on front panel shows how to use bore length and stone length to determine proper stroke length for most applications 17 FEED FORCE Sets feed force level as indicated on dial above knob 18 HONING TOOL INDICATOR SCALE SELECTOR Four position selector switch sets Honing Indicator for honing tool used and indicator scale desired 19 STONE FEED Handwheel feeds up tool to set amount of stock removal to adjust final bore size and to compensate for stone wear manually Three scales are color coded to match three sets of tool families displayed in HONING TOOL box above Counter clockwise rotation increasing numbers feeds tool to a larger diameter
51. abled TABLE 2 2 Safety Symbols SAFETY SYMBOLS For a description of safety symbols used on this machine refer to Table 2 2 WORKHOLDING FIXTURE Fixtures used on these machines are custom made for each job refer to Appendix RUNOUT MANDREL Reduce mandrel runout as follows NOTE Mandrel runout should be adjusted before truing mandrel and stone Then if required adjust for conical and parallel runout as outlined later in this section 1 Select a concentric alignment bushing or truing sleeve with a bore size close to final honed bore size see Sunnen Honing Supplies Catalog Place alignment bushing on mandrel so that it is centered on stone and shoe section of mandrel WARNING Do NOT step on foot pedal to lock alignment bushing on mandrel Spindle will turn if foot pedal is depressed SYMBOL DESCRIPTION FUNCTION Warning Label Warns that an electrical hazard exists Label Designates this machine is CE compliance Warning Label Warns that no drilling is allowed Drilling any new holes may void warranty Warning Strip Warns that a physical hazard exits and that proper precautions should be taken Caution Label Moving Parts Warns that a finger hazard exists Do not touch while stroker is operating Warning Label Light Warns that power must be OFF when belt guard is opened to prevent injury Warning Label Safety Glasses Warns that safety
52. aller than desired bore size Insert sensing unit into setting fixture see Figure 2 13 6 Line up one of four screws with micrometer spindle and tighten clamp screw on setting fixture As you tighten clamp screw press downward on sensing unit as shown refer to Figure 2 13 Downward force assures that sensing unit is flat against frame of setting fixture This is necessary for best accuracy With wrenches provided adjust sensing screw to just touch micrometer spindle tip and tighten locking nut Repeat step for each sensing screw 7 Note micrometer reading Loosen micrometer spindle lock and back off spindle Check each of four sensing screws with micrometer ratchet All sensing screws should read within 0 03 mm 001 Be sure to hold sensing unit flat on setting fixture frame each time you tighten clamp screw 8 Back off adjustment screw slightly so that first part honed will be undersized rather than oversized if there was any inaccuracy in setting 9 Sensing tip or sensing unit is adjusted by turning adjustment screw inside stem of tip with a 1 16 hex wrench Sensing tip or sensing unit can be set to size with a micrometer or by inserting it into a TABLE 2 3 ASC Sensing Tips INCHES MILLIMETERS
53. alteration of this type should shorten stone and shoe equally from both ends so that honing area remaining is centered over wedge contacts on stoneholder If greater accuracy is required than is obtained after alteration refer to Troubleshooting Chart on page 31 Additional information is provided in Data File 102 Honing Short Bores Write for free copy ALTERATIONS FOR BLIND HOLES If at all possible provide a relief undercut at closed end of hole to permit stone to overstroke honed surface Relief does not have to be more than a few thousandths deep and can actually blend in with bore when finish honed but it should be as long as possible preferably 1 3 length of stone Sunnen honing units in K J K AK J AK BL L BAL AL and P28 groups can be utilized for honing bores that have one end closed In honing blind holes it is necessary for stone and guide shoe to extend flush with tip of honing unit If your applica tion utilizes one of P28 group of honing units install blind hole wedge and R28 honing stones see Honing Supplies Catalog Remaining mandrel groups have a tip which extends slightly beyond front end of stone and guide shoe For all blind hole work this tip must be cut off as illustrated below Mandrels which have been altered in this manner can still be used for honing open holes using a full length stone and guide shoe Blind hole Y mandrels are available on special order but P20 and D Honing Unit groups are n
54. ct your local authorized Sunnen Distributor Additional information available at http www sunnen com or e mail NOTE Sunnen reserves the right to change or revise specifications and product design in connection with any feature of our products contained herein Such changes do not entitle the buyer to corresponding changes improvements additions or replacements for equipment supplies or accessories previously sold Information contained herein is considered to be accurate based on available information at the time of printing Should any discrepancy of Information arise Sunnen recommends that user verify the discrepancy with Sunnen before proceeding ESD PREVENTION REVIEW Let s review the basics of a sound static control system and its effective implementation First in the three step plan 1 Always ground yourself when handling sensitive components or assemblies 2 Always use a conductive or shielded container during storage or transportation These materials create a Faraday cage which will isolate the contents from static charges Open ESD safe containers only at a static safe work station At the static safe work station follow these procedures before beginning any work A Puton your wrist strap or foot grounding devices B Check all grounding cords to make sure they are properly connected to ground ensuring the effective dissipation of sta tic charges Make sure that your work surface
55. e abrasive particles failed to break out of bond when cutting edges wore off This con dition shows up when bond is too hard and or cutting pressure is too low GUIDE SHOES Part of honing unit that stabilizes bore being honed on tool HARDNESS As applied to honing stone describes strength of bond that holds abrasive particles together A hard bond will hold abrasive grains longer a soft bond will permit stone to break down faster exposing new sharp abrasive grains HARD TIP STONE Honing stone having a tip or end of harder abrasive than remaining length of stone Used for honing blind holes where sufficient relief cannot be provided See Alterations for Blind Holes for how to make hard tip stones 43 APPENDIX B HONING Abrasive machining process primarily used for stock removal precision sizing and surface finishing of internal and external cylindrical surfaces Characterized by use of a self sharpening abrasive stone a relatively large area of contact with work and relatively low cutting speeds HONING LENGTH Actual length of surface being honed HONING STONE Abrasive stick consisting of thousands of small abrasive grains bonded together cemented to metal holder HONING UNIT Complete honing tool consisting of adapter if required mandrel and wedge stone s guide shoe s truing sleeve and stone retainer or tension block LOADED STONE Honing stone with cutting action impaired due to cut
56. ed by foot pedal so that speed at which stone contacts workpiece bore is related to speed of operator s foot Likewise raising foot will move wedge back If STROKING is set to MANUAL spindle will run only when Pedal is depressed and honing cycle will stop when Foot Pedal is released If STROKING is set to AUTOMATIC Foot Pedal will control feed until it is completely depressed As soon as Foot Pedal is at bottom of its travel feed system will be controlled by machine and foot pedal can be released without stopping cycle Releasing foot pedal prior to that point will stop cycle 24 STROKE POSITION LOCK This hand lever tightens a screw to lock stroker in position To adjust stroke position this hand lever screw must be loosened 25 STROKE POSITION HANDWHEEL When Stroker Position Lock is loosened this handwheel changes position of stroke relative to spindle and honing tool Graduations are in millimeters Turning in direction of increasing numbers moves carriage out away from spindle 26 SPINDLE SPLASH GUARD Attaches to rear of stroker carriage with a knurled thumb screw Contains coolant spinning off spindle in most applications May have to be removed if stroker carriage must stroke too close to spindle housing 27 COOLANT MANIFOLD Valves regulate flow of coolant through each of four coolant lines and one Main Valve controls total amount of coolant flow 28 MASTER ON OFF SWITCH Disconnects power from switch to comp
57. ed tip to fit in fill slot in cylinder PROBLEM Spindle and or Stroker seems to stall under high honing load SOLUTION Check belt tension If deflection midway between pulleys is greater than 4mm 158in when a 33N 7 4 16 load is applied then belts can be tightened Loosen four bolts holding motor assembly in place Tighten belt tightening screw against its wedge slightly until appropriate tension is achieved Retighten mounting bolts If belt tension is correct and Spindle Stroker is still stalling then reduce feed force being used Continued operation under these loads can be detrimental to machine life PROBLEM Machine stops during or at end of a cycle and power to machine is automatically turned off SOLUTIONS Are Spindle and Stroker Drives configured for voltage that 18 being supplied to machine See Machine Conversion in Installation section at beginning of this book For Models ML 2000CE and ML 2000CD only Did something enter Opto Electronic Screen during honing cycle If so machine will turn its power off so that operator will be aware that workpiece in machine has not been honed to completion PROBLEM No Coolant flow or insufficient coolant flow SOLUTIONS First check coolant level gage for sufficient coolant in reservoir and check plastic valves in work area to be sure they are open Pull coolant system out far enough to view it but leave it connected electrically Open reservoir cover and r
