Plug and play precision    

Modern manufacturing demands ever tighter tolerances on complex components, and while machine tools and CNC controls continue to assist when it comes to cycle time reduction, one element of the process has remained firmly in the hands of the operator.


Until now, adjusting tools to micron level accuracy has long been a labour intensive, time consuming process, often fraught with the potential to scrap high-added value components. Rigibore’s digital adjustment system, Smartbore allows precise setting of fine boring tools without the need to unclamp/clamp, thereby eliminating the negative impact of conventional tool adjustment.

“On many high value components, the difference between perfect and scrap is often a matter of microns – scrap parts are expensive in terms of material and the loss of valuable machining time impacts heavily on a company’s bottom line,” says Roger Bassett, chairman, Rigibore.

“Until now the conventional method of fine adjustment meant unclamping the boring tool, making the adjustment, re-clamping and taking a test cut. This process requires skilled operators, is time consuming and never guaranteed to give you a true size adjustment, meaning further test cuts, or worse scrap parts.”

In both mechanical and other digital systems, adjustment of a tool’s cutting edges involves some form of physical clamping – and even in the best systems this can and often does result in tool deflection, particularly when chasing fine tolerances, resulting in the fine tolerance limit previously reached being offset.

In anticipation, operators tend to over-compensate when making adjustments in an attempt to anticipate for this mechanical error. The result is a compromise; a compromise that is overcome with the development of Rigibore’s Smartbore system.

Rigibore’s innovative design sees Smartbore tools positively pre-loaded in the opposite direction to the cutting force. The result is that accurate adjustment, by as small a movement of 0.001mm on diameter is achieved with no measurable backlash.

This rigid design allows operators to plug and play by inserting a handheld Smartbore adjuster, delivering incremental diameter changes and then removing the adjuster guaranteeing right first-time precision. The Smartbore adjuster displays the adjustment reading on the LCD, allowing fine tolerances to be set by operators of all skill and experiences levels. Tools can therefore be quickly and accurately adjusted in the machine spindle with minimum downtime and in the knowledge that the adjustment requested is the adjustment made.

Smartbore can be applied to through a range of designs, including precision finishing cartridges, units and a precision boring head known as the Smartbore Nano.

“At Rigibore we pride ourselves on delivering the most accurately adjustable boring tools in the world,” Mr Bassett adds. “With developments such as Smartbore we are continuing that drive for accuracy and consistency within the manufacturing sector.

“Increasing industry challenges mean greater incorporation of technology to improve management of the production environment. Rigibore innovations such as Smartbore, alongside our fully-automated, closed-loop boring solution Zenith offers companies a number of key performance benefits including reduced cycle time, elimination of scrap and improved part quality.

Rigibore www.rigibore.com

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Rigibore

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