HONING SUPERFINISHING HONING TOOLS PRECIDOR HIGH PRECISION EXTREME TOOL LIFE MOST ECONOMICAL.

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Berenice Carpenter
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1 HONING SUPERFINISHING HONING TOOLS PRECIDOR HIGH PRECISION EXTREME TOOL LIFE MOST ECONOMICAL

OUR KNOW-HOW YOUR ADVANTAGE Fascination Technology Know-how NAGEL is the world s leading specialist for honing and superfinishing technology.

Our quality, focus on customer service, and customer satisfaction has allowed us to become the only hone and superfinishing machine manufacturer with manufacturing locations on

TECHNOLOGIES The HONING process produces high geometric accuracies and a surface with the tribological properties required of the application.

The NAGEL Group works continuously on improvement and further development. With our machines, honing is a working process which can be easily learned and mastered.

Superfinishing does not deform or structurally alter the surface of the workpiece and is extremely economical in application.

NAGEL actively integrates this philosophy in our own facilities as well in our product and process Research & Development.

service life has increased, reducing the demand for earth s fossil fuels.

2 OUR KNOW-HOW YOUR ADVANTAGE Fascination Technology Know-how NAGEL is the world s leading specialist for honing and superfinishing technology. For more than half a century we have provided our customers a technical advantage using innovative solutions. Our quality, focus on customer service, and customer satisfaction has allowed us to become the only hone and superfinishing machine manufacturer with manufacturing locations on four continents. We are always there for you in markets such as Brazil, China, Japan, India, the USA and, of course, Germany. TECHNOLOGIES The HONING process produces high geometric accuracies and a surface with the tribological properties required of the application. Long tool life provides consistent, repeatable results exemplified by a very narrow distribution of the measured characteristics. The NAGEL Group works continuously on improvement and further development. With our machines, honing is a working process which can be easily learned and mastered. The SUPERFINISH process (ceramic stone and paper media abrasive) produces high shape accuracy with advantageous tribological sealing properties. Superfinishing does not deform or structurally alter the surface of the workpiece and is extremely economical in application. RESPONSIBILITY Together with our customers, it is our common goal to conserve earth s resources. NAGEL actively integrates this philosophy in our own facilities as well in our product and process Research & Development. As a result of engine design and innovative honing technology supplied by NAGEL, in recent years the oil consumption of a combustion engine has dramatically decreased while service life has increased, reducing the demand for earth s fossil fuels. FOCUS ON THE CUSTOMER We do everything possible to meet our customer s requirements in a reliable and timely fashion. From on-site service support, customized manufacture of tooling and abrasives, to prototype component machining from all our facilities worldwide. USE Products machine by or on NAGEL equipment can be encountered in all aspects of everyday life: automobiles, aircraft, watercraft, appliances, to name a few. Anywhere mobility or productivity is required; components machined by NAGEL are in use. But you will also find examples of our know-how in the production chain of your newspaper, your electricity, in refrigerators and glass fibre cables. Our common goal: Machinery and tooling to produce the highest quality, productivity, and process reliability.

PERFECTION IN FINE MACHINING PRECIDOR HONING HONING SUPERFINISHING The technology developed for the Precidor honing process can yield honed geometric and size accuracy to less than 0.001 mm.

interruption. Guidance zone Tool length Cutting coating length Max.

3 PERFECTION IN FINE MACHINING PRECIDOR HONING HONING SUPERFINISHING The technology developed for the Precidor honing process can yield honed geometric and size accuracy to less than mm. The Precidor tool design with its adjustable mandrel, in combination with either a plated abrasive body or expandable diamond abrasive ledges, is ideally suited long bore lengths, with or without interruption. Guidance zone Tool length Cutting coating length Max. bore length Connection for bayonet Nominal diameter Connection for collet chuck The entire hone cycle takes place in a single stroke (in special cases several strokes can be employed). The tool (abrasive diameter) is preset to the desired output diameter. Automatic tool compensation for abrasive wear can also be employed. Precidor honing can be combined with a conventional honing process or utilized in stages for multiple pass operations to accommodate high material removal conditions. Due to low wear on cutting coatings, Precidor tools achieve extremely long tool lives and, besides their technological advantage, offer a great potential for economization. NAGEL engineering can help select the correct tool design based on your application. Whether it is through hole or blind hole, tool design with optimized coolant supply or customized tool connections, NAGEL has the right tool for any application. s [mm] t [sek] Is your tool not among these? We would be glad to send you further catalogues:» Large-area honing tools» Diamond honing shafts» N-series Or contact us to specify your own tool. werkzeuge@nagel.com 3

