Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B24—GRINDING; POLISHING
  • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
  • B24B33/00—Honing machines or devices; Accessories therefor
  • B24B33/10—Accessories
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B24—GRINDING; POLISHING
  • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
  • B24B33/00—Honing machines or devices; Accessories therefor
  • B24B33/08—Honing tools
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B24—GRINDING; POLISHING
  • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
  • B24B33/00—Honing machines or devices; Accessories therefor
  • B24B33/02—Honing machines or devices; Accessories therefor designed for working internal surfaces of revolution, e.g. of cylindrical or conical shapes
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B24—GRINDING; POLISHING
  • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
  • B24B33/00—Honing machines or devices; Accessories therefor
  • B24B33/02—Honing machines or devices; Accessories therefor designed for working internal surfaces of revolution, e.g. of cylindrical or conical shapes
  • B24B33/022—Horizontal honing machines
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B24—GRINDING; POLISHING
  • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
  • B24B33/00—Honing machines or devices; Accessories therefor
  • B24B33/08—Honing tools
  • B24B33/083—Honing tools with different sets of honing stones
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B24—GRINDING; POLISHING
  • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
  • B24B33/00—Honing machines or devices; Accessories therefor
  • B24B33/08—Honing tools
  • B24B33/084—Honing tools having honing stones at the end of bars
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B24—GRINDING; POLISHING
  • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
  • B24B33/00—Honing machines or devices; Accessories therefor
  • B24B33/08—Honing tools
  • B24B33/089—Honing tools with a rack-and-pinion mechanism for expanding the honing segments
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B24—GRINDING; POLISHING
  • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
  • B24B33/00—Honing machines or devices; Accessories therefor
  • B24B33/10—Accessories
  • B24B33/105—Honing spindles; Devices for expanding the honing elements

Definitions

• the invention relates to a tool system with tool components for configuring honing tools with different effective diameter ranges and to a method for producing a honing tool.
• Honing is a machining process using geometrically indeterminate cutting edges.
• a honing tool is moved up and down or back and forth within the bore to be machined to generate a reciprocating motion in the axial direction of the bore, and simultaneously rotated to generate a rotary motion superimposed on the reciprocating motion.
• the cutting pads attached to the honing tool are pressed against the inner surface to be machined via a feed system with a feed force.
• Honing typically creates a cross-ground pattern on the inner surface, typical of honing, with intersecting machining marks, also known as "honing marks.”
• Honing tools are available for a wide variety of different machining tasks. While honing tools that are delivered fully pre-assembled by the manufacturer and may only cover a relatively small effective diameter range are often used for machining bores with relatively small or medium diameters (e.g., in the diameter range from approximately 1 mm to approximately 100 mm), there are also concepts with modular tool systems, particularly for machining larger diameters, that allow users to configure their own honing tools optimized for the intended machining task using coordinated tool components of a tool system.
• a honing head comprising an elongated, cuboid-shaped tool body, fits directly onto the drive shaft of the processing machine and features a universal joint and a rotational expansion system.
• a toothed expansion rod is housed in an axial bore of the tool body as an infeed element.
• the tool body has several cross bores aligned transversely to the tool axis, each one for receiving a guide pin of a support bar unit.
• the cross bores are open to the axial bore so that, when the honing tool is assembled, the guide pins can be in force-transmitting contact with the feed element arranged in the axial bore.
• the cross bores form several bore groups distributed around the circumference of the tool body, each with two cross bores arranged at an axial distance from one another.
• the tool components also include several sets of support bar units.
• the support bar units to be attached to the tool body each have two axially parallel guide pins on the side facing the tool body, which also have teeth. The intermeshing of the teeth and the resulting rotation of the toothed expansion rod move the installed support bar units outwards or inwards.
• the support bar units that fit a tool body differ only in the length of the guide pins, allowing a specific effective diameter range to be covered with one and the same tool body and support bar units from a matching set.
• the assembly described above is given additional rigidity by incorporating a support bracket.
• the invention is based on the object of providing a tool system with tool components for configuring honing tools, whereby honing tools can be assembled with relatively few different tool components that cover a relatively large range of different effective diameters.
• the honing tools assembled with tool components of the tool system should ensure trouble-free honing operation even with large effective diameters without vibrations that are detrimental to the honing result, so that honing processes can be carried out reliably and honed surfaces of high quality can be produced.
• the production of the Tool components should be cost-effective and resource-efficient, and assembly should be quick and reliable even for inexperienced users.
