Abstract: Pneumatic comparator probes for engaging internal diameters of bores are provided herein. Pneumatic comparator probes include a probe body configured to contact a bore to be measured and a measuring component moveably connected to the probe body. The measuring component includes a port through which pressurized air passes when the pneumatic comparator is in use. The pneumatic comparator probes also include a variable separating mechanism moveably connected to the probe body, and movement of the variable separating mechanism adjusts a position of the measuring component in a direction of diametrical expansion relative to the probe body. Pneumatic comparator probe systems are also provided that are capable of holding and facilitating precise adjustment of the pneumatic comparator probes. Further provided are methods of measuring the bore size of a workpiece using the pneumatic comparator probe systems.

Abstract: Lapping tools are provided that include at least one angled feature that forms at least one surface angle with the lapping surface. In some examples, angled features may include a first surface angle and a second surface angle. Each surface angle of the angled feature is configured to retain abrasive grit and provide a desired type of finish.

Abstract: An apparatus, system, and method using an elastic biasing element in combination with an encoder arrangement for precise control of force or torque applied to a moving object, is applied for controlling a feed force applied to an abrasive element of a bore finishing tool, to respond to changes in the feed force such as can arise from contact with a workpiece bore surface and variations therein, such as tapers, hourglass shapes, barrel shapes, and the like. The elastic biasing element can include a single or multiple springs in one or more sets, and the feed force can be selected to have a constant value or vary as a function of time, position, or other variables or conditions.

Abstract: An automated bore finishing process particularly adapted for lapping automatically corrects one or more bore parameters, such as diameter, geometry, surface finish, in an iterative manner to reach a final value, controlled by algorithms that process feedback from a measurement process. The process determines bore parameter information and determines an optimum set of values for the process parameters, such as stroke position, stroke length and duration of the next lapping iteration. This optimization is targeted to achieve the desired final bore parameter or parameters within the specified bore size limits, and may be used to alter the stroke profile either for the entire next iteration or in a continuously changing manner, to minimize or eliminate bore defects over one or a succession of iterations.

Abstract: A bore finishing tool has an arbor with a tapered outer circumferential surface and a sleeve over the arbor having a tapered inner circumferential surface cooperatively disposed in surface to surface overlaying relation to at least a substantial portion of the tapered outer circumferential surface of the arbor. The sleeve is adjustably movable relative to the arbor for expanding a diametrical extent of the sleeve and has a plurality of internal material relief features at circumferentially spaced locations in the tapered inner circumferential surface extending partially through the sleeve so as to reduce a level of force required for expanding the diametrical extent of the sleeve. Exemplary material relief features include flutes and fractures. The sleeve can also include an external retraction feature enabling application of a retraction force by an external device for reducing the diametrical extent.

Abstract: An apparatus, system, and method using an elastic biasing element in combination with an encoder arrangement for precise control of force or torque applied to a moving object, is applied for controlling a feed force applied to an abrasive element of a bore finishing tool, to respond to changes in the feed force such as can arise from contact with a workpiece bore surface and variations therein, such as tapers, hourglass shapes, barrel shapes, and the like. The elastic biasing element can include a single or multiple springs in one or more sets, and the feed force can be selected to have a constant value or vary as a function of time, position, or other variables or conditions.

Abstract: A honing tool holder that mounts in a rotatable spindle of a machine tool or machining center lacking a feed system, capable of holding and automatically operating an in-process adjustable feed honing tool for honing a work piece to a desired diameter or other characteristic, the feed force being adjustable with the tool on the spindle via centrifugal applied force, and further adjustable in range by restraining and releasing one or more of the weights while on the holder, or removing or adding weights, and/or a feed force profile being adjustable by replacing cams of the holder.

Abstract: A honing tool holder that provides a capability for automatically feeding the honing elements or stones when in the bore of a work piece, and for automatically stopping the feeding when a particular condition such as a bore size, is reached, so as to enable use of an in-process adjustable feed honing tool in a machine tool, machining center, or the like, lacking a feed mechanism or system. The holder can also include apparatus to automatically prevent feed past a limit. Both the feed force and feed limit can be adjustable, including by simple movements of the tool holder by the machine tool.

Abstract: A honing tool holder utilizes pressure of a through-the-spindle coolant delivery system for automatically feeding the honing elements or stones of an attached honing tool when in the bore of a work piece, and for automatically stopping the feeding when a particular condition such as a bore size, is reached, so as to enable use of an in-process adjustable feed honing tool in a machine tool, machining center, or the like, lacking a feed mechanism or system but including a coolant delivery system. The holder can also include apparatus to automatically prevent feed past a limit. Both the feed force and feed limit can be adjustable, at least the latter by simple movements of the tool holder by the machine tool.

Abstract: A bore finishing tool has an arbor with a tapered outer circumferential surface and a sleeve over the arbor having a tapered inner circumferential surface cooperatively disposed in surface to surface overlaying relation to at least a substantial portion of the tapered outer circumferential surface of the arbor. The sleeve is adjustably movable relative to the arbor for expanding a diametrical extent of the sleeve and has a plurality of internal material relief features at circumferentially spaced locations in the tapered inner circumferential surface extending partially through the sleeve so as to reduce a level of force required for expanding the diametrical extent of the sleeve. Exemplary material relief features include flutes and fractures. The sleeve can also include an external retraction feature enabling application of a retraction force by an external device for reducing the diametrical extent.

