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Dismantling & Identification Marking
Cleaning & Derusting
Sleeve Preparation
Boring
Sleeve and Body Pre-cleaning & Press fitting
Drilling Fluid Holes
Chamfering
Honing
Final clean and Quality check
Pressure Testing & Assembly


Dismantling & Identification Marking

Assembled cylinders are dismantled, tagged and stamped with an identification mark and the parts from each cylinder placed in a marked container for later cleaning, checking and final assembly.

Cleaning & Derusting
Cylinders are degreased and wet or dry bead/shot blasted or chemically cleaned.

Sleeve Preparation
Cylinders are measured for bore size and length of sleeve to be fitted. Sleeves are cut from hydraulic quality stainless steel brake tubing, circlip grooves and chamfers are cut as required.

Boring
Cylinders are bored in the Halray precision jig which is mounted on the carriage of a lathe. The jig enables any type of cylinder to be set up quickly and accurately. In conjunction with a range of set up mandrels, support plates and centres, exact alignment with the centre line of the lathe is achieved. For true boring of the body to accommodate the sleeve, Halray six fluted tungsten tipped adjustable cutters are used. Typical time, bench to bench to set up and bore a tandem master cylinder to fit 25.4mm (1") x 178mm (7") sleeve is approximately 1 ½ minutes.

The jig can be mounted in various ways:
· Dedicated mounting to a suitable lathe carriage
· Mounted via pivoting mount (CL400) enables the lathe to be used for conventional turning and sleeve preparation as well as boring cylinders (with the jig locked down in place).
· Jig mounted on an air operated slide (CL4000). This enables the lathe to be used for conventional machining as well as boring. It has a second chuck to hold the set up mandrel, eliminating cutter and mandrel change over time.
· CL400 & CL4000 also have the option of hydraulic or manual clamping jig. Both have rapid traverse to the carriage as standard. A range of specialised boring machines are also available.

Sleeve and Body Pre-cleaning & Press fitting
After boring, the cylinder body and sleeve are chemically cleaned and allowed to flash dry. The cylinder bore and the outside of the sleeve are lightly coated with an approved sealer/retainer. The sleeve is pressed into the bore using the Halray long stroke variable pressure press.

Halray adjustable sleeve pushers are used to accurately fit sleeves needing to be pushed below the end face of the body. After fitting the sleeve, excess sealer/retainer is removed. If clearance fitting sleeves, the press, adjustable pushers and chamfer cutters are not required as the sleeves have a 0.076mm (0.003") clearance in the bore and are fitted by hand. Oven curing is required for clearance fitted sleeves.

Drilling Fluid Holes
All fluid port and compensating holes are now drilled. Some holes require the use of special hardened guides for accurate positioning.

Chamfering
Chamfering is carried out with the range of Halray 60° high speed steel chamfer cutters to allow easy entry of cups when assembling. Centre valve seats are recut or cleaned up with an abrasive lap.

Honing
Cylinder bores are deburred and honed to the required size and surface finish using the Halray honing machines and Multi-hone spring flex heads and cloth-backed abrasive tape.

Final clean and Quality check
Cylinders are cleaned of honing fluid. Bores are checked against a light source for quality of finish and to ensure that all holes have been drilled and are free of burrs and sealer/retainer.

Pressure Testing & Assembly
A percentage of cylinder are pressure tested with special O-ring mandrels fitted, or assembled with pistons, cups, etc. and then function tested.

100% testing should not be necessary, particularly if all steps of the sleeving process are strictly controlled and adhered to.

This is a brief summary of the process and a comprehensive manual (hard copy or CD-ROM) is supplied with the complete brake cylinder sleeving system, giving a step by step guide through the Halray process, including explanatory diagrams, chemicals used, quality control and troubleshooting advice.

 >> ACRABORE 2000
The newest addittion to the Halray range of sleeving centres is now available. For details on this amazing piece of machinery click here.

 

 
Halray has recently upgraded it's after sales services by providing access to training and technical documentation on-line. Go to on-line manual.
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