• the invention provides a tool system having the features of claim 1. Furthermore, a method for producing a honing tool having the features of claim 14 is provided. Advantageous further developments are specified in the dependent claims. The wording of all claims is incorporated into the description by reference.
• a tool system comprises tool components for configuring honing tools with different effective diameter ranges.
• effective diameter refers to the minimum diameter of an enveloping cylinder that encloses the abrasive cutting surfaces of the honing stones at a given radial feed position.
• the effective diameter can be varied by means of the feed system within design and technological limits. It is therefore an expandable or expandable honing tool.
• the tool components include at least one tool body, which defines a tool axis.
• the tool body forms the basis of a honing tool to be constructed with it.
• the tool axis corresponds to the axis around which the honing tool is to rotate during a honing operation.
• Coupling structures can be provided at a machine-side end of the tool body, enabling the honing tool to be coupled to an adapter, a drive rod, or a tool spindle of a processing machine.
• An axial bore arranged coaxially to the tool axis is formed in the tool body for accommodating an (internal) feed element of a feed system.
• the current effective diameter of the honing tool can be changed during operation via the machine tool. This makes it an expandable or widenable honing tool, preferably with a continuously variable effective diameter.
• the tool body is provided with a plurality of transverse bores aligned transversely to the tool axis, which are open to the axial bore and are designed to receive a guide pin of a support bar unit to be inserted therein.
• the transverse bores form a plurality of bore groups distributed over the circumference of the tool body, each with at least two transverse bores arranged at an axial distance from one another.
• an even number of evenly spaced transverse bores are provided over the circumference.
• distributed hole groups are provided; for example, four hole groups can be provided, each offset by 90° around the circumference.
• Other pitches are possible, e.g., with three or five or six or seven or eight hole groups, which can be evenly or unevenly distributed around the circumference.
• the tool system further comprises a plurality of support bar units that fit the tool body or can be used on the tool body.
• Each support bar unit has a support bar that has at least two guide pins insertable into the transverse bores of a bore group on an inner side facing the tool body, and is designed to support at least one honing bar on an opposite outer side.
• a tool body of the tool system includes two or more sets of support bar units.
• the components of the tool system thus comprise a first set of support bar units and at least one second set of support bar units.
• Each set of support bar units comprises a number of support bar units corresponding to the number of bore groups, which are preferably nominally identical to one another.
• Support bar units of the first set have first guide pins with a first length
• support bar units of the second set have second guide pins with a second length, wherein the second length is greater than the first length.
• Support bar units of different sets therefore differ at least with regard to the length of the guide pins, so that by selecting a suitable set of support bar units it is possible to specify which effective diameter range a honing tool can cover.
• the support bar units of a set are attached to the tool body, distributed around the circumference, by inserting the guide pins provided on the support bars into the designated transverse bore of the tool body.
• the feed element When the feed element is inserted into the axial bore, they are then in mechanical contact with the tool body, so that a working movement of the feed element causes the support bar units to advance.
• the lower limit diameter of the corresponding effective diameter range can be set with the support bar units fully retracted. However, if the support bar units from the set with the longest guide pins are used with the tool body unchanged, the upper limit of the effective diameter range that can be achieved with the same tool body can be reached.
• the tool system comprises at least one set of bolt guide elements assigned to the tool body, which are designed for mounting or fastening to the tool body, wherein a set of bolt guide elements has a bolt guide element for each of the transverse bores provided for receiving a guide bolt with a guide bore formed therein, which runs coaxially with the transverse bore when the bolt guide element is firmly mounted on the tool body.
• the number of bolt guide elements corresponds at least to the number of cross holes, so that one bolt guide element is available for each of the cross holes.
• the number of guide pins is conveniently defined depending on the cutting bar length to ensure stability and process reliability.
• the bolt guide elements are tool components of the tool system that can be manufactured and kept separately from the tool body and that can be attached to a tool body if required in order to achieve more stable guidance when using longer guide bolts.
• Bolt guide elements can be configured so that the connection to the tool body is structurally detachable, or so that the bolt guide elements can be easily established and released again as needed, for example, by the end user, without damaging the tool body or the bolt guide element.
• a screw connection can be provided for this purpose. It is also possible to attach or fasten bolt guide elements to a tool body in such a way that they remain permanently on the tool body. In this case, a tool body can be extended using the bolt guide elements, so that a modified multi-part tool body unit is created on the basis of a tool body by attaching the bolt guide elements.
