Abrasives key to high Cpk honing

"The most common problems, such as variable abrasive life, fluctuating cost per honed part, inability to meet Cpk targets and surface finish, are often due to small, but critical, variations in the abrasives,” he says. “Customers who track their honing costs and part quality quickly realise that both often improve when they switch to Sunnen abrasives.

“This is a primary reason Sunnen has been manufacturing honing abrasives for much of the company's 90+ years. Over decades, our manufacturing process has been so perfected that many customers resume use of genuine Sunnen abrasives after trying other options. In fact, customers with non-Sunnen machines often specify our stones."

Sunnen employs more than 100 people in its abrasive R&D and manufacturing operations. Mr Hooper says the company manufactures its own conventional and bonded superabrasives, as well as diamond-plated single stroke honing tools.

"We offer the industry's widest range of honing abrasives from aluminium oxide and silicon carbide to diamond and superabrasives. These are matched with similarly wide range of bond types, grain sizes and stone configurations," he adds. "Most importantly, Sunnen has developed proprietary manufacturing steps to ensure our abrasive consistency is second to none."

Sunnen also manufactures precision tooling, including its exclusive in-process expanding, diamond-plated mandrels. As a service to customers, the company also supplies tooling and abrasives for most other brands of honing machines.

"Even where customers think they have seen everything in conventional abrasives, we continue to roll out new products, such as our 60-grit premium red aluminium-oxide abrasive that cuts material 25 – 50% faster than other conventional abrasives," says Mr Hooper. "Likewise, our bonded diamond and CBN superabrasives are setting production records honing exotic materials as easily as ordinary hardened steel."

With many possible ways to hone a part, Mr Hooper stresses that Sunnen's honing lab is often the best place to determine which abrasive, coolant and honing technique will produce the most cost-effective results.

"Customers who visit our lab are amazed at what they learn from our machinists and metrology experts," he concludes. “When you consult Sunnen, you tap into decades of knowledge developed in a research facility dedicated entirely to the study and advancement of honing technology. It's often the first stop for customers on the route to a better process."

Sunnen www.sunnen.co.uk