58. een pulleys is approximately 4mm 158in when a 33N 7 4 16 load is applied 5 30 GENERAL SECTION 5 TROUBLESHOOTING This section contains Troubleshooting information in table form which should be used when problems occur with your Machine TABLE 5 1 Operational Troubleshooting OPERATIONAL TROUBLESHOOTING For suggestions on correcting problems with bore con ditions or with honing operation consult Table 5 1 Standard Sunnen Tooling and Procedures will satisfy all ordinary honing requirements If problems are encountered they can usually be solved by following procedure suggested below For detailed information on difficult or unusual honing problems contact your local Sunnen Field Engineer or Sunnen Customer Service Department in St Louis Missouri USA Honing dial needle moves too slowly pressure sure you arc using Sunnen Industrial Honing Oil one with a Lower hardness number CONDITION TO BE CORRECTED STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STONE GLAZED Sharpen A or J stone Increase cutting Increase stroking Use a softer stone Check oil to be STONE Stone surface looks with MAN 700 pressure speed one with a lower sure you are using NOT clean but cutting diamond dresser use hardness number Sunnen Industrial CUTTING grains are dulled LBN 700 dressing stick Honing Oil
59. emove sediment tray to view inside of coolant system Turn machine power on and set coolant selector to CONSTANT Refer to Appendix C SPECIAL TOPICS FEED REGULATOR Feed Regulator on ML 2000 is a feed rate limiter On earlier model Sunnen Honing Machines this feature was called Stone Saver Without Feed Regulator at beginning of each cycle machine feeds rapidly until stone contacts work piece This high speed contact at full feed force in a rough bore can cause some stone break down resulting in greater stonewear Without Feed Regulator ML 2000 Feed System is a constant force feed system cutting rate will varying depending on condition of bore fully or partially cleaned up hardness of bore and condition of stone free cutting or glazing Feed Regulator can provide three benefits 1 Stone Saving Limiting feed rate just before stone contacts bore can eliminate excessive stone breakdown 2 Very Low Feed Force Honing There are practical limitations in applying a very low feed force consistently while tool expands very slowly In many applications with extremely small mandrels D2 family optimum feed force is somewhere less than machine minimum of 1 Using Feed Regulator set at a very slow speed restrains feed system and effectively delivers less than a feed force of 1 to stone 3 Elimination of glazing If stones are glazing first recommendation is to use a softer stone or to increase feed force If t
60. en hoods are open or performing service not requiring power CLEANING Weekly wipe exterior of machines with a clean dry cloth To clean exterior use warm water and a mild detergent or mild industrial liquid Rinse thoroughly with clean hot water and wipe dry FIGURE 4 3 LUBRICATION Spindle Only Lithium complex base grease Viscosity ISO VG 150 NLGI Grade Moblith AW or equivalent Sunnen SML 110 1 Gal Can All other lubrication Lithium complex base grease Viscosity ISO VG 220 NLGI Grade Moblith AW 1 or equivalent Sunnen SML 120 Cartridge Feed Regulator Oil ISO VG 150 Oil ROUTINE MAINTENANCE SCHEDULE The following procedures and suggested maintenance periods are given as guides only and are not to be construed as absolute or invariable Local conditions must always be considered Each machine must be maintained individually according to its particular requirements Daily Check coolant level Gage front of Coolant System and add coolant as necessary CAUTION DO NOT overfill system If using Sunnen Coolant Concentrate check concentration and add water or concentrate as necessary Every 500 Hours CAUTION Over filling spindle can cause it to run hot Apply two or three pumps of grease to spindle see Figure 4 1 Apply grease to Feed Force Screw Stop Blocks see Figure 4 1 Apply grease all other grease fitting
61. ength be less than twice tandem distance center area of stone and guide shoe will not wear and a resulting hump in honing unit will bellmouth inside ends of both bores of tandem In some tandem applications it is necessary to alter honing unit by cutting away area of stone and guide shoe that would become hump Remove from center of both stone guide shoe an amount equal to amount stone and guide shoe is short of being twice tandem distance For example a part having a 2 3 4 tandem spacing would require a 5 1 2 stone and guide shoe but honing unit has a stone and guide length of only 4 1 2 This honing unit be used by removing 1 from center of 4 1 2 stone and guide shoe length Multiple stone honing units P20 and P28 can sometimes be used by setting up honing unit to leave out center stones and shoes Special tandem type mandrels can generally be supplied for those applications which have too long a tandem distance for honing with altered honing units Contact your Sunnen Field Engineer or factory Additional discussion on honing tandem and multiple land bores is contained in Data File 106 Write for free copy CENTER TO CENTER TANDEM DISTANCE AA S SS s IF STONE AND GUIDE SHOE LENGTH IS LESS THAN TWICE TANDEM DISTANCE ALTERATION IS REQUIRED SEE TEXT jap REMOVE ALTERATION FOR TANDEM BORES 42 ALTERATIONS FOR SHORT BORES USING AUTOMATIC SIZE CONTROL Alwa
62. er nozzles are preferred if they can be positioned close to workpiece For convenience one coolant nozzle can be clamped in back of stroker carriage on a rib nearest spindle pointing up to rear of workpiece bore see Figure 3 3 Note that almost all workpieces will be positioned with rear of bore in this location so this one nozzle will not require adjusting when changing setups 39 Return COOLANT selector to CYCLE ONLY 40 Replace Spindle Splash Guard on back of Stroker Carriage Press STROKER JOG to check Splash Guard clearance 41 Set STROKING selector to AUTOMATIC 42 Set SIZE CONTROL selector to desired size control mode 43 Set Automatic Size Control ASC Unit refer to Section 2 44 Set EXTRA STROKES to desired value NOTE Changing amount of Extra Strokes is an easy way to compensate for ASC sensing tip wear However keep in mind that more extra strokes there are more final bore size can vary since bore is being plug gaged before extra strokes If honing rates vary over time more or less extra material may be removed during finishing If final size tolerances are close keep amount of extra strokes to a minimum 45 Using Sunnen Precision Bore Gage measure bore size of a workpiece and place it on honing tool WARNING Do NOT step on foot pedal to lock alignment bushing on mandrel Spindle will turn if foot pedal is depressed 46 Turn Feed Selector to EXPAND Rotate workpiece by hand s
63. es that power is applied to Transmitter Receiver Green indicates that light curtains are aligned and no object is in light curtain detection zone Red indicates light curtains are not aligned or an object is in light curtain detection zone Machine cannot be run when this light is on or afterwards until machine error 4 has been cleared Pressing Cycle Stop button clears error 4 Individual Beam Indicates Receiver Unit has a red visible Individual Beam Indicator IBI adjacent to each infrared beam Infrared beams have a vertical spacing of 30mm The IBI will light when an object blocks detection zone of light curtains or light curtain units are not aligned with each other SECTION 2 PREPARING FOR OPERATION GENERAL MAJOR COMPONENTS Consult this section when preparing the Machine for For location of major components on your machine operation see Figure 2 1 OPERATOR CONTROL STATION FRONT CONTROL PANEL STROKER CARRIAGE ELECTRICAL ENCLOSURE COOLANT CART FOOT PEDAL FIGURE 2 1 ML 2000 Honing Machine 7 OPERATOR CONTROLS For location and function of the operator controls for your machine refer to Figures 2 2 thru 2 5 Refer to Table 2 2 for symbols used on CE machines Q 1 POWER OFF Turns machine power off All functions are disabled however spindle speed stroker speed and extra stroke settings are retained 2 POWER ON Turns machine power on Lighted button is an indicat
64. esent We can supply hard tip stones in most stone sizes Minimum order quantity is one standard package of any individual part number Allow one week for shipment A customer made alteration can achieve same results as a hard tip stone Select a stone considerably harder than one normally used for job and alter as illustrated For additional techniques on blind hole honing refer to Troubleshooting Guide and request copies of Sunnen Bore Sizing amp Finishing Technology Data Files 102 and 103 ALTERATIONS FOR TANDEM HOLES Sunnen honing units can be used to size two or more in line or tandem bores in perfect alignment Stone and guide shoes must be of proper length so that entire stone surface will contact one or other of bores at some time during honing stroke To keep honing unit true during operation STONES AND GUIDE SHOE LENGTH MUST BE AT LEAST TWICE CENTER TO CENTER TANDEM DISTANCE OF BORES see illustration When honing unit meets this requirement alteration is not required It may be necessary to reverse part end for end on honing unit to obtain identical bore sizes Never stroke either of tandem bores completely off stone and guide shoes APPENDIX TANDEM DISTANCE Ca MAN IF STONE AND GUIDE SHOE LENGTH IS EQUAL TO AT LEAST TWICE TANDEM DISTANCE ALTERATION IS NOT REQUIRED L TOOLING FOR TANDEM BORES Should stone and guide shoe l
65. f 8 Center truing sleeve over stone and shoes Grasp truing sleeve and holding fixture firmly with your left hand and slowly depress foot pedal 9 As mandrel begins its rotation stroke truing sleeve forward and back Use short strokes at first then gradually lengthen strokes until stroke is about as long as sleeve or stone whichever is longer 10 Reverse truing sleeve frequently WARNING Always release pedal before removing truing sleeve or workpiece from tool 11 If honing indicator needle is not moving and feed force feels too light then stop and increase Feed Force by a small amount 12 If needle on honing indicator goes below zero then stop and feed stone up 13 If mandrel dries out apply a little more coolant 14 Concentrate truing on area where you feel most pull or resistance 15 Frequently stop and examine shoes and stone For most applications at least a full line of contact should be seen on stone and both shoes If wear does not show sufficient contact use truing sleeve some more see Figure 2 8 NOTE When using keyway mandrels stone and shoes must fully radius to within 0 13 mm 005 before bores with keyways can be honed LOADING FIGURE 2 8 Stone Loading ALIGNMENT BUSHING FIGURE 2 9 Alignment Bushing PIVOT LOCK LEVER ALIGNMENT lt BUSHING INDICATING GAGING POINT REFERENCE GAGING POINT BUSHING FIGURE 2
