Computer Controlled Bore Shaping Hone

The Air Force needs an automated system for honing various shapes of taper in smooth-bore tubes. We propose to develop an automatic bore hone (ABH) to meet Air Force needs. Our ABH will automatically produce required diameter profiles to tight tolerances. Bore-gage transducers measure the bore diameter. A hydraulic telescoping drive shaft deploys from a retracted length of 40 feet to a fully-deployed length of 200 feet to hone tubes up to 200 feet in length. Transducers measure the deployment of the telescoping drive shaft, and, therefore, the axial position of the honing head and bore-gage transducers. A hydraulic feed system applies a prescribed amount of honing pressure to the honing stones. A real-time active control system uses measurements of bore diameter and axial position (actual diameter profile), along with the required diameter profile, to generate command inputs of honing pressure at each axial position. In Phase I, we will demonstrate a breadboard ABH by honing a 0.015 inch taper in a 20-foot long 4-inch diameter steel tube. In Phase II, we will demonstrate a prototype ABH by honing required diameter profiles in 3.0 to 8.0 inch-diameter tubes with lengths up to 200 feet.