Compact, High Performance Honing Solution

KADIA announced it has redesigned its E line honing machine, from the spindle concept and working area to the measuring and control technology, to provide customers with an advanced, high-performance honing solution in a compact machine concept.

"The E line series is the cost-efficient entry into high-performance honing," explained Henning Klein, Managing Director of Kadia Produktion GmbH + Co. "From prototype production and small batches to economically optimized series machining, we now cover a very broad application spectrum. This includes honing bores starting at approximately 1.5 mm in delicate small components, as well as machining tasks up to 40-50 mm in diameter-for example in hydraulic components or precision automotive parts."

At the heart of the machine is the completely redesigned LH2x honing spindle. Three direct drives for oscillation, rotation, and expansion are housed within a rigid monocoque structure that minimizes vibration and absorbs high dynamic forces. Four patents underscore the technological ambition of this development. Compared to the previous LH2, the new spindle generation offers higher cutting speeds, increased material removal rates, greater versatility, and improved serviceability. Larger volumes of material can be removed in shorter timeframes, machining times are reduced, and cycle times decrease-without compromising process stability, the company reported. For components with demanding geometries, the improved temperature and power stability further enhances machining accuracy and reliability.

Enlarged Working Area, Intelligent Adaptation

The working area has also been significantly expanded. The new rotary table provides approximately 30% greater diameter for fixtures, substantially broadening the range of components that can be processed. The machine automatically detects the moving mass and adjusts transport speeds accordingly: heavier components are moved more gently, lighter ones more dynamically. This adaptive control reduces imbalance, extends the service life of mechanical components, and lowers wear and maintenance costs over the machine's lifecycle. Additionally, access to the loading and unloading station has been widened by 12%, considerably improving manual loading ergonomics.

The machine bed is now 10% heavier and designed with a double-wall structure, increasing rigidity and further enhancing vibration damping. Despite these technical enhancements, the E line requires only 2.8 sq. m of floor space. The fully enclosed rear design and side access to all maintenance and electrical cabinets enable space-saving installation close to walls-a major advantage in production environments where layout compatibility and floor efficiency are critical.

Integrated Deburring and Optimized Process Environment

The E line remains a three-station machine in its basic configuration, consisting of a loading/unloading station, honing station, and measuring station. For the first time, an integrated deburring unit can be incorporated into the loading and unloading station, including an automatic brush changer. This removes loose machining burrs directly after honing-increasing process reliability and component cleanliness. The coolant system remains fully integrated but now features significantly improved filtration fineness of 10 µm (previously 25 µm). This offers more consistent oil quality, reduced tool wear, and more stable machining parameters. Due to the double-wall bed design, external drip trays are no longer required. An optional extraction module efficiently removes coolant mist, keeping the working environment noticeably cleaner.

HMC100 Control

A key pillar of the high-performance concept remains the HMC100 control system, which, together with the spindle technology, forms the technological core of the machine. The latest operating system version expands capabilities for complex applications. Continuous contour scanning of the entire bore has now become the standard measuring method. The machine captures up to 500 measurement values per millimeter of bore length, generating a precise representation of the geometry-including areas that are difficult to access using conventional measurement techniques. This level of measurement accuracy substantially increases process reliability.

In addition, fully independent three-stage honing processes can now be executed within a single honing cycle, with individually adjustable infeed impulses, speeds, accelerations, and rotational speeds. The result: reduced cycle times, higher throughput, and optimized process design.

With the software function Form Honing, defined contours such as tapering, funnel shapes, pre-expansions, or barrel forms can be generated directly on the machine. This opens new application fields and allows unfavorable design conditions to be actively compensated.

Advanced Measuring Technology

The measuring station has also been further developed. An optional rotary measuring axis can now be integrated. This system automatically detects the orientation of the workpiece and positions the measuring probes accordingly-a significant advantage for components with longitudinal grooves or cross-bores. Orientation-specific loading is no longer required, making the loading process faster and less error-prone while simplifying and reducing the cost of automation solutions. Depending on the application, shorter measuring probes can also be used, improving measurement accuracy and enabling further cycle time reductions.

Designed for Precision-Focused Manufacturers

The E line is aimed at manufacturers requiring high precision in small to medium batch sizes, while simultaneously demanding economic efficiency, flexibility, and a compact footprint. The machine is suited for accurate prototype and sample production as well as economically optimized series processes in industries such as hydraulics, precision engineering, automotive, and aerospace.

For more information contact:

KADIA Inc.

8020 Kensington Ct.

Brighton, MI 48116

248-446-1970

info@kadiausa.com

www.kadiausa.com