Abstract: A honing tool holder utilizes pressure of a through-the-spindle coolant delivery system for automatically feeding the honing elements or stones of an attached honing tool when in the bore of a work piece, and for automatically stopping the feeding when a particular condition such as a bore size, is reached, so as to enable use of an in-process adjustable feed honing tool in a machine tool, machining center, or the like, lacking a feed mechanism or system but including a coolant delivery system. The holder can also include apparatus to automatically prevent feed past a limit. Both the feed force and feed limit can be adjustable, at least the latter by simple movements of the tool holder by the machine tool.

Abstract: A honing tool holder that provides a capability for automatically feeding the honing elements or stones when in the bore of a work piece, and for automatically stopping the feeding when a particular condition such as a bore size, is reached, so as to enable use of an in-process adjustable feed honing tool in a machine tool, machining center, or the like, lacking a feed mechanism or system. The holder can also include apparatus to automatically prevent feed past a limit. Both the feed force and feed limit can be adjustable, including by simple movements of the tool holder by the machine tool.

Abstract: The honing feed system and method utilizes feedback from various sources during rapid feeding of the honing tool while rotating and stroking, to detect initial contact with a bore surface, to slow the feed to a normal honing rate, involving conditioning the feedback signals to eliminate noise factors such as the stroking movement and forces generated to rotate and feed the tool unopposed.

Abstract: An automated bore finishing process particularly adapted for lapping automatically corrects one or more bore parameters, such as diameter, geometry, surface finish, in an iterative manner to reach a final value, controlled by algorithms that process feedback from a measurement process. The process determines bore parameter information and determines an optimum set of values for the process parameters, such as stroke position, stroke length and duration of the next lapping iteration. This optimization is targeted to achieve the desired final bore parameter or parameters within the specified bore size limits, and may be used to alter the stroke profile either for the entire next iteration or in a continuously changing manner, to minimize or eliminate bore defects over one or a succession of iterations.

Abstract: The method of the invention provides a capability for accurately and uniformly determining the sizes of bores of workpieces, both pre- and post-process, to improve process control, particularly compensation for tool or stone wear and other factors, and process data collection. The present method makes all required bore measurements, including those in both the workpiece bore and the calibration ring or sample workpiece bore, with the honing tool, under controlled static, non-honing conditions, including expanding the tool in the bores in a predetermined manner, such as at a predetermined rate. The method of the invention has utility for honing multiple workpieces to a finished size with a single tool, and also for multiple spindle applications.

Abstract: The method of the invention provides a capability for accurately and uniformly determining the sizes of bores of workpieces, both pre- and post-process, to improve process control, particularly compensation for tool or stone wear and other factors, and process data collection. The present method makes all required bore measurements, including those in both the workpiece bore and the calibration ring or sample workpiece bore, with the honing tool, under controlled static, non-honing conditions, including expanding the tool in the bores in a predetermined manner, such as at a predetermined rate. The method of the invention has utility for honing multiple workpieces to a finished size with a single tool, and also for multiple spindle applications.

Abstract: The honing feed system and method utilizes feedback from various sources during rapid feeding of the honing tool while rotating and stroking, to detect initial contact with a bore surface, to slow the feed to a normal honing rate, involving conditioning the feedback signals to eliminate noise factors such as the stroking movement and forces generated to rotate and feed the tool unopposed.

Abstract: The feed system for a honing machine provides a capability to dynamically correct in real time errors in bore size inferred arising from variations in feed force, and a method of operation of the same. The system allows a user to select between rate and force controlled honing modes, which provides one or more of the advantages of both modes. The system provides capabilities for automatic rapid automatic bore wall detection, compensation for elasticity of elements of the feed system and honing tool, and automatic tool protection. The system is automatically operable using feed force, feed rate and positional information for honing a work piece to one or more target parameters, such as one or more in-process sizes and a final size.

Abstract: The feed system for a honing machine provides a capability to dynamically correct in real time errors in bore size inferred arising from variations in feed force, and a method of operation of the same. The system allows a user to select between rate and force controlled honing modes, which provides one or more of the advantages of both modes. The system provides capabilities for automatic rapid automatic bore wall detection, compensation for elasticity of elements of the feed system and honing tool, and automatic tool protection. The system is automatically operable using feed force, feed rate and positional information for honing a work piece to one or more target parameters, such as one or more in-process sizes and a final size.

Abstract: The feed system (30) for a honing machine (10) provides a capability to dynamically correct in real time errors in bore size inferred arising from variations in feed force, and a method of operation of the same. The system (10) allows a user to select between rate and force controlled honing modes, which provides one or more of the advantages of both modes. The system provides capabilities for automatic rapid automatic bore wall detection, compensation for elasticity of elements of the feed system (30) and honing tool (14), and automatic tool protection. The system is automatically operable using feed force, feed rate and positional information for honing a work piece (20) to one or more target parameters, such as one or more in-process sizes and a final size.