• a bolt guide element attached to the tool body provides a mechanically stable and resilient bolt guide with its guide bore, which is located at a greater distance from the tool axis than the corresponding cross bore in the tool body.
• the guide holes in the bolt guide elements prefferably have the same diameter as the corresponding cross holes. This allows the effective guide length for the guide bolts to be extended outward, allowing a guide bolt to be guided in both the cross hole and the adjacent guide hole.
• the diameter of the first guide pins is adapted to the diameter of the cross holes in the The tool body is adapted in such a way that a sliding guide for the first guide pins can be created or is formed in the transverse bores of the tool body, and that the diameter of the second guide pins (second diameter) is smaller than the first diameter and is adapted to a diameter of the guide bore of a bolt guide element in such a way that a sliding guide for the second guide pins can be created or is formed in the respective bolt guide elements.
• the second guide pins which are longer than the first guide pins, are only guided in the area of the guide bores of the bolt guide elements, while they sit with play in the associated transverse bores but are not guided there.
• the guidance of the longer second guide pins only takes place in the area of the bolt guide elements attached to the tool body and is thus displaced outwards with respect to the tool axis.
• the maximum projection length of the longer guide pins remains relatively short during the infeed of the support bar units, so that the leverage under the influence of the machining forces remains limited and sufficient mobility of the second guide pins is always maintained for the infeed.
• the diameter differences between short and longer guide pins can be small, for example, in the range of approximately 500 ⁇ m to approximately 1000 ⁇ m. The diameter differences may not be noticeable when viewed with the naked eye.
• one elongated guide holder is provided for each of the bore groups, which guide holder has a number of bolt guide elements that corresponds to the number of cross bores in a bore group and are connected to one another.
• it can be a one-piece component, i.e. made from a single piece of material.
• Such guide holders offer, among other things, the advantage that the center distances between the guide bores provided in the guide holder can be maintained with a high degree of positioning accuracy during production, so that when an elongated guide holder is attached to the tool body, each of the guide bores formed in the guide holder can be attached exactly coaxially with the associated cross bore on the tool body, within the framework of the small manufacturing tolerances.
• a guide holder comprises mounting structures for establishing a detachable connection with the tool body. This makes it possible to use one and the same tool body or one and the same type of tool body for at least two different diameter ranges. For the smaller diameter range, which encompasses the lower limit of the total effective diameter range, the tool body is used without attached guide holders. If a larger effective diameter range is to be used, the guide holders are attached to the tool body and the support rail units with the longer guide pins (second support rail units) are used.
• a set of bolt guide elements comprises a separate column-like extension piece for each of the transverse bores, which is also referred to in this application as a "guide column.”
• the length of such a guide column, measured parallel to the guide bore contained therein, is preferably greater than the diameter of the guide bore contained therein.
• Such a permanent connection between the tool body and the bolt guide elements can also be provided if the bolt guide elements are grouped together to form guide holders.
• the transverse bores are designed as radial bores directed radially to the tool axis. This results, among other things, in a better distribution of forces in the honing tool when the support bar units are advanced during operation.
• the feed element comprises several, i.e., two, three, or more axially offset conical sections with inclined surfaces, and the guide pins have complementary inclined surfaces at their free ends.
• the inventors assume that this type of feed contributes to the honing tools being significantly less prone to vibration during operation than the conventional honing tools mentioned above.
• the tool body is a one-piece component that has alternating tube sections in the axial direction with a wall thickness that is essentially constant in the circumferential direction and cross-bore sections that contain cross-bores located therebetween.
• each of the cross-bores is formed in an outwardly projecting column section such that a bore length of the cross-bores is greater than an average wall thickness in the tube sections, in particular by at least 20%, at least 30%, or at least 40% greater, possibly even approximately twice as large.
• the column sections have in common that the cross bores of the tool body are arranged within them.
• the external shape of the column sections can vary.
• the column sections are essentially sleeve-shaped, resulting in a cylindrical outer shape and the cross bore is partially guided within a sleeve protruding outward from the tool body.
• a column section can also have a rectangular outer contour. This makes it particularly easy to manufacture precision surfaces on the tool body that serve as contact surfaces for bolt guide elements (individual guide columns or integrated in the guide holder) to be attached to the tool body.
• the tool system already offers a multitude of different possible applications based on the tool components described so far.