66. glasses should be worn at all times when operating this machine Warning Label Use Fixture Warns that a holding fixture should be used to secure part when manual honing Warning Label Do Not Hold Warns that part should not be held in hand for honing Warning Label Foot Pedal Warning gt gt EOS Warning Label Foot Pedal General Warning 26 SPINDLE SPLASH GUARD 25 STROKE 24 STROKE POSITION POSITION HANDWHEEL eth 29 5 77 E UNIT CLAMP 30 ASC POSITION SCREW 25 STROKE POSITION HANDWHEEL 24 STROKE POSITION LOCK 32 STROKER DISABLE SWITCH NOT SHOWN 28 MASTER ON OFF SWITCH 427 COOLANT MANIFOLD 31 PROBE BODY CLAMP KNOB FIGURE 2 5 Machine Controls TRUING SLEEVE FIGURE 2 6 Runout NUMBERED SET SCREW FIGURE 2 7 Numbered Set Screws 2 Turn FEED selector to EXPAND to lock alignment bushing on mandrel Look to Honing Indicator If needle reads somewhere on scale then alignment bushing is properly locked on If not turn STONE FEED DIAL until there is an indicator reading Turn Dial same direction as you wish needle to move 3 Turn FEED selector to RETRACT 4 Set Spindle Speed to 200 rpm WARNING Do not attempt to adjust mandrel runout at any speed higher than 200 rpm 5 Depress Foot Pedal fully to start spindle with alignment bushing
67. hat tool can follow existing hole without moving its centerline Fixture includes a torque arm so that a rigid torque absorption point is provided for workpiece or a special workholding fixture to bear against during honing cycle Universal Fixture is designed for maximum flexibility In both configurations fixture can be reversed from left to right to suit operator s preference Also Hinge and Latch may be unscrewed from outside of gate piece and reattached on inside for longer workpieces NOTE To mirror fixture from left to right requires removing components from gate reversing gate and then reattaching components If entire assembly is simply reversed then fingers will end up in a position where they are not adequately supported to resist high stroking loads ADJUSTING FINGER FIXTURE Set fixed fingers on carriage to contact workpiece as close as possible to tool leaving enough clearance between tool and fingers so that there is no danger of contact during honing There two aluminum collars on each fixture support bar backing up Hinge and Latch Loosen screws holding these collars and move collars out of way NOTE Collars with Hinge have a loose pin spacing them apart 36 FIGURE A 1 Universal Fixture Move finger fixture assembly on fixture support bars to a position where workpiece will be held with minimal end clearance approx 1mm more if workpiece length is expected to vary
68. his is not possible or produces unacceptable results then setting Feed Regulator to desired cutting rate and increasing feed force significantly will produce cycles of consistent duration without glazing Feed Regulator has an adjustable MAXIMUM RATE control and an INITIAL DIAMETER setting knob INITIAL DIAMETER knob should be set so that feed system feeds rapidly at its normal rate up to some point slightly smaller than smallest bore you expect to encounter At this initial diameter Feed Regulator takes over slowing feed to rate that is set with MAXIMUM RATE dial From that point feed will continue at that rate or slower if normal cutting rate at selected feed force is slower than maximum rate selected For details on setting Feed Regulator see Setup Power Stroking TRUING Sunnen mandrels shoes and stones are manufactured to close tolerances so that in many low to medium precision applications it will not be necessary to true stone and shoes A proper setup will generate and maintain parallelism between stone and shoes 35 If you choose not to true honing unit remember following Hone first workpiece undersize by a fair amount so that you can check straightness of bore If is not acceptable you will have to adjust stroke length or stroke position or stop honing cycle frequently and flip part end for end Continue to hone parts under sized until bore straightness is acceptable If bores do not straighten out after a few
69. his will make first part honed undersized by approximately 0 025 mm 001 NOTE Final size can be adjusted after first workpiece by either turning adjustment screw or by changing number of Extra Strokes displayed on operator panel 10 Screw Sensing Tip or Sensing Unit on to stud on Probe Body see Figure 2 14 If required use Probe Extension to reach into counterbore in workpiece or reach past fixturing 11 Press STROKER JOG and hold in to get stroker to front of stroke 12 Turn spindle by hand until shoes are up and then place a workpiece on mandrel WARNING Keep hands away from ASC unit when turning ASC Probe Selector to move ASC probe up or down 13 Make sure that ASC unit is a safe distance from honing tool and with hands away from work area turn ASC PROBE selector to UP 14 Loosen Clamp Screw on ASC unit and slide unit up to workpiece Sensing Tip should be depressed about 3 mm 1 8 Tighten Clamp Screw NOTE If desired use Stop Clamp supplied with ASC unit to allow quick return to ASC setup position again if unit needs to be moved back along Rail for honing tool runout adjustment or replacement Attach Stop Clamp to ASC Rail against back of ASC unit with supplied brass tipped set screw 15 Loosen locknut on ASC Fine Position Screw Look through hole near top of ASC arm to red light on proximity switch Turn ASC Fine Position Screw until point is reached where light is just turned on Fr
70. id machine member Never try to absorb honing torque by holding workpiece with your hand 3 Slide workpiece on mandrel and center workpiece over stone It may be necessary to back off Stone Feed Dial clockwise to get workpiece on mandrel 4 Turn POWER ON 5 Make sure that Feed Force is set to desired set ting and then turn FEED selector to EXPAND Turn workpiece several revolutions on mandrel to seat workpiece on stone WARNING Do NOT step on foot pedal to set stock removal amount Spindle will turn if foot pedal is depressed 6 Turn Stone Feed Dial until needle on Honing Indicator shows amount of stock to be removed Make sure that Honing Tool Indicator Scale Selector is set to appropriate mandrel family 7 Turn FEED selector to RETRACT 8 Check Spindle Speed setting and verify that STROKING selector is set to MANUAL WARNING Recommended speeds may not be suitable for all applications For MANUAL HONING always start with a speed that is no more than half speed recommended on chart then increase speed in small increments only when job seems to be running safely Never exceed recommended speed when manually honing 9 Slowly depress Pedal while stroking workpiece If bore is rough or out of round DO NOT fully depress Pedal until bore has smoothed out as evidenced by diminishing vibration Use same Overstroke at each end of stroke If possible frequently stop machine and reverse workpiece on mand
71. ificantly different from another ML 2000 machine then contact a Sunnen Service Technician to check Feed System calibration PROBLEM Increasing roughing pressure makes no difference in honing rate SOLUTION Is Feed Regulator turned on If so increasing pressure may make no difference in honing rate because honing rate is limited by maximum rate selected on Feed Regulator If Feed Regulator is turned off then check Air Pressure Regulator Pressure should be 0 55 MPA If it is low then adjust it by turning knob on top of Regulator PROBLEM When using Feed Regulator at higher feed forces Initial Diameter where needle begins to slow down on Honing Indicator appears different during a cycle than it did when it was set by recommended procedure SOLUTION This is normal behavior caused by amount of compression in feed system However this indicates that stones are contacting workpiece bore immediately after cycle begins although not at full feed force selected If this initial contact still seems too rough then turn Initial Diameter knob counterclockwise some to make Feed Regulator begin at a smaller diameter PROBLEM Turning INITIAL DIAMETER knob on FEED REGULATOR smaller does not seem to change point where FEED REGULATOR begins working 34 SOLUTION Damper Cylinder inside machine may be low on oil Fill cylinder and try again To fill cylinder without removing it from machine requires a long spout with a flatten
72. ing workpiece bore immediately after cycle begins although not at full feed force selected If this initial contact still seems too rough then turn Initial Diameter knob counterclockwise some to make Feed Regulator begin at a smaller diameter 18 SECTION 3 SETUP amp OPERATION GENERAL This section gives step by step setup and operating procedures for Sunnen ML 2000 Power Stroked Honing Machine SAFETY PRECAUTIONS The following precautions should be observed to ensure maximum safety while working on or around your Machine Wear proper Safety Items such as safety glasses and other personal safety equipment as necessary or required e DO NOT wear loose fitting clothes or jewelry while working on or around Machine Keep area around Machine free of paper oil water and other debris at all times e Keep Machine and area around machine cleaned of excessive lubricant and lubricant spills Keep tools and other foreign objects clear of Machine while in operation Keep tools clean and in their proper storage compartments to maintain them in proper working condition and to prolong tool life Inspect Tools before using Check for cracks burrs or bent parts that might effect operation e DO NOT force tools when operating Tools will do a better and safer job when operated at the rate for which they were designed Turn OFF electrical power when performing service on your machine which does not require power
