Overview

Rottler machines, when equipped with the proper tooling, provide a full solution for Automatic Rough Boring, Finishing Boring, and Installation of Lifter Bushings. Rottler also manufactures custom sized tooling for specific applications. Consult with a Rottler representative at any time if you require a specific size for your lifter bushing applications.

Sections

Process Overview:

1. Setup Block in fixture: 4th axis (690-3-63, 5537A) is recommended for full automation, but not required to perform boring and installation.
2. Rough Boring: Use End Mills (.980” or 1.125”) from 650-2-69 Kit
3. Finish Boring: Use Adj. Boring Bar and bore to final diameter for proper press fit (.005” Max)
4. Press Bushing: Use correct press fit tool for specific lifter size and type.

Setup:

If using 4th axis 690-3-63 or 5537A. The block to perform work on should be mounted and secured with the appropriate locators. Once the block is secured create (2) new programs in the Rottler block software, the programs required are titled LIFTER BORE and LIFTER BUSHING INSTALL.

Rough Boring:

Use either the .980” or 1.125” Roughing Endmill from the 650-2-69 kit to remove the bulk of material for the bushing to be installed. The endmills can be held in either a 1” set screw style holder or a 1” Collet Chuck. Using the Lifter Bore program plunge the bore’s with the endmill at the below recommended starting parameters.

• Feed and Speed for cast iron blocks are as follows: 300 RPM – 0.004” Feed
• Feed and Speed for aluminum blocks are as follows: 500 RPM – 0.004” Feed Finish

Boring:
Use the Micro Adjustable Boring head in the supplied toolholder from the 650-2-69 kit. The micro adjustable boring bar allows for .0001” increments using the vernier scale incorporated into the boring head. Set the boring head to perform a “skim” pass on the first hole. Using a gauging device of your choice, i.e. a calibrated dial bore gauge, check the size of the finished hole and adjust the vernier scale on the boring head accordingly to bore to final size.

Lifter Bushing Installation (Pressing):
Use the correct lifter bushing installation mandrel in accordance with the bushing to be installed. Please not that if installing keyed lifter bushing’s that the bushing MUST be indexed and installed on the mandrel to that the alignment pin fits in the keyway, AND the bushing registers itself flush against the ledge at the top of the reduced diameter of the mandrel! Failure to do this will result in damage to bushing, block, or machine! Follow the machine speed parameters below for optimal results:

• MAX Interference fit .005” on diameter
• Feed rate during press 6.00 Inches per Minute

Video Links

Lifter Boring

Lifter Bushing Installation Tech Tip and Tool Review

CONTACT

For additional information regarding the new Honing Measurement software on Rottler hones, please contact Ryan Thompson or Nick Jenkins via the emails listed below.

• Ryan Thompson, Lead Applications Engineer, Tel: +1 (206) 707-2458
• Nick Jenkins, Applications Engineer, Tel: +1 (206) 406-1880