• the flexibility of use is further increased by the fact that the tool components comprise a plurality of interchangeable units that can be interchangeably mounted on a support bar of a support bar unit and each have a bar-shaped adapter plate that has receiving structures on one side for receiving at least one honing bar and connecting elements of a connecting device for detachably connecting the adapter plate or the interchangeable unit to a support bar on an opposite mounting side. If such interchangeable units are provided, it is particularly easy and convenient for an end user to equip the honing tools with cutting surfaces that are optimally adapted to the machining task.
• the tool system comprises sets of adapter plates with different thicknesses or heights. This makes it possible to cover at least two different effective diameter ranges with one and the same support bar unit.
• the support bars in some embodiments have at least two through holes that are arranged at a distance from one another and run through from the outside to the inside, and the exchange unit has connecting elements in the form of pins that can be inserted into the respective through opening without play, wherein the pins preferably have a threaded section for producing a screw connection between the exchange unit and the support bar unit.
• the honing stone is the element that bears the cutting layer.
• the cutting layer on honing tools essentially consists of irregularly shaped cutting grains of varying shapes and sizes, bonded within a bond system. By selecting the type of cutting layer, a honing tool can be precisely adapted to the desired machining task.
• Cutting grains can be diamond grains or cubic boron nitride (CBN), for example.
• Cutting grains can also be made of corundum and/or other types of ceramic materials, such as SiC.
• the bond can be made of a ceramic material or synthetic resin, for example.
• Metallic bond systems, such as electroplated bonds or sintered bonds, are also possible, as are brazed bonds if necessary.
• the honing stone may consist entirely of a cutting layer.
• it may be a strip-shaped honing stone with a ceramic bond.
• the honing stone is constructed in several parts and has a strip-shaped base plate that supports the cutting layer on one side.
• the base plate can be made of steel or another metallic material, for example.
• the cutting layer can be attached to the base plate by sintering, soldering, gluing, or by means of another adhesive layer.
• the base plate can provide additional mechanical stability to the honing stone or cutting layer.
• the tool system offers a wide range of possible uses while requiring a relatively small number of different tool components. It is, in principle, possible to construct an entire tool system with a single type of tool body, since by using different sets of bolt guide elements in conjunction with correspondingly adapted sets of support bar units, one end user can easily produce honing tools for several different Effective diameter ranges can be constructed which cover a relatively large total effective diameter range.
• a tool system it is also possible for a tool system to have exactly two different tool bodies, the use of which, in conjunction with the tool components that can be attached to them, can make an even greater variety of different effective diameter ranges available.
• the tool system comprises exactly three differently dimensioned and designed types of tool bodies. These, in conjunction with the tool components that can be attached to them, can cover almost all conceivable machining tasks over a very large total effective diameter range.
• One embodiment of a modular tool system for example, is designed for a total effective diameter range of approximately 110 mm to approximately 600 mm and requires exactly three differently designed tool bodies.
• the tool components comprise at least one set of annular stabilizing elements, the number of which corresponds to the number of transverse bores in a bore group and which have receiving bores distributed over the circumference for each receiving a columnar stud guide element.
• the tool system can further comprise components of a cooling lubricant supply system that can be optionally mounted on the tool body, in particular a connection and distribution ring that can be mounted on the tool body and in which a circumferential distribution channel is formed, as well as a plurality of connecting and distributing rings that communicate with the distribution channel and are arranged axially parallel to the Tool axis and nozzle tubes with nozzle openings for dispensing cooling lubricant that can be mounted at a radial distance from the tool body.
• a cooling lubricant supply system that can be optionally mounted on the tool body, in particular a connection and distribution ring that can be mounted on the tool body and in which a circumferential distribution channel is formed, as well as a plurality of connecting and distributing rings that communicate with the distribution channel and are arranged axially parallel to the Tool axis and nozzle tubes with nozzle openings for dispensing cooling lubricant that can be mounted at a radial distance from the tool body.
• the invention also relates to a method for producing a honing tool that can be produced or configured using tool components of the tool system.
• a tool body of appropriate dimensions, as described here for the first time, is selected, and an infeed element is inserted into the receiving bore.
• a set of support bar units is selected, each with a number of support bar units corresponding to the number of bore groups.
• Each support bar unit has a support bar that, on an inner side facing the tool body, has at least two guide pins that can be inserted into transverse bores of a bore group, and is designed to support at least one honing bar.
• At least one honing bar is attached to each of the support bar units.
• the support bar units are mounted on the tool body either before or after this, with the guide pins of the support bar units being inserted into the transverse bores provided for this purpose.