73. ings Wide faces of outer races are in contact Clean and repack e Replace bearing keeping same back to back arrangement NOTE One bearing takes a much greater load than other Bearing life will be extended if both bearings held together are reversed when they are replaced so that over time both bearings wear evenly 8 Reverse steps above to reassemble When tightening two screws fastening cover alternate between two to seat bearings evenly 9 Use screw against wedge to tension belt before tightening screws on base plate Tension belt so that deflection at midway between pulleys is approximately 4mm 158in when a 33N 7 4 Ib load is applied STANDARD COOLANT an SYSTEM FILTER CANISTER MACHINE EQUIPPED WITH OPTIONAL PF 150 FILTRATION SYSTEM FLOW CONTROL ON OFF VALVE COOLANT MANIFOLD tN DIRTY FLUID FIGURE 4 4 Coolant System FIGURE 4 6 Stroker Belt 29 STROKER BELT To replace Stroker Belt proceed as follows see Figure 4 6 1 Loosen four screws holding stroker motor base plate to stroker frame 2 Loosen one screw on wedge that bears against motor base plate 3 Slide stroker motor up to loosen belt 4 Remove and replace belt 5 Reverse steps above to reassemble Use screw against wedge to tension belt before tightening screws on base plate Tension belt so that deflection at midway betw
74. ion Runout Indicator is now set to measure parallel runout of honing unit Rotate spindle by hand while observing Runout Indicator If necessary turn Knob B to get an indicator reading Turn spindle until high point is found Loosen nearest numbered screw 1 2 3 4 on rear of spindle nose and tighten screw on opposite side Repeat this procedure until parallel runout is within acceptable limits Parallel runout of less than two divisions on indicator is acceptable for most honing applications For close tolerance applications parallel runout should be less than one division 11 Conical runout should not be affected by adjustment of parallel runout however it is a good practice to double check conical runout again If amount of parallel adjustment was large then conical runout may have changed slightly If it is necessary to readjust conical runout then always recheck parallel runout after that 12 Remove indicator from threaded stroker drive shaft 13 Set FEED selector to RETRACT and remove alignment bushing AUTOMATIC SIZE CONTROL Optional Set Automatic Size Control ASC Unit as follows 1 If ASC Unit has been removed from machine then it must be installed NOTE If setting up ASC for first time on a new machine it may be necessary to adjust ASC unit Only necessary for a new machine or a new ASC unit 2 Select and adjust proper Sensing Tip or Sensing Tip Unit for final bore size to be gaged see Table 2 3
75. ion of power on status 3 STROKER JOG Pressing this and holding it down causes stroker carriage to move slowly to one end of stroke Repeating this will cause stroker to move slowly to other end of stroke Releasing button will stop stroker immediately even though end of stroke may not have been reached 2 CYCLE STOP Stops honing cycle 5 CYCLE START Starts honing cycle if STROKING selector is set to POWER 6 COOLANT Two position selector switch CONSTANT Coolant flow at all times when power is on 7 CYCLE ONLY Coolant flow only during honing cycle 59 7 ASC PROBE Two position selector switch UP Automatic Size Control actuator lifts probe into gaging position DOWN Automatic Size Control actuator moves probe to its retracted position 8 FEED Two position selector switch EXPAND Used for setup only Expands honing tool until stone contacts workpiece for setting Stock Removal amount Locks an alignment bushing on honing tool for checking and adjusting tool runout Honing cycle cannot be started when EXPAND is selected RETRACT Retracts honing tool Q 9 EMERGENCY STOP Opens electrical circuits to stop all machine functions Cancels all setup information requiring operator to re enter setup before continuing Button must be rotated clockwise until it pops up before machine can be re started with POWER ON button 10 SIZE CONTROL Two position selector
76. ll wear at least that much If you feed up more than stone actually wears then bore will be oversized when you hone to zero SETUP POWER STROKED HONING Follow ALL steps for power stroked honing carefully and in the order listed 1 Press Emergency Stop to clear any previous setup 2 Turn OFF coolant supply by turning Main Control Valve on Coolant Manifold fully clockwise 3 If ASC unit is attached to machine loosen Clamp and slide unit out away from spindle Turn ASC PROBE selector to DOWN Unit can also be removed from machine entirely 4 Set FEED selector to RETRACT 5 Turn FEED REGULATOR off by turning INITIAL DIAMETER knob fully clockwise 6 Remove Spindle Splash Guard 7 Disengage Stroker Carriage from power stroker Turn STROKING selector to UNLATCH Pull Stroker Carriage forward to provide access to spindle 8 Select correct honing unit and stone from Sunnen Honing Supplies Catalog 9 Assemble Honing Unit according to instructions 10 Set HONING TOOL INDICATOR SCALE selector to position that matches tool being used and scale you wish to read NOTE For most applications it is recommended that A scale be used unless stock removal is expected to be more than 240u 009 in Finer resolution on A scale gives a clearer indication of honing rate 11 Turn STONE FEED dial clockwise until you meet resistance then advance it counterclockwise approximately 10 turns CAUTION Do not
77. lockwise about two turns 3 With workpiece removed from tool turn FEED selector to EXPAND while watching Honing Indicator Needle will drop quickly to initial diameter point and then move very slowly If point that needle stops is not desired point then turn FEED selector to RETRACT adjust INITIAL DIAMETER knob and expand again while watching indicator NOTE To use FEED REGULATOR efficiently initial diameter should be set to a point just smaller than smallest starting bore diameter that you expect to encounter It may be necessary to measure several workpieces to know how they will vary Set initial diameter to point where Honing Indicator reads difference between initial diameter and final bore size There are trade offs to setting this initial diameter If it is too large a workpiece slightly smaller than expected may be contacted at full feed force possibly damaging stone or tool If initial diameter is set too small cycle time gets excessively long with significant time spent just cutting Use your best judgement based on your knowledge of variability of starting diameter of workpieces When using Feed Regulator at higher feed forces Initial Diameter where needle begins to slow down on Honing Indicator may appear different during a cycle than it did when it was set by recommended procedure This is normal behavior caused by amount of compression in feed system However this indicates that stones are contact
78. mber of extra strokes Over time as sensing tip wears size can be adjusted easily with this feature The following adjustments may require running several cycles to observe pattern of stonewear cutting rate etc 9 Is finished bore tapered from one end to other with direction of taper consistent with workpiece s orientation in stroking fixture If so loosen Stroker Position Lock and adjust stroke by turning Stroke Position Handwheel slightly to move stroker carriage in direction that workpiece bores are larger WARNING NEVER adjust stroke length or stroke position while machine is running 10 Is honing rate reasonable Is cylindricity of finished bore acceptable Feed forces may have to be adjusted In general increase Feed Force if honing is too slow and finished bores are round and straight and of consistent size Also in general decrease Feed Force if bores are not as cylindrical as desired if size is inconsistent or if stonewear is excessive 11 To correct other problems with workpiece bores see Troubleshooting 25 5 26 SECTION 4 ROUTINE MAINTENANCE GENERAL The following procedures are given as guides only and are not to be construed as absolute or invariable Each machine must be maintained individually according to its particular requirements WARNING ALWAYS have power OFF wh
79. mpt any repair or maintenance procedure beyond those described in this book Contact your Sunnen Service Representative for repairs not covered in this book Manual stroked honing and truing should only be performed by operators trained to use safe manual honing practices The key for switch to disable stroker and allow manual honing should be kept by a supervisor or skilled honing operator to prevent unauthorized manual honing Much of the safety of the honing operation is dependent on how workpiece is fixtured Several standard fixturing components are available but each is limited to certain types of applications Homemade fixtures are also not uncommon and can be quite effective if designed and used properly Sometimes it is necessary to clamp workpieces lightly when honing with special fixtures to minimize bore distortion Likewise tooling for small diameter honing is inherently fragile Therefore Always start a new setup with speeds and feed forces that are much lower than recommended to test stability of tooling and fixturing After that speeds and feed forces may be increased slowly to recommended values If specially built automation components are added to this system be sure that safety is not compromised If necessary obtain special enlarged work area safety system from Sunnen Products Co Indicates CE version ONLY 1 DO NOT touch electrical components until main input power has been turned off and CHARGE lamps ex
