Improve Process Control With ActiveEdge

Whether your boring operation involves high volume production of the same part, or design and manufacture of a component bespoke to the customer’s application, achieving  good process control is essential to success in precision hole making operations like boring.

Good process control allows the desired size and finish on bores in an consistent and repeatable manner. In modern day manufacturing there is increasing pressure on organisations to conduct micron-precise adjustments, ensuring components are of certified quality with no undersized or oversized bores.

For many organisations,Process Control provides a clear indication of production efficiency, allowing assessment of how well the process is meeting the specifications set. Perhaps the most important value that outlines the success of a process is Cpk.

Cpk monitors the data sets between an upper and lower specification limit, analysing how central the mean is between these two pre-determined limits. The lower the standard deviation of the process, the greater the Cpk value and the greater the Cpk, the less defects in operation.

Rigibore’s ActiveEdge has been implemented by industry leading organisations on a global scale. Results have shown a consistent and measurable improvement in organisations process Control since the application of ActiveEdge.

What Is ActiveEdge?

ActiveEdge is an auto-compensating boring system whereby changes to the tools cutting edge are made via wireless technology, ensuring micron-accuracy in adjustment.

Adjustments are made via radio transmission with the tool remaining in the machine spindle throughout the duration of the process, ensuring spindle downtime is minimised.

ActiveEdge tooling can be successfully integrated with a gauging or probing device, allowing CNC programmes to monitor bore sizes and adjust accordingly as part of a closed loop process. This process is explained in greater detail below.

Closed Loop Manufacturing with ActiveEdge

Closed Loop Manufacturing process undergoes a continuous process of measuring, monitoring and if needs be, adjusting to ensure bore sizes remain between specification limits. Rigibore partner custom designed Statistical Process Control (SPC) macros with ActiveEdge tooling capabilities, to ensure micron-accuracy through a closed loop boring operation.

1)  Firstly, a hole is bored by the Rigibore ActiveEdge tool.

2)  This bore is then measured using a probing device, establishing the bore diameter. This measured value is then translated and saved in a variable in the CNC machine.

3) This bore measurement is assessed against a set of set of Statistical Process Control (SPC) macros supplied by Rigibore, calculating whether the bore sizes are within the required tolerance band, between a set of customisable upper and the lower warning limits.

4)  If the bore sizes are not within this user-defined parameter, an automatic compensation request is sent directly to the ActiveEdge tool, the cutting edges adjust within a matter of seconds to ensure the next machined bore is returned to nominal size.

Improving Cpk with ActiveEdge

Implementation of ActiveEdge technology can contribute to a profound improvement in Process Control capabilities. this is as demonstrated in the figures below.

 Fig 1. This first diagram outlines the structure of the adjustment process. An organisation’s main objective is to maintain bore sizes between the upper and lower control limit. The closer to nominal bore sizes are throughout the operation means greater accuracy and reliability of the process
Fig 1- This first diagram outlines the structure of the adjustment process. An organisation’s main objective is to maintain bore sizes between the upper and lower control limit.
The closer to nominal bore sizes are throughout the operation means greater accuracy and reliability of the process

 

 

Fig 2. This diagram simulates the process of manual adjustment in boring operations. There is a high deviation on bore sizes towards and sometimes outside the upper and lower control limits, creating high probabilities for oversized or undersized bores.
Fig 2- This diagram simulates the process of manual adjustment in boring operations.
There is a high deviation on bore sizes towards and sometimes outside the upper and lower control limits, creating high probabilities for oversized or undersized bores.

 

 

 Fig 3. ActiveEdge tooling maintains a much tighter tolerance on bore sizes, setting a smaller tolerance band on the upper and lower control limits. This demonstrates a much lower deviation, with bore sizes always close to nominal diameter, and achieving a high Cpk value.

Fig 3- ActiveEdge tooling maintains a much tighter tolerance on bore sizes, setting a smaller tolerance band on the upper and lower control limits.
This demonstrates a much lower deviation, with bore sizes always close to nominal diameter, and achieving a high Cpk value.

 

Industry Applications

ActiveEdge tooling was recently applied to an industry leading heavy plant manufacturer to improve repeatability and accuracy of bore sizes.

A closed loop process was integrated, leading to significant and measurable performance benefits in a small period of time.

The full project including results can be viewed by following the link:-

ActiveEdge Hydraulic Pump Case Study

 

More information on  ActiveEdge tooling can be found on the Rigibore website, or contacting one of the following address‘.

 

       

 

Leave a Reply

Fill in your details below or click an icon to log in:

WordPress.com Logo

You are commenting using your WordPress.com account. Log Out / Change )

Twitter picture

You are commenting using your Twitter account. Log Out / Change )

Facebook photo

You are commenting using your Facebook account. Log Out / Change )

Google+ photo

You are commenting using your Google+ account. Log Out / Change )

Connecting to %s