• Tool components of the tool system according to the claimed invention are used to produce the honing tool. If required, this preferably also includes suitable bolt guide elements, which are present, for example, in the form of guide holders or guide columns in the tool system and which enable an increase in the effective diameter range that can be reliably achieved with a specific tool body type.
• the following examples illustrate a modular tool system comprising a multitude of coordinated tool components that can be used to configure honing tools for different applications.
• This example shows a tool system that can be used to assemble honing tools that can cover a total effective diameter range of 110 mm to 600 mm. Other effective diameter ranges can, of course, also be covered using the same principles.
• the exemplary modular honing tools are particularly suitable for machining deep bores with large diameters, such as those found in pipes for pipelines or cylinder liners for larger combustion engines.
• large diameters such as those found in pipes for pipelines or cylinder liners for larger combustion engines.
• functionally and/or structurally similar or identical Components generally use the same reference symbols in all examples to avoid confusion.
• the tool system comprises a total of exactly three differently designed tool bodies, which are Fig. 1 to 3 are shown in an oblique perspective, namely a first tool body 100-1 ( Fig. 1 and longitudinal section in Fig. 4 ), the second tool body 100-2 and the third tool body 100-3.
• the tool body 100-1 defines a tool axis 112, which can also be referred to as the longitudinal center axis of the tool body and corresponds to the rotational axis of the honing tool during honing.
• Each of the tool bodies (general reference numeral 100) is manufactured in one piece from a relatively thick-walled steel tube using material-removing machining processes such as milling, turning, spark erosion, and, if necessary, finishing, etc., to form a stable base for the honing tool.
• material-removing machining processes such as milling, turning, spark erosion, and, if necessary, finishing, etc.
• a tool body can also be composed of several parts.
• a cylindrical axial bore 114 is provided coaxially to the tool axis 112 over most of its length, extending from the machine-side end 116 to the free end 117 of the tool body.
• the axial bore serves as a receiving bore and guide bore for an internal tool feed element 120, which, in the example, comprises three axially spaced conical sections 122 with inclined surfaces for feeding support bar units, which will be explained later.
• An axial bore with an internal thread 124 is formed in the machine-side end section of the feed element 120.
• a longitudinal groove extends along the outer side, into which a dowel pin engages to prevent rotation of the feed element 120.
• a set screw 128 with a wide head and a threaded portion with an external thread matching the internal thread 124 is screwed into the internal thread at the front end. Rotation of the set screw 128, for example, using an Allen key, causes an axial displacement of the feed element 120. This creates a rotary expansion that is compatible with many conventional drive and feed systems for larger honing tools.
• the tool body 100-1 has twelve transverse bores (general reference numeral 130) aligned transversely to the tool axis 112, the bore axes 132 of which are each oriented radially to the tool axis 112, so that the transverse bores 130 are also referred to below as radial bores 130.
• the transverse bores or radial bores 130 extend from the outside to the receiving bore 114 and form a total of four bore groups 135 evenly distributed over the circumference of the tool body, each with three axially parallel and equidistant radial bores 130.
• a total of four bore groups, each with three radial bores, are provided, each offset by 90°.
• the tool body 100 is more or less tubular overall and has, in the axial direction, alternating tube sections 113 and transverse bore sections 115 containing transverse bores 130.
• the tool body In the region of the tube sections, the tool body has an average wall thickness corresponding to approximately 20% to 30% of the average outer diameter of the tool body in the wall sections.
• an outwardly projecting column section 134 is formed for each of the transverse bores such that the bore length of a radial bore (transverse bore) 130, measured in the radial direction, is significantly greater than the average wall thickness, for example, approximately twice as large.
• the outwardly projecting column sections 134 have approximately the shape of cylindrical sleeves.
• the design with outwardly projecting column sections offers a weight-optimized design of the tool body, while at the same time the radial bores 130 offer relatively long guide lengths for the guide pins of support bar units, which will be explained later.
• the tool system further includes a plurality of support bar units 150 that fit or can be used on the first tool body to configure a honing tool.
• Fig. 6 to 9 A support bar unit 150 matching the first tool body is explained in more detail. It belongs to a first set of support bar units that fit into a first tool body 100-1.
• the support bar unit 150 comprises a support bar 155 made of steel with a flat rectangular cross-section and a length that is slightly greater than the length of the associated bore group 135.
• three cylindrical guide pins 160 are fastened to the inner side of the support bar, which will later face the tool body. These are inserted with one end into corresponding fitting bores on the support bar 155 and fastened there by soldering, welding, gluing, or the like.