80. n Clamp and slide unit out away from spindle Turn ASC PROBE selector to DOWN Unit can also be removed from machine entirely 4 Set SIZE CONTROL selector to ZERO SHUT OFF 5 Set STROKER key switch to DISABLE Set Stroking selector to MANUAL 6 Set FEED selector to RETRACT 7 Turn FEED REGULATOR off by turning INITIAL DIAMETER knob fully clockwise 8 Remove Spindle Splash Guard 9 Disengage Stroker Carriage from power stroking unit Turn STROKING selector to UNLATCH Then pull Stroker Carriage forward to provide access to spindle 10 Select correct honing unit and stone from Sunnen Honing Supplies Catalog 11 Assemble Honing Unit according to instructions 12 Set HONING TOOL INDICATOR SCALE selector to position that matches tool being used and scale you wish to read NOTE It is recommended that A scale be used unless stock removal is expected to be more than 240u 009 Finer resolution on A scale gives a clearer indication of honing rate 13 Turn STONE FEED dial clockwise until you meet resistance then advance it counterclockwise approximately 10 turns CAUTION Do not force STONE FEED DIAL or damage to feed system may result 14 Pull Mandrel Wedge straight back as far as possible 15 If required install Spindle Sleeve LN 570A not supplied with machine on Honing Unit 16 Rotate spindle by hand until large set screw is up 12 o clock position 17 With set screw inden
81. ne CBN Cubic Boron Nitride synthetic abrasive that is second in hardness to more chemically stable than and as costly as diamond CBN is best suited for steels especially tool steels high speed steels and superalloys General Electric tradename for CBN is Borazon CBN is designated by letter N in Sunnen stone code example K12 NR53 1 CONICAL RUNOUT Honing unit not parallel to rotation centerline which causes eccentric motion of one end of workpiece CORK BOND Bonding material for abrasive composed of powdered cork and a phenolic resin Cork bonded honing stones are used where extremely fine finishes say 2 to 4 microinches on non ferrous materials are required DEBURRING Honing process used to remove burrs sharp edges or similar material from rough bores DIAMOND Hardest abrasive known to man but chemically not suited for honing materials such as steel Diamond is only Sunnen abrasive capable of honing very hard materials such as tungsten carbide ceramics and glass It is designated by letter D in Sunnen stone code example K12 DV57 DIAMOND STONES Honing stone made with crushed diamond particles bonded together It is only abrasive material capable of honing very hard materials such as tungsten carbide glass and ceramics DIAMOND DRESSER Diamond abrasive used to dress aluminum oxide and silicon carbide honing stones GLAZED STONE Stone with cutting action impaired becaus
82. ode requirements before sizing and installing the incoming power wiring End user must use a step down transformer where factory electrical power varies more than 10 of machine s nameplate voltage All wiring is to be preformed by a competent licensed electrician Note Step down or voltage regulating transformers are external peripheral to machine tool and are considered primary input line source for machine Local electrical code or practice may require a circuit breaker or other switching device for isolation of electrical power when this type of transformer is used In such cases machine tool end user is required to supply necessary circuit breaker or switching device FAILURE TO COMPLY CAN RESULT IN PERSONAL INJURY AND OR DAMAGE TO MACHINE ELECTRICAL All wiring is to be performed by a competent Licensed Electrician in accordance with all local state and federal codes and regulations Along with the information provided on the machine Electrical Specification Plate 1 Loosen Safety Latches using a screwdriver or if applicable unlock doors to Electrical Control Enclosure using key supplied with machine WARNING Residual Voltage exists for 2 3 minutes after Master ON OFF Switch is turned OFF 2 Turn Master ON OFF Switch to OFF position and open doors see Figure 1 7 3 Insert Electrical Supply Cord through Oil Tight Fitting in enclosure entrance hole 4 Strip 254 mm 10 in off cable
83. om that point turn ASC Fine Position Screw 1 1 2 turns clockwise Tighten locknut on Fine Position Screw 16 Loosen Probe Body Clamp Knob and move whole Probe Body to center Sensing Tip on workpiece bore Tighten Probe Body Clamp Knob 17 Press STROKER JOG repeatedly to see how Sensing Tip engages bore and to see if Proximity Switch is being made at end of stroke It may be necessary to reposition Probe Body or to adjust Fine Position Screw NOTE STROKER JOG will not operate if FEED selector is set to EXPAND 18 Return ASC PROBE selector to DOWN STOCK REMOVAL RATE 1 Make sure Honing Tool Indicator Scale Selector Switch is set for proper tool and scale 2 With a measured workpiece seated on mandrel turn Tool Feed Switch to Expand 3 Turn Stone Feed Dial until needle on Honing Indicator reads the amount of stock you want removed NOTE There is some backlash in Stone Feed Dial For best accuracy in setup always turn Dial until Honing Indicator reads some amount less than desired stock removal and then feed up counterclockwise until needle shows correct amount of stock removal FEED REGULATOR Use of FEED REGULATOR is optional If it is not to be used on this application then skip this step Refer to Appendix A for guidelines on when Feed Regulator may be beneficial To set FEED REGULATOR proceed as follows 1 Turn MAXIMUM RATE dial to slowest speed 2 Turn INITIAL DIAMETER knob counterc
84. ome to get it to seat fully on mandrel 47 Turn stone feed dial until needle on Honing Indicator reads amount of stock to be removed from diameter of workpiece on mandrel NOTE There is some backlash in STONE FEED dial For best accuracy in setup always turn dial until Honing Indicator reads some amount less than stock removal and then feed up counterclockwise until needle reads correct amount of stock removal 48 Set FEED REGULATOR NOTE Use of FEED REGULATOR is optional If it is not to be used on this application then skip this step and go to step 49 See Appendix A for guidelines on when Feed Regulator may be beneficial 49 Set Spindle Speed Use chart below knob to determine spindle speed based on bore diameter 50 Set Stroke Speed Use chart below knob to determine stroke speed based on stroke length WARNING Recommended speeds may not be suitable for all applications and for all fixtures Always start a new setup with speeds that are much lower than recommended to test stability of tooling and fixturing OPERATION POWER STROKED HONING Follow ALL steps for power stroked honing carefully and in the order listed NOTE Before honing review your setup of machine 1 Install workpiece in workholding fixture WARNING To prevent personal injury and damage to machine DO NOT hone without installing workpiece in a workholding fixture 2 Install workpiece with workholding fixture
85. on mandrel If runout is excessive center honing unit following steps 6 amp 7 If runout does not seem excessive then mandrel runout adjustment is complete 6 With bushing or sleeve rotating on honing unit touch a marking pencil to sleeve to indicate high side see Figure 2 6 Turn FEED selector to EXPAND This stops spindle while keeping sleeve locked on mandrel This also will disable Foot Pedal to prevent accidental starting 7 Loosen numbered set screw on spindle nose that is on same side as high pencil mark and tighten screw on opposite side see Figure 2 7 8 Turn FEED selector to RETRACT and repeat steps 5 7 as necessary until minimum runout is obtained TRUING MANDREL amp STONE True mandrel and stone as follows NOTE Adjust for mandrel runout before truing mandrel and stone 1 CE amp CD Models ONLY Turn keyed Stroker Disable Switch to DISABLE 2 For safety start truing with a very low Feed Force 1 For tools smaller than 6 mm 25 in 1 2 For larger tools 3 Place a truing sleeve or suitable undersized work piece in a torque absorbing fixture and on mandrel 4 Set FEED selector to EXPAND and turn STONE FEED DIAL until HONING INDICATOR shows a reading 5 Return FEED selector to RETRACT 6 Set COOLANT selector to CONSTANT 7 Slowly open main coolant valve on coolant manifold until there is flow at one or more coolant nozzle Wet shoes and stone with coolant then turn coolant of
86. on or limitation of liability for consequential or accidental damages and to the extent this is true the above limitations may not apply Any alteration or reverse engineering of the software is expressly forbidden and is in violation of this agreement SPC reserves the right to update the software covered by this agreement at any time without prior notice and any such updates are covered by this agreement SAFETY INSTRUCTIONS READ FIRST The ML 2000 like any machine tool may be dangerous if used improperly As a result of our commitment to continual safety improvement many new safety features have been incorporated into this machine However these features cannot protect the operator from all hazards of misuse or abuse of the product Please read all warnings and instructions before attempting to use this machine DO NOT turn power on until all guards and covers are securely in place DO NOT remove or defeat any safety device Depressing foot pedal with power ON can start spindle and stroker motion Use foot pedal ONLY to start a honing cycle after workpiece is securely fixtured and located on honing tool Begin each new setup by depressing Emergency Stop button to clear all previous spindle and stroker speed settings NEVER open or remove any machine cover or protective guard with power ON Always disconnect power at main enclosure before servicing ML 2000 Always wear eye protection when operating ML 2000 DO NOT atte
87. onents in electrical enclosure Enclosure doors cannot be opened with this switch in ON position 17 FEED FORCE 18 HONING TOOL INDICATOR SCALE SELECTOR 20 HONING INDICATOR 16 STROKE LENGTH 32 STROKER DISABLE SWITCH 21 FEED REGULATOR MAXIMUM RATE CE amp CD MODELS ONLY 15 STROKE LENGTH INDICATOR 22 FEED REGULATOR INITIAL DIAMETER FIGURE 2 4 Front Panel 29 ASC UNIT CLAMP Turning this knob clockwise locks Automatic Size Control unit in place Counter clockwise rotation frees unit so that it can be positioned to gage workpiece at end of stroke With further loosening entire ASC unit can be removed from machine 30 ASC FINE POSITION SCREW Adjusts position of ASC unit Clockwise rotation moves ASC unit closer to workpiece 1mm per revolution This direction of rotation is matched to STROKE POSITION HANDWHEEL rotation for easy adjustment after making a stroke position adjustment A knurled locknut holds screw in place after making adjustment 31 PROBE BODY CLAMP KNOB Locks ASC Probe Body to actuator arm When loosened probe body can be aligned with workpiece bore then locked in position 32 STROKER DISABLE SWITCH CE amp CD models only This key switch can be turned to disable stroker for manual honing When DISABLE is selected automatic stroker cannot run and light curtain is also dis
