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As the manufacturing industry continues to develop, the requirement for a significantly improved process is essential for organisations wishing to compete on a global scale.

Organisations must ensure exceptional accuracy in assembly and process control, industries such as Automotive and Aerospace machine extremely expensive component materials, with the demand to meet precision tolerances in an accurate and repeatable manner.

Cpk — Statistical Process Capability

A common measure in manufacturing process is Cpk, the Cpk estimates what the process is capable of.

Fig 1. Process Control Limits

Organisations seek to create a process with a Cpk of 1.97.

1.33 Cpk (Roughly 75% ± of tolerance)

1.67 Cpk (Roughly 60% ± of tolerance)

1.97 Cpk (Roughly 50% ± of tolerance)

Why Bore?

Boring is the process of producing accurate, concentric holes in a manufacturing operation, this can be either using a single point tool or through multiple cutting edges.

Boring operations can create the perfect circle, rotating around the centreline of the machine spindle.

Boring applies greater flexibility and precision in machining small diameter holes than alternative operations such as reaming.

ActiveEdge is not just a tool, this closed loop boring solution ensures organisations can create and sustain continuous improvements to their process control and a significantly higher Cpk.

Traditional Boring Operations

Many traditional boring operations are adjusted using a wrench to dial adjust boring units, this process:

  • Is conducted manually
  • Requires a skilled operator
  • Is time consuming
  • Risks accuracy

Fig 2. Traditional Boring Operation Process Control

The blue line is used to represent the tolerance in a traditional boring operation. Because of the time, skill and risk involved making an adjustment, operators often set the tool as high as possible, allowing machining to continue until the insert reaches the lower tolerance level.

Whilst this maximises the time spent between adjustments, the process sacrifices precision by using all of the tolerance. This method of adjustment shows a high deviation of bore sizes, often outside of the upper and lower tolerance limits with minimal time operating at nominal tolerance.

ActiveEdge Adjustments

ActiveEdge adjustments are carried out automatically based on information provided by accurate probing measurement, they are micron accurate and triggered when bore sizes reach the warning level.

  • Automatic adjustments remove the risk of human error
  • Organisations can set a pre-determined upper and lower warning limit
  • No backlash adjustments
  • Adjustments can be made in machine carousel

ActiveEdge tooling allows organisations to set an upper and lower warning limit on bore sizes, if bore sizes stray outside of this tolerance, a compensation request is sent to the tool via wireless technology, automatically adjusting to the required tolerance.

Ultimately, more frequent, smaller adjustments are made when applying ActiveEdge tooling (orange Line) in comparison to traditional operations (blue Line). Bore sizes have a low standard deviation from nominal diameter and a considerably higher Cpk.

What Does This Mean For Modern Part Requirements?

ActiveEdge’s auto-compensating capabilities allow organisations to meet and maintain the precision tolerances required when producing component parts.

The ability to set pre-determined warning limits provides complete control to organisations, allowing them to customise their process to best suit productivity and accuracy objectives.

Learn More About ActiveEdge

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