• At least one set of such support rail units with relatively short guide pins there is also at least a second set of support rail units whose guide pins have a greater free length and preferably also have a different guide cross-section or diameter.
• a support bar unit 150 is a modular unit which, in addition to the support bar 155 with the guide pins 160 attached thereto, also has a flat adapter plate 170 which serves as a carrier for the honing stones 175 attached thereto and which has a flat rectangular groove on one side for receiving the honing stones (cf. Fig. 9 ).
• the outer rectangular groove serves to accommodate one or more honing stones, which can be glued into the groove, for example.
• Two axially parallel through-holes 157 are provided in the support bar, each of which is arranged in the area between two guide bolts.
• the adapter plate 170 has sleeve-shaped projections 172 on its underside facing the support bar, which fit precisely into the through-holes 157 of the support bar, so that the adapter plate can be attached to the support bar in the correct position.
• the connection between the adapter plate 170 and the support bar 155 is easily removable due to its design.
• an internal thread is provided in the area of the projections 172 of the adapter plate 170, into which the external thread of a threaded section of a fastening screw 175 fits, so that, as shown in Fig. 7
• the adapter plate 170 can be securely and correctly positioned, yet detachably attached to the support bar using a screw connection. This allows for particularly quick and convenient replacement of honing stones, for example, after wear, while maintaining the correct position of the honing stones. The use of only two screws allows for quick replacement of the adapter plate.
• a honing tool can be constructed that can be used for honing within a first effective diameter range.
• the three guide pins 160 of a support bar unit are each inserted radially into the three associated radial bores 130 of a bore group 135 and pushed inward until the inclined surfaces 161 of the guide pins rest on the inclined surfaces of the expansion cones 122 of the feed element 120.
• the support bar units With the help of tension springs that engage hook sections of the support bar units, the support bar units are preloaded radially onto the expansion cones and can be fed radially outwards upon axial movement of the feed element towards the free end.
• the diameters DF1 of the cylindrical first guide pins 160 are adapted to the diameters DR1 of the transverse bores in the first tool body (also referred to as first diameters) in such a way that a radial sliding guide of the guide pins 160 is formed in the tool body.
• honing tools can also be configured that are suitable for a larger effective diameter range than those that can be achieved using the support bars 150 with the shortest guide pins.
• at least one set of support bars can be assigned to the selected first tool body 100-1, which basically has the same structure as the support bar 150 of the Figs. 6 and 7 , but the guide pins (second guide pin 160L) protrude from the support bar over a larger second length L2.
• These guide pins could have the same guide cross-section or diameter DF1 as the first guide pins 160 and be guided directly in the transverse bores 130 of the first tool body 100-1.
• the problem may arise that the overhang length of the guide pins becomes relatively large, resulting in instability of the honing tool under the process forces at a large overhang, which may lead to vibrations or other disturbance phenomena.
• the tool system comprises at least one set of bolt guide elements 210 adapted to the first tool body 100-1 so that they can be mounted or fastened thereto.
• a set of bolt guide elements has a guide bore 212 for each transverse bore or radial bore 130 of the tool body, which, when the bolt guide element is fastened to the tool body, runs coaxially with the corresponding transverse bore.
• the Figs. 10 and 11 show, in an oblique perspective and a longitudinal section, an embodiment of an elongated guide holder 200, which is a component made separately from the tool body, preferably in one piece, made of suitable steel.
• the guide holder 200 comprises three bolt guide elements 210, which are interconnected via a strip-shaped connecting piece 215.
• a through-hole 212 is formed in each of the bolt guide elements 210, to which a substantially cylindrical, enlarged section 214 adjoins on the side facing away from the connecting strip.
• at least one through-hole 211 is formed in each bolt guide element for receiving and passing through a fastening screw.
• the inner diameter of the enlarged section 214 is adapted to the outer diameter of the sleeve-shaped projections 134 in the transverse bore sections such that the guide holder 200 can be placed onto these column-like projections. can, whereby the column-like projections then engage in the extended sections 214 and thus ensure reliable positioning of the guide holder on the tool body.
• the guide bores 212 within the bolt guide elements 210 run exactly axially parallel to one another within the manufacturing tolerances, with center distances that exactly correspond to the center distances of the transverse bores 130 of a bore group. If the guide holder 200 is placed onto the sleeve-shaped sections of a bore group and secured with the fastening screws, the axes of the guide bores 212 automatically run coaxially with the radial bores 130 with high precision.