88. oning See Catalogs or contact your Sunnen Filed Service Engineer for more information NOTE No standard fixture is provided to grip workpiece to transmit honing torque to torque bar Several optional fixtures are available Also some types of workpieces are easily fixtured with common hardware items Contact your Sunnen Field Service Engineer for fixturing Refer to Appendix E for Carriage Hole Pattern 34 If using standard Universal Fixture adjust fingers on gate and on stroker carriage to contact workpiece as close to tool as possible without risking accidental contact with tool Position gate so that workpiece is captured but not held tightly between fingers There should be only a small amount of clearance between fingers and workpiece Less than 1 mm 04 in is preferable but more is acceptable if workpiece length is expected to vary 35 If using standard Universal Fixture position Torque Arm to resist torque of workpiece as shown see Figure 3 1 Adjust bar so that torque is taken as far from honing tool as possible but with out risk of workholding fixture slipping past torque bar refer to Appendix A 36 If using an optional fixture purchased from Sunnen Products carefully follow all setup instructions supplied with that fixture If constructing your own special fixture make sure that honing torque will be resisted adequately and that workpiece is captured axially for stroking but free to float and align it
89. ot adaptable for honing blind holes bn 3 4 BORE 25 LENGTH ALTERATION OF INTEGRAL SHOE MANDREL ALTERATION FOR BLIND HOLES In honing blind holes STONE AND GUIDE SHOE LENGTH SHOULD BE 2 3 to 3 4 OF BLIND HOLE LENGTH including relief length This is necessary to provide for proper stroking When alteration of stone and shoe length is necessary remove material only from back end as shown To maintain stability of stone in mandrel it is important that at least 50 of stone be behind forward wedge contact on stoneholder Otherwise stone could rock causing bore inaccuracies as work is stroked over honing unit To avoid any chance for stoneholder to rock when honing extremely 41 APPENDIX shallow or short blind holes it may be necessary to cut back die cast stoneholder as well as abrasive mandrel shoes and wedge tip so that only 1 5 mm 1 16 extends beyond front wedge contact Pressure from wedge is then applied evenly to stoneholder NOTE THAT AT LEAST HALF OF STONE 3 4 BORE LENGTH IS BEHIND LENGTH FRONT WEDGE B CONTACT 1 16 in 1 5 mm SEE gt lle ALTERATION FOR BLIND HOLES Extremely Short Some improvement can be obtained in honing blind holes where no relief is possible at blind end by using a HARD TIP stone Front section of abrasive has a harder bond than rest of stone This harder abrasive reduces excessive wear that stone tip is exposed to when no relief is pr
90. provide adequate clearance for manual honing 26 Install and position Torque Bar on stroker carriage so that work holding fixture can bear against it to resist honing torque 27 True mandrel and stone refer to Section 2 28 Set coolant lines to supply a continuous supply of coolant to front and back of bore Coolant nozzles are attached to small aluminum bases that can be attached to stroker carriage Turn COOLANT selector to CONSTANT and adjust valves on coolant manifold Use as much coolant as possible without losing any to splashing or spraying out of machine NOTE There are two sizes of coolant nozzles provided Black nozzles have small openings for delivering a steady narrow jet of coolant from a distance Use these if it is difficult or inconvenient to place nozzle close to workpiece Orange nozzles have larger openings and can deliver a larger volume of oil with less splash Larger nozzles are preferred if they can be positioned close to workpiece OPERATION MANUAL HONING Follow ALL steps for manual honing carefully and in the order listed NOTE machine Before honing review your setup of 1 Gage bore size using Sunnen Precision Bore Gage to determine amount of stock to be removed 2 Install workpiece in workholding fixture WARNING To prevent personal injury and possible damage to machine DO NOT hone without installing workpiece in a workholding fixture that transmits honing torque to a sol
91. r 10 Stroker Enable Key is Off A cycle will not be started when stroker enable key is in OFF position Turn stroker enable key to ON position Error 11 Electrical Fault The machine has had an electrical fault Check circuit breakers drives overloads and motor temperature 32 FIGURE 5 1 Stroker Pivot Free Play Problems Solutions WARNING Some troubleshooting procedures require examining parts inside machine enclosure ALWAYS have power OFF when hoods are open If problem cannot be diagnosed by Power Off inspection then consult a Sunnen Service Technician PROBLEM Machine does not start when Cycle Start is pressed SOLUTIONS Is power on Is FEED selector set to RETRACT Is foot pedal cover in place Is STROKING selector on AUTOMATIC For Models ML 2000CE and ML 2000CD only Is STROKER key switch set to ENABLE Is green LED on Light Curtain lit If red LED is lit then something is blocking a light beam If yellow LED is lit then light curtain needs to do its startup self check routine Put your hand through light beam path and then pull it out again to trigger self check routine PROBLEM One or more of switches on operator panel do not seem to work SOLUTION Some setup functions such as STROKER JOG will not work if other switches are set improperly Check following Is power on Is FEED selector set to RETRACT Is foot pedal cover in place Is STROK
92. rel NOTE If bore is shorter than stone then Overstroke is amount bore extends past stone at end of stroke If stone is shorter than bore then Overstroke is amount that stone extends past end of bore at end of stroke Overstroke should be 1 3 to 1 2 of bore length or stone length whichever is shorter 10 If needle on Honing Indicator appears to be moving too slowly then increase Feed Force But never increase feed force to point that it is difficult to stroke workpiece smoothly and consistently by hand 21 CAUTION Very small mandrels may break before you encounter significant resistance to stroking With very small mandrels do not increase feed force unless needle on Honing Indicator shows that cutting has virtually stopped 11 Hone until needle on Honing Indicator reaches zero Do not hone below zero Below zero feed force drops from set value which can cause glazed stones poor accuracy and an unnecessarily long honing cycle 12 Gage hole size If workpiece was correctly seated on mandrel when stock removal was set and if Stone Feed Dial or Feed Force dial has not been moved then bore should be undersized by amount that stone has worn Advance Stone Feed Dial by this amount and hone again to zero 13 If more than one workpiece is to be honed then place next workpiece on mandrel and repeat honing operation Do not advance Stone Feed dial at beginning of a cycle unless you are confident that stone wi
93. roke Length Guide printed on front panel of Machine NOTE Maximum stroke length is bore length or stone length whichever is longer If workpieces have long counterbores or large over hangs shorten stroke length to gain stability For workpieces with blind holes maximum stroke length should be bore length including relief minus 2 3 stone length For workpieces with tandem holes using a solid line of stones stroke length should equal total stone length minus tandem distance For workpieces with tandem holes using separated tandem stones maximum stroke length is tandem land length or individual stone length whichever is longer 30 Lock stroke length by tightening Stroke Length Lock securely 31 Engage Stroker Carriage with power stroking unit Push Stroker Carriage back until it stops Turn STROKING selector to AUTOMATIC 32 If Stroker Carriage is very close to spindle then loosen Stroke Position Lock and turn Stroke Position Handwheel to move It away from spindle 33 Install Workpiece Fixturing Workpiece must be fixtured to resist honing torque and to drive workpiece back and forth for stroking The ML 2000 includes following standard fixturing components A Universal Fixture with Fingers for stroking and small Torque Arm to absorb honing torque These can be used for most applications however other fixturing components are available from Sunnen Products Company for certain types of applications such as square h
94. s see Figure 4 1 Apply grease to contact points on Indicator Assembly see Figure 4 2 Apply grease see Figure 4 3 to Cam Assembly Connection Pins Every 1000 Hours Clean and repack feed rod thrust bearings NOTE This service period can be stretched to 2000 hours if machine is only used at low speeds less than 1500 rpm and low feed forces less than 6 Inspect belts for cracks and excessive wear COOLANT SYSTEM If using optional PF 150 Filtrtion System Clean side of reservoir will be pumped low when filter in PF 150 gets dirty see Figure 4 4 Either decrease flow to workpiece by adjusting valves in work area or replace filter in PF 150 Follow directions that came with PF 150 to change filter SPINDLE BELT To replace Spindle Belt proceed as follows see Figure 4 5 1 Remove two screws holding feed rod thrust bearing cover to thrust bearing housing 2 Slide feed rod and thrust bearings forward out of thrust bearing housing 3 Loosen four screws holding spindle motor base plate to deck 4 Loosen one screw on wedge that bears against motor base plate 5 Slide spindle motor in toward spindle to loosen belt 6 Remove and replace belt 7 It is recommended that feed rod thrust bearings be cleaned and repacked with grease at this time Loosen screw in end of feed rod holding bearing in place Pull bearings off of feed rod Note back to back arrangement of these bear