TECHNICAL DATA TOOL TYPE DAN DAL DAS DAZ-L Diameter range 2.25 11.8 8.0 39.8 11.8 39.8 11.8 85.

titanium, inconel HIGHEST PRECISION TOOL TYPE DAZ-L Properties» Significant shape improvement for

flexibility for bonding and cutting material coating» Optimised coolant flow Honed by Precidor *

002 / 107-01 - B - 1 TYPE KEY Tool type Targeted honing diameter per operation Grain size of

length for new tools So: Special versions Version index consecutive Connection type B: Bayonet

4 TECHNICAL DATA TOOL TYPE DAN DAL DAS DAZ-L Diameter range Materials» Steel (mild and hard), GG, GGG, non-ferrous and carbides, glass, ceramic, graphite, titanium, inconel HIGHEST PRECISION TOOL TYPE DAZ-L Properties» Significant shape improvement for straightness and roundness» Tool evenly expands over the entire cutting length» Highest flexibility for bonding and cutting material coating» Optimised coolant flow Honed by Precidor * Cylindricity µm < 1 Roundness µm < 0.5 Diameter µm < 0.5 Roughness Rz µm < 0.5 DAZ-L / B - 1 TYPE KEY Tool type Targeted honing diameter per operation Grain size of cutting material Design shape 01: Standard version, short 02: Standard version, long = preferred length for new tools So: Special versions Version index consecutive Connection type B: Bayonet connection Z: Gripper connection Special connections: SW16: Bilz quick-change connection Z28: Cylindrical connection 4 * Example of machining

COMPLETE COATING VERSION DAN / DAS TOOL TYPE HONING

980 / 107 - S1 - B -L W -1 TYPE KEY Tool type

of cutting material Design shape 01: Standard

Special versions Connection type B: Bayonet

connections (only for design shape So) Version

shape N = additional longitudinal groove W =

groove Coating G = galvanised coating L = soldered

Honed by Precidor * Cylindricity µm < 1 Roundness

5» Best application for grooved or interrupted

bores» Ideal cost-performance ratio for small to

applied over the entire tool body Roughness Rz µm <

Optimized coolant flushing at high material removal

5 COMPLETE COATING VERSION DAN / DAS TOOL TYPE HONING SUPERFINISHING DAN / S1 - B -L W -1 TYPE KEY Tool type Targeted honing diameter per operation Grain size of cutting material Design shape 01: Standard design up to 1998 S1: Standard design from 1999 So: Special versions Connection type B: Bayonet connection Z: Gripper connection S: Special connections (only for design shape So) Version index consecutive, only for design shape So Groove shape N = additional longitudinal groove W = additional spiral groove no character = without add. groove Coating G = galvanised coating L = soldered coating Examples of workpiece DAN / DAS properties Honed by Precidor * Cylindricity µm < 1 Roundness µm < 0.5 Diameter µm < 0.5» Best application for grooved or interrupted bores» Long tool life» Able to produce very round bores» Ideal cost-performance ratio for small to medium numbers of pieces» Abrasive coating is applied over the entire tool body Roughness Rz µm < 0.5 MANDREL DESIGN TOOL TYPE DAL Properties» Optimized coolant flushing at high material removal rates» Long tool life» Economical solution for medium to high production volume» High flexibility for a variety of abrasive types» Able to produce very round bores 5

6 PRECIDOR HONING INSTRUCTIONS FOR USE Stroke speed Circumferential speed m/min m/min GG Steel Coolant recommendation for steel/gg: Nagel Hono Plus C2 (5-6% may be possible for GG emulsion) PRECIDOR HONING SPECIAL SOLUTIONS D3S Tool for the horizontal honing of crankshaft bores. Machining of all materials, including compound materials such as cast iron/aluminium. Optimal alignment of the tool in the prepared bore by expandable guide ledges. DAL WITH UPPER GUIDANCE Use for required perpendicularity between bore and plane surface of the workpiece to be machined. Shape and surface values as for DAL. DAN STAGED BORE Two bores are machined together with high demands on concentricity. Shape and surface values as for DAN. 6

ACCESSORIES FEED HEADS FOR PRECIDOR TOOLS HONING SUPERFINISHING The exact determination is made depending on the type of collet chuck used.. Feed head PK.

./35-1 for bayonet Ø 35 mm Feed head PK20 collet chuck FM-4949 Ø 4-13 mm TOOL MANAGEMENT / TOOL PREPARATION Honing tools are precision tools and require proper care and maintenance.