• Fig. 13 shows a partial section through the free end of an assembled honing tool 300.
• the guide holder 200 is attached to the tool body 100-1 by fastening screws.
• a support bar unit 150 with second guide pins 160L is used, which are longer than the first guide pins, which can be used without the guide holder.
• the second guide pin extends through the guide opening 212 of the guide holder 200 and the radial bore, and its beveled end rests on the expansion cone.
• the guide diameter DF2 of the second guide pin 160L is slightly (e.g., a few tenths of a millimeter) smaller than the guide diameter DR1 of the shorter first guide pin 160.
• the guide diameter DR2 of the guide bores 212 in the stud guide elements 210 is slightly smaller than the diameter DR1 of the transverse bores. This ensures that the longer guide pins 160L are guided exclusively in the guide bores 212 of the guide holder 200, but not in the slightly larger transverse bores 130 in the tool body. This prevents constraining forces between the tool body and guide holder.
• the reliable sliding guidance in the guide bore 121 of the stud guide elements 210 is located at a greater radial distance from the tool axis 112 than the guidance of the shorter guide pins, which takes place in the tool body itself.
• the first tool body 100-1 can thus be used in at least two different configurations. If it is used "naked," i.e., without the attachment of bolt guide elements or guide holders, support rail units with short guide pins can be securely guided in the transverse bores 130. If support rail units with longer guide pins 160L are to be mounted and securely guided, a set of guide rails 200 (one for each bore group) is screwed to the tool body. This creates, so to speak, a modified tool body, which then is suitable for guiding support rail units with longer guide pins at a greater distance from the tool axis in such a way that even with the support rails fully extended, the projection beyond the guide bore 212 remains so short that stable operation is possible even under high process forces.
• the second tool body 100-2 has a similar structure to the first tool body 100-1, but is designed to produce honing tools that function reliably over a medium effective diameter range.
• the second tool body is also manufactured in one piece from a tubular semi-finished product, has an axial through-bore coaxial with the tool axis, and has four groups of bores, each circumferentially offset by 90°, each with three axially offset radial bores.
• the center distances are identical to the center distances of the first tool body.
• the axial bore 114 has a larger diameter, and the wall thickness of the tubular sections is greater, thus ensuring high stability.
• the transverse bores 130 i.e., the radial bores 130, oriented radially to the tool axis, are formed at a greater distance from the tool axis.
• the sleeve-shaped projections 134 are seated on cuboid-shaped bases, so that relatively long guide lengths can be provided in the transverse bores at a greater distance from the tool axis 112.
• support rail units with guide pins of different lengths can be used, similar to the first tool body. However, those with the shortest guide pins are longer than the shortest guide pins usable on the first tool body. If the diameter range is to be expanded to larger diameters, a guide holder 200 can be placed on each of the sleeve-shaped projections 134 as described above to shift the location of the radial guidance further outward.
• the second tool body 100-2 it is also possible to use the second tool body 100-2 to create a modified tool body by attaching bolt guide elements that works for support rail units with relatively long guide bolts.
• FIG. 14 Another possibility is described in which a separate bolt guide element 310 is provided on the third tool body 100-3 for each radial bore 130.
• the third tool body 100-3 can be modified using twelve such bolt guide elements 310 so that using this modified tool body Honing tools can be designed for an effective diameter range whose lower and upper limits are shifted to larger diameter values compared to the use of a "naked" second tool body.
• the bolt guide elements 310 of this example are each fastened to the sleeve-shaped projections 134 of the individual radial bores such that the guide bore 312 formed in a bolt guide element runs coaxially with the corresponding radial bore 130. Similar to the first example, the guide bores 312 have a smaller diameter than the corresponding radial bores.
• the support rail units adapted to them have corresponding guide bolts with a diameter that, together with the guide bores 312, forms a sliding guide.
• the individual bolt guide elements 310 are also referred to here as "guide columns" because they provide guidance for the guide bolts of the support bars and have a column-like structure with an axial length that is smaller than the diameter.
• the guide columns are positioned in the bores provided on the tool body with a fit and thread and are firmly connected to the tool body.
• a permanent connection can be achieved, for example, by welding, in particular laser welding, or by other means.
• the guide pillars are very simple individual parts that can be manufactured from a material with special properties and without heat treatment.
• tool steel or pre-hardened tool steel can be used.
• Fig. 15A shows an example of a threadless guide column, which is inserted into the bore in the tool body with a tapered pin and then permanently connected to it by welding, gluing or similar.