95. s outer jacket 5 Strip 6 mm 1 4 in of insulation off each wire 6 Connect Green Wire GRN to PE Terminal 7 Connect other three wires to Electrical Disconnect Block 8 Route and secure cord inside of Enclosure 9 Tighten Oil Tight Fitting 10 Close and secure lock Door s to Electrical Control Enclosure GND PE TERMINAL PF150 CORD CONNECTIONS 11 Route and connect Electrical Supply Cord to main power source 12 Turn ON Master ON OFF Switch ELECTRICAL OPTIONAL PF 150 WARNING All wiring must be performed by a competent 1 Licensed Electrician accordance with all local lt state and federal codes and regulations along with _ hh OPTIONAL any special information provided on the machine d 150 nameplate or electrical specification plate Verify supply voltage is the same as voltage on Machine nameplate or Electrical Specification Plate Please note some models are sold with an FIGURE 1 9 Coolant Cart external transformer that steps down voltage OE to the machine s nameplate voltage PF 150 nameplate voltage MUST BE THE SAME as ML2000 nameplate voltage ML 2000 has fuse blocks pre wired for PF 150 Filter Unit These are located in main electrical enclosure and are labeled as described on wiring a diagram see Figure 1 8 PF 150 is supplied with a cable that is to be ins
96. s required for proper operation 1 Remove hose barb and install Quick Disconnect not supplied in airline port on Airline Filter Regulator NOTE Elbow has 1 8 NPT threads Elbow and adapter can be removed to access R 1 8 BSPT threads in inlet port of filter regulator CAUTION Do not connect ML 2000 to any air supply with a pressure greater than 1 4 MPa 200 psi 2 CONNECT 1 2 in 50 mm factory air supply line not supplied to Quick Disconnect Route a 6 mm 1 4 IN ID air supply line through slot in bottom of machine base up through openings in top of base to air filter regulator Do not route air supply line over top of base or hood will not be able to close properly and will pinch air supply line 3 Filter regulator has been factory set to 55 MPa 80 psi Air supply to machine must be at least this or machine will not operate properly With air supply connected check regulator gage for 55 MPa 80 psi If not set correctly lift knob on top of regulator and turn to adjust After setting correct regulated pressure push knob down to lock TRANSFORMER INSTALLATION Most machine models are shipped wired for 230 volt To install optional transformer for other voltages refer to wiring instructions on front of transformer see Figure 1 6 CAUTION A step down transformer is optional on some machine models Be certain to verify transformer Kva rating where applicable as well as local electrical c
97. sary for maintenance which should only be done with power turned off 9 Unpack boxes packaged with Machine and check all items against enclosed packing list Notify Sunnen Products Company of any missing or damaged items 10 After unpacking and installing Machine clean and lubricate Use a good quality industrial solvent to remove all grease and preservative from the machine surfaces refer to Section 4 SIDE TRAY Unpack side tray Place mat provided into tray Tray can hang on either side of machine or on side of coolant cart Plastic spacers on bottom of tray bracket can be placed in two different positions to accommodate different widths of machine side and coolant cart side see Figure 1 4 Only one tray is provided as standard If needed a second tray can be ordered Sunnen part ML 6510 4 aN BS N FIGURE 1 5 Air Line Routing THE TRANSFORMER MOUNTED VERY EASILY ON THE BACK SIDE OF THE MACHINE FIGURE 1 6 Transformer GND PE TERMINAL ELECTRICAL DISCONNECT BLOCK MASTER ON OFF SWITCH FIGURE 1 7 Electrical Connection PNEUMATICS Connect pneumatic line airline as follows see Figure 1 5 NOTE The Factory Air Supply Line is not supplied A minimum of 0 55 MPa 80 psi clean dry compressed air i
98. self tool 37 Set stroke position With hands clear from work area press Stroker Jog and hold it in until stroker carriage stops at one end of stroke Measure overstroke distance from end of stone to end of workpiece bore Place workpiece in fixture or hold it next to tool to measure Press Stroker Jog and hold it in until stroker carriage moves to other end of stroke Measure overstroke on that end If overstroke is not equal on both ends then adjust stroke by loosening Stroke Position Lock and then turning Stroke Position Handwheel Handwheel is graduated in millimeters with numbers increasing as carriage is moved away from spindle Tighten Stroke position Lock and recheck overstroke on each end FIGURE 3 1 Universal Fixture 23 38 Set coolant lines to supply a continuous supply of coolant to front and back of bore Coolant nozzles are attached to small aluminum bases that can be attached to stroker carriage see Figure 3 2 Turn COOLANT selector to CONSTANT and adjust valves on coolant manifold Use as much coolant as possible without losing any to splashing or spraying out of machine NOTE There are two sizes of coolant nozzles provided Black nozzles have small openings for delivering a steady narrow jet of coolant from a distance Use these if it is difficult or inconvenient to place nozzle close to workpiece Orange nozzles have larger openings and can deliver a larger volume of oil with less splash Larg
99. some to compensate for this change in compression PROBLEM Needle on Honing Indicator hangs up cutting appears to stop at very low feed force SOLUTION With Feed Regulator off and no work piece on tool turn Feed selector to Expand If needle goes immediately to a position below zero then there is no machine problem Feed force selected is probably too low for application try increasing feed force If needle stops at some position above zero try following Are you trying to feed up past maximum size of tool you are using Is tool running out Try adjusting tool runout Spindle runout can make feed system stick at low feed force Lubricate feed rod at grease fitting inside machine Try using a slightly higher feed force If problem persists contact a Sunnen Service Technician see next problem PROBLEM An application that ran well at a certain feed force on another ML 2000 or at another time on this machine runs differently now SOLUTION Small differences in honing performance can be attributed to slight differences in individual machines machine changes over time or usually to normal variations in cutting performance of abrasive Machines are calibrated to exact specifications before leaving factory Over time they may change slightly It will be easiest to merely adjust feed force to get optimum performance If you suspect that honing performance has changed significantly or if you find it to be sign
100. t Clamp Pivot Block clockwise to open clamp Position clamp on Rail as shown and tighten clamp to secure ASC unit to machine frame 2 Check that ASC unit movement will not interfere with stroker or fixturing Turn ASC PROBE selector switch to DOWN Pull Actuator Arm away from machine so that cylinder is extended and Arm is horizontal Plug in and thread on keyed Cable End to connector at back lower left corner of work area Connect white air line by pushing into place into air fitting with white washer Connect black air line to other fitting WARNING Keep hands away from ASC unit when turning ASC PROBE selector to move ASC probe up or down 3 Turn ASC PROBE selector switch back and forth between UP and DOWN ASC unit movement should be smooth and crisp without bouncing If necessary adjust speeds by turning flow control valves on black and white air lines inside left hood of machine NOTE Following steps 4 amp 5 are used to adjust ASC unit to machine They are listed here because they need only be done once However it may be easier to do this during first setup where ASC will be used See Section 3 Setup Power Stroked Honing 4 Set coarse vertical position of Probe Select and install honing unit according to instructions Adjust runout of tool using concentric part or alignment bushing Lock bushing onto mandrel with EXPAND switch leaving about 12 mm 1 2 in of bore extended past tool Select ASC probe of
101. ta Mandrell eu cco taba tee law dd ae Wa ee Rien 13 Mandrtel amp Stoney 2 45 eased e Widsets l mbes ona wkd weeks es 13 Runout lt Conical g lt Paralel lt we eas hogan wid wba we aka whee 14 Automatic Size Control Optional 4 4 15 wie os 17 Feed Regulat r yasa ayy wiwa A Ee eae OTIS EY 17 SECTION 3 SETUP amp OPERATION General ae ews SR ea ene CU Sue LN AOR Ca BCR 19 Safety E E E ons 19 Operating ens S Saa SAE ade dy 19 Setup Manual Honing scarlet et ele Gs ged vat 19 Operation Manual Honing 42 22 21 Setup Power Stroked 71 1 7 21 Operation Power Stroked Honing 4 0 25 SECTION 4 ROUTINE MAINTENANCE meua
102. talled into ML 2000 main a NV N electrical enclosure Fuses that protect PF 150 from OUTLET short circuit conditions are shipped with PF 150 4 Refer to ML 2000 wiring diagram for electrical amp ELECTRICAL connection k RECEPTACLE BREDAL 1 Open door to ML 200 electrical enclosure 2 Install fuses supply with PF 150 as shown 3 Route cable into ML 2000 Electrical Enclosure and attach wires as shown Red Wire 10L1 to Fuse 4 5FU1 Line L1 White Wire 101 2 to Fuse 4 5FU2 Line 1 2 Black Wire 10L3 to Fuse 4 5FU3 Line L3 Green Wire to Ground Lug PE 7 ELECTRICAL PLUG FIGURE 1 10 Quick Coupling N COOLANT SYSTEM Add coolant as follows see Figure 1 9 1 Remove packing materials from coolant system LATCH 2 Move coolant cart close enough to machine to connect coolant system cable from machine FIGURE 1 11 Foot Pedal Safety Latch ANGLE PLATE FINE POSITION ROD BASE SCREWS CLAMP UME BLOCK SCREW PROBE BODY BUMPER SCREW PROBE BODY oe ae CLAMP KNOB ACTUATOR FINE POSITION SCREW KNOB CLAMP KNOB FIGURE 1 12 Automatic Size Control NOTE If Sunnen PF 150 Filtration Unit is used make connections following instructions supplied with PF 150 3 On operator station turn coolant selector to CONSTANT and turn machine power on momentarily to check pump motor rotation An arrow