7 ACCESSORIES FEED HEADS FOR PRECIDOR TOOLS HONING SUPERFINISHING The exact determination is made depending on the type of collet chuck used.. Feed head PK../ZK-1 collet chuck FM-977 Ø 4-20 mm Feed head PK../ZK-3 collet chuck FM-979 Ø mm Feed head PK../35-1 for bayonet Ø 35 mm Feed head PK20 collet chuck FM-4949 Ø 4-13 mm TOOL MANAGEMENT / TOOL PREPARATION Honing tools are precision tools and require proper care and maintenance. The quality of the preparation and the components used have a significant influence on economy and the attainable precision of the machine. The replacement of diamond cutting bars as well as the measurement and guide ledges require a particularly high degree of experience and knowledge. NAGEL offers an extensive range of Tool Management services:» Short delivery and turnaround time accomplished by in-stock tool parts and abrasives» State-of-the-art tool manufacture and repair equipment and procedures, complete with 100% inspection and quality control» Abrasive and guide ledge replacement programs» Calibration of in-tool measurement system» Logistical services» NAGEL s more than half a century experience Whether it is for a large series with high tool turnover or for small series production you define your own needs and the extent of the services. Please contact our tool sales department for details. 7

WORLD-WIDE PRESENCE ALWAYS THERE FOR YOU NAGEL Locations GREAT BRITAIN PERMAT Machines Ltd. Station Road Coleshill-Birmingham B 46 1JG P: +44 (0) 1675 463351 F: +44 (0) 1675 465816 info@permat.

, Ltd GERMANY Nagel Maschinen- und Werkzeugfabrik GmbH 2-6-16 Senjyu-Azuma Abdachi-Ku 120-0025 Tokyo Oberboihinger Straße 60 72622 Nürtingen P: +49 (0) 7022 6050 F: +49 (0) 7022 605250 info@nagel.

288 Dino Drive Ann Arbor / MI 48103 70/1 Mission Road Bangalore 560027 P: +1 (0) 734 4265650 F: +1 (0) 734 4265649 info@nagelusa.com www.nagelusa.com BRAZIL Nagel do Brasil Máquinas e Ferramentas Ltd.

8 WORLD-WIDE PRESENCE ALWAYS THERE FOR YOU NAGEL Locations GREAT BRITAIN PERMAT Machines Ltd. Station Road Coleshill-Birmingham B 46 1JG P: +44 (0) F: +44 (0) info@permat.com JAPAN NAGEL-AOBA Precision Co., Ltd GERMANY Nagel Maschinen- und Werkzeugfabrik GmbH Senjyu-Azuma Abdachi-Ku Tokyo Oberboihinger Straße Nürtingen P: +49 (0) F: +49 (0) info@nagel.com P: +81 (0) F: +81 (0) info@nagel-aoba.jp USA NAGEL Precision Inc. INDIA NAGEL Special Machines Pvt. Ltd. 288 Dino Drive Ann Arbor / MI /1 Mission Road Bangalore P: +1 (0) F: +1 (0) info@nagelusa.com BRAZIL Nagel do Brasil Máquinas e Ferramentas Ltd. P: +91 (0) F: +91 (0) nagel@blr.vsnl.net.in Av. Brasilia, Salto-SP P: +55 (0) F: +55 (0) diretoria@nagel.com.br CHINA NAGEL Machinery Trading (Beijing) Co., Ltd. Room 2810, Jing Guang Center Hu Jia Lou, Chao Yang District Beijing P: +86 (0) F: +86 (0) allanzhang@nagel-tbt.com.cn OUR PARTNER COMPANIES: HONING SUPERFINISHING NAGEL Maschinen- und Werkzeugfabrik GmbH TBT Tiefbohrtechnik GmbH + Co. Siemensstraße 1, D Dettingen a. d. Erms P: +49 (0) F: +49 (0) info@tbt.de, Oberboihinger Straße 60 D Nürtingen P: +49 (0) F: +49 (0) info@nagel.com September 2009 ELGAN Diamantwerkzeuge GmbH & Co. KG Oberboihinger Str. 60, D Nürtingen P: +49 (0) F: +49 (0) info@elgan.de,

80 FLEXIBLE HONING SYSTEM

NAGEL L ECO E 80 FLEXIBLE HONING SYSTEM NEW DEVELOPMENT For Small and Medium Production Runs In-process gauging, Roughing and finishing in a single spindle Tel: 734-426-1812 www.nagelusa.com MACHINE HIGHLIGHTS