• Corresponding threaded sections are formed on the tool body and on the guide column in order to be able to screw the guide columns onto the tool body.
• the guide column has a tapered centering pin 311, which fits into a cylindrical recess on the tool body to secure its position and is connected to a threaded section. The screw connection can then be secured against accidental loosening, for example, with adhesive.
• FIG. 16 An embodiment of a completely assembled honing tool 400 is shown, which was constructed using the third tool body 100-3. In contrast to the first and second tool bodies, this has no outwardly projecting cylinder sleeves on the individual radial bores, but rather protruding cuboid sections 434, into which a radially aligned stepped bore is introduced, the inner region of which forms the radial bore, which is adjoined on the outside by a section of larger diameter, which transitions inwardly to the radial bore at a radial step.
• Individual bolt guide elements 410 or guide columns 410 are provided for this purpose, which have a fastening section at the invisible inner end, to which a flange-like section 412 and a longer sleeve-like section 415 adjoin on the outside.
• the guide columns formed in this way are penetrated by a guide bore, which forms a sliding guide with the guide bolt of the associated support units.
• the tool system also features sets of stabilizing rings 430, which can be attached to the circumference of the guide columns 410 as shown, thus enabling a low-vibration and reduced-noise honing process.
• Each stabilizing ring has four radial bores offset by 90° around the circumference, into which the outwardly projecting sleeve-shaped sections 415 of the guide columns fit essentially without play. Elongated holes are formed in the circumferential direction between the radial bores to achieve a weight reduction on the rings.
• the guide pillars 410 are first inserted from the inside into the radial bores of the retaining rings 430 until the flange-like projection abuts the ring from the inside.
• the retaining ring with the attached guide pillars can then be pushed over the tool body.
• a separate stabilizing ring is provided for each transverse bore section. Once the stabilizing ring is correctly positioned, the inner fastening sections of the guide pillars 410 can be inserted into the receiving bores on the tool body and the guide pillars can then be fastened there.
• the four support bar units can then be attached to the honing tool by inserting the respective guide pins into the associated guide bores of the guide pillars 410 and the coaxial radial bores of a bore group until the inclined inner ends of the guide pins are in contact with the conical surfaces of the feed element.
• the tool system further comprises, at least in the variant described below, tool components of a cooling lubricant supply system 180, which can optionally be attached to a tool body.
• the components are attached to the first tool body 100-1. They comprise a connecting and distribution ring 182, in which a circumferential distribution channel is formed, which is connected via a not shown Connection pieces can be pressurized with coolant under pressure.
• Four nozzle tubes 185 extend from the distribution channel, axially parallel to the tool axis 112 and at a radial distance from the tool body, to an annular holding element 183, which can be screwed onto the free end of the tool body.
• the nozzle tubes 185 each have two circumferentially offset nozzle openings at the level of the transverse bore sections, through which coolant can be sprayed to the circumferentially adjacent support bar units with honing stones.
• correspondingly suitable component sets are provided, which essentially only differ in the diameter of the annular components to be attached to the tool body.
• honing tools constructed using the first tool body 100-1 can cover effective diameters in the range from 110 mm to 200 mm
• honing tools with effective diameters from 200 to 300 mm can be constructed using the second tool body 100-2
• the effective diameter range from 300 mm to 600 mm can be covered using the third tool body, provided that the appropriate guide columns are mounted on the tool body 100-3 for the larger diameters.
• the production of the components of the tool system is relatively cost-effective overall.
• only three different tool bodies are required for the entire diameter range.
• tubular semi-finished products are produced in a single clamping process entirely by turning, milling, and, if necessary, other manufacturing processes. Subsequently, it is only necessary to grind the bore for the expansion element.
• thermal treatment of the tool body after forming is not necessary. Bridging the desired effective diameter ranges is achieved using guide pillars and/or guide holders, i.e., using the additionally attachable bolt guide elements.
• the honing tools are designed as a relatively lightweight, modular structure with the tool body at the center and functional components projecting radially outward. Like a kit, the user can assemble the required Select tool components from the tool system that are suitable for its purpose and compatible with each other and thus configure a suitable honing tool.
• the tool system can include sets of adapter plates with different heights of the bar-shaped part, allowing honing stones to be mounted on the same support bar at different distances from the support bar.
• adapter plates of different thicknesses it is possible to cover certain effective diameter ranges with identically dimensioned support bar units.
• the honing bar(s) can be removed from the existing adapter plate and then reused.

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