103. tation on honing unit in 9 o clock position insert honing unit as far as it will go Rotate honing unit 1 4 turn clockwise to engage wedge with feed rod then push honing unit all way in until it bottoms 18 Test wedge hookup by pulling honing unit straight out do not rotate If wedge is hooked up it will not allow unit to come out If honing unit comes out repeat step 19 Push honing unit back in until it bottoms 19 Tighten large set screw in spindle 20 Release Emergency Stop and turn power on 21 Set Feed Force Dial to desired level 20 CAUTION When manually honing always start at a low feed force for safety 22 Reduce Mandrel Runout refer to Section 2 23 Set Spindle Speed Use chart on operator station as a guideline for determining speed WARNING Recommended speeds may not be suitable for all applications For MANUAL HONING always start with a speed that is no more than half speed recommended on chart then increase speed in small increments only when job seems to be running safely Never exceed recommended speed when manually honing 24 Position Stroker Carriage for manual honing Push Stroker Carriage back until it stops Turn STROKING selector to MANUAL Set STROKER LENGTH to 6 mm 1 4 in Loosen Stroke Position Lock and turn Stroke Position Handwheel to move Stroker Carriage in until it stops Tighten Stroke Position Lock 25 Remove any fixturing components that do not
104. ting surface being partially covered with foreign material usually material being honed This condition is sometimes encountered when honing soft materials MANDREL Part of honing unit which holds and positions honing stone and guide shoes in their correct relative positions METAL BOND Metallic bond used with diamond or CBN Borazon grit to provide a very long lasting honing stone WORKPIECE AT ONE END OF STROKE MANDREL TYPICAL A STONE OVERSTROKE B PART OVERSTROKE OVERSTROKE Distance that workpiece is stroked over end of stone it can also be distance stone extends beyond end of workpiece at end of each stroke This distance is generally one half length of stone or of part whichever is shortest If for any reason a shorter stroke is used the follow ing formulas are useful Stone or shoe overstroke on either end Stroke length Stone length Part length 2 Part overstroke on either end Stroke length Part length Stone length 2 APPENDIX PARALLEL RUNOUT Off center rotation of honing unit which causes eccentric motion of workpiece 777777777 RAINBOW bow Sometimes called camber banana shape Condition where a bore s diameter may be same over its full length but whose axis or center line is curved RELIEF Enlargement of diameter at bottom of blind hole which makes it possible for end of honing stone to pass beyond bottom end of surface being honed SIL
105. tinguished WARNING The capacitors are still charged and can be quite dangerous IMPORTANT NOTE The temperature requirements of the Sunnen ML 2000 Power Stroked Honing Machine have been established as 35 degrees C 95 degrees F Above this temperature an optional cooler will be available to handle temperatures from 35 to 46 C 95 to 115 F IT IS NOT recommended that the ML Machine be operated at temperatures above 46 C 115 F Sunnen Products Company warrants the ML Machine for Operating environments up to 35 C 95 F For operating environments of 35 to 46 C 95 to 115 F the warranty only applies if the optional cooler is installed on the Machine No warranty coverage is offered for operating environments above 46 115 TABLE CONTENTS Page General Information bch Dace ase ii ESD Prevention REVIEW ii Sunnen Limited Product Warranty 4 iii Sunnen Software License Agreement 22 iii 6 iv Safety Instructions LL u TS cee iv Table er aa i aE a by doin ede Deel eGo G e v General Information amp 5 1 4 1 vii
106. trokes to 10 A3 ASC Up Before Cycle or Square Honing The primary use for the A3 DIP switch is for square honing This activates the solenoid that normally raises the ASC arm 0 5 seconds before the cycle starts However for square honing the ASC arm is not on the machine and the square honing fixture is plugged into these ports instead of the ASC arm and activates regardless of ASC ZERO SHUTOFF switch position In this condition Zero shutoff is desirable as well as activation of the ASC solenoid 0 5 seconds before the start of the cycle to lock the fixture that is now plugged in The machine must be allowed to keep this fixture locked and run to zero for shut off Square honing is used often for honing connecting rods This also works well for applications using ASC on a job with a very large fixture The arm rising 0 5 seconds before the beginning of the cycle helps to prevent interference between the arm and fixture but will still raise if you switch to zero shutoff because of the above description For this application put the ASC ZERO SHUTOFF in the ASC position 37 APPENDIX A 5 Ignore Oversize Workpiece In ASC mode if plunger fails to strike workpiece within first few strokes machine determines that workpiece is over size Turning this switch on will prevent ML from reporting an Error 5 condition Switch Bank B B1 B2 Factory Settings These switches should be left in default factory position DO NOT attempt to
107. until plastic cone on cam grips threaded stroker drive shaft 5 Note reference gaging point and indicating gaging point on indicator see Figure 2 11 They should be spaced as far apart as possible without exceeding length of alignment bushing If necessary remove Knob A reference gage point by unscrewing it and inserting it in another hole Sliding Block will slide out to provide even greater separation of gaging points 6 Position stroker carriage so that gaging points will contact alignment bushing 7 Move pivot lock lever to Release position so that entire indicator will follow alignment bushing by contact of reference gaging point 8 With pivot lock lever in Release position Runout Indicator is now set to measure conical runout of honing unit Rotate spindle by hand while observing indicator If necessary turn Knob A to get an indicator reading Turn spindle until high point is found Loosen nearest lettered screw A B C D on front of spindle nose and tighten screw on opposite side Repeat this procedure until conical runout is within acceptable limits Conical runout of less than two divisions on indicator is acceptable for most honing applications For close tolerance applications conical runout should be less than one division 9 With runout indicator remaining on alignment bushing move pivot lever to Lock and turn Knob A counterclockwise two or three revolutions 10 With pivot lock lever in Lock posit
108. widely Move collars to back up both sides of Hinge Latch and tighten them in place TORQUE ARM Torque arm is shipped assembled to a split collar on left fixture support bar For very short workpieces there may not be room for this collar Collar may be removed and torque arm can be attached to top of stroker carriage An extra screw of appropriate length is provided for that purpose HINTS If you need to hone very long workpieces and standard fixture support bars are not long enough longer bars are available as an option 370mm long Sunnen Part Number ML 7190 DIP SWITCH SETTINGS There are two sets of DIP switches located on PED 2202 console board that select different modes of operation Do not attempt to change any settings while power is on To Change a DIP Switch Setting 1 Turn main disconnect off 2 Open console 3 Locate DIP switches 4 Move switch to desired setting 7 8 BANKA 1234 ON 1234 5 67 5 Close and fasten Console 6 Turn main disconnect on Switches Bank A2 A4 A6 amp A7 Factory Settings Those switches should be left in default factory position DO NOT attempt to change these settings unless specified by a Sunnen Representative Al Slow Extra Strokes This causes Stroker to run a Jog speed for number of Extra Strokes selected The program will limit number of Extra S
109. xt listed problem Stroking load may be excessive see solution above to Stroke length changes over time PROBLEM Cannot set stroke speed to anything above 200 SPM SOLUTION Look at stroke length setting If it is at 90mm or above machine control will not allow stroke speed to be set over 200 SPM which would be dangerous to operator and destructive to stroker PROBLEM When setting up to adjust conical and parallel tool runout stroker carriage cannot be placed in a position where runout indicator can pick up con centric bushing centered on abrasive section of tool SOLUTION Runout indicator can be pulled off of pin that it pivots on and aluminum base that holds that pin can be turned upside down and rotated so that pin is in a different position when aluminum base is clamped on threaded stroker shaft If indicator still cannot reach required position it may be necessary to make a special pin for indicator to pivot on mounting to front of stroker carriage PROBLEM When attempting to hone a workpiece with only a very small amount of material to remove 1 to 5 cycle stops immediately without removing required amount of material 33 SOLUTION Feed System normally feeds up rapidly and there is somewhat of an impact when stone contact workpiece Sensitive electronic transducer that reads feed rod position will sometimes pick up this vibration and read a position that is less than zero for a fraction of a second thus
110. ys consider possibility of stacking parts with short bores so that they may be honed as one long bore using standard honing units For precision sizing of open holes stone and guide shoe length should be between 2 3 and 1 1 2 times bore length to be honed 2 3 TO 1 2 BORE ALTERATION OF INTEGRAL SHOE MANDREL Mandrels can be altered as illustrated to hone short bores using automatic size control Alteration allows sensing tip to be positioned closer to end of honing stone Alteration is necessary if overstroke of a short bore does not depress sensing tip a sufficient amount to allow automatic size control to work GLOSSARY OF TERMS ADAPTER A part used with certain mandrels to adapt them to fit spindle on honing machine ALTERED STONE A standard honing stone which has been shortened or otherwise changed for a spe cific application ALUMINUM OXIDE An abrasive material generally most suitable for fast stock removal in tough materials such as most types of steel It is designated by letter A in Sunnen stone code example K17 A57 BARREL SHAPE A condition where extreme ends of a bore are smaller in diameter than middle hk Ld Z 77777777 BELLMOUTH A condition where extreme end ends of a bore are larger in diameter than middle OF BLIND HOLE bore that is constricted closed at one end BOND Material that holds abrasive grains together in a honing sto

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