Heartland Honing for Cylindricity

At Heartland Enterprises, we have extensive experience operating honing equipment that improves the geometric form and surface texture on pipes, tubes, cylinders, and liners.  In honing operations, a rotating tool carrying abrasives removes metal from the interior surface of a bore or cylinder. The main purpose is to finish the surface to a particular diameter and geometric cylindricity. It’s almost always a secondary machining operation that finishes a part or relieves stress. A typical production cycle is to rough turn the OD, bore the ID, hone, finish turn and complete any required mill work. The honing operation typically removes from 0.001” to 0.010″ (0.03-0.3 mm) of material.

Although the honing process can be applied to any surface, it is most commonly done on internal cylinder walls using a combined rotating and reciprocating motion. Low cutting pressure, low velocity, and relatively small amounts of material removal characterize it. Typical speeds are around 250 fpm (76 m/min). However, unlike conventional machining, higher speed is not always an advantage. Each application has a honing abrasive chip load which is a limiting factor. With abrasive honing stones, the proper choice of bond and coolant optimizes stone performance and cost per part.

We typically utilize abrasive stones that are used along a controlled path to remove minute amounts of material in order to attain almost perfect cylindricity on parts. Unlike conventional machining, the accuracy of a honing process is not entirely dependent on the machine. The tool and abrasive are the keys to accuracy. Another difference from conventional machining is that it needs no chucking or alignment. The part aligns itself with the tool because the tool or the part is floating in most applications. Often, the part is placed in a specially designed honing fixture that provides floating action.

Honing machines allows precise size, surface finish, roundness, straightness and consistent surface texture to be achieved. And with our equipment we can achieve surface finishes between 6-8 RMS with tolerances as tight at +/-0.001″ or meet virtually any customer specified requirement.  Our facility is equipped with a Sunnen Model HL 80 precision horizontal hone that handles diameters from 3″ to 22″ with a 60″ stroke.  We also have a Sunnen Model MBC-1805 hone with auto sizing and power stroke capability; accommodating diameters ranging from .160″ to 3.5″ with a 6″ stroke.

A Natural Gas Compression Legacy

Since Heartland’s inception, and with three decades of operations, machining natural gas compressor parts is in our DNA.  As an AS9100D / ISO 9001:2015 certified contract manufacturer focused on CNC machining of larger diameter (2” to 42” turned and 2” to 30” milled) production parts Heartland has significant experience machining to print parts for a diverse group of players in the natural gas compression market.  Over almost 30 years Heartland has manufactured compressor parts gaining invaluable knowledge including;

  • Pistons / Piston Halves / Ring Carriers – Machining medium to large size parts that meet exacting standards for integration within highly engineered systems
  • Piston/Rod Assemblies – Producing and assembling pistons and rods that are concentric within .001
  • Cylinder Liners – Experience planning and executing efficient machining processes to ensure success with ultra tight tolerance parts. Including staging multiple operations that includes turning, honing, and milling tubular parts
  • Rods & shafts – Extensive experience making parts that are heat-treated, ground to very tight tolerances, with rolled threads

With years of experience Heartland possess a diversity of knowledge not only with different parts but also diverse materials. From bar stock, castings and forgings we’ve machined parts from materials including alloy steel, aluminum, cast iron, titanium, and nickel based alloys.

Based on this expertise Heartland can take on a wide variety of production parts for your organization.

Heartland Enterprises Now ISO 9001:2015 + AS9100D Certified

We are ecstatic to announce that Heartland Enterprises has upgraded to ISO 9001:2015 and added the AS9100D certification. The achievement of this milestone was a team effort driven by our quality assurance manager.

While there are many reasons we decided to pursue the additional AS9100D certification the primary reason simply is that it will make us better. Heartland’s primary objectives have been and will continue to be;

  • Taking care of our customer
  • Taking care of our employees.

AS9100 widely adopted and standardized quality management system for the aerospace industry will propel Heartland to the next level as a leader in the machining of highly engineer parts. The new standard will help up better achieve our primary objectives of continuously meeting the needs and objectives of our customer and employees in the following ways;

  1. Increased customer satisfaction: The AS9100 standard requires a focus on understanding customer requirements so that we can better meet their needs.
  2. Raising the bar: AS9100 is the internationally recognized standard for Quality Management Systems for aerospace companies and it is the default expectation for customers.
  3. Improved decision-making: AS9100 embeds our top management into the Quality Management System, and champions making decisions based on evidence and data rather than vague attitudes.
  4. Increased efficiency: AS9100 is based on the process approach to understanding how we provide products and services, and emphasizes understanding how these processes interact.
  5. Engaging employees: By defining and mapping the processes, and involving the people within those processes in the activity, we will not only ensure that our processes are functioning as expected, but we can engage our workforce towards the goals of process improvement and customer satisfaction.
  6. More robust supplier relationships: By focusing on mutually beneficial relationships with suppliers, we will find ways to work together in order to improve customer satisfaction.
  7. Habitual improvement: One of the principles that is ingrained into the AS9100 requirements is the need to find ways to make the management system incrementally better over time, a process called continual improvement. By making improvement a part of our daily business, we can harness the power of our engaged workforce and focus them on finding ways to make the processes that they are involved in better, faster, and cheaper to run.

As one of only ~10,000 certified organization world wide Heartland looks to expand on our past success while taking care of employees and old and new customers alike.

Heartland Enterprises Overview

Dave Campbell:  We are an ISO certified production machine shop.  Our capabilities focus on 2″ to 42″ diameter parts.   We utilize a wide range of CNC equipment.  We like to use top of the line and we try to stay with Okuma, its very robust equipment.

We built the business with two pillars: taking care of employees and taking care of customers surrounded with the whole element of quality.  Because quality is a mindset and when you want employees you want them thinking quality.   Everybody here cares about the customers and meeting customer needs so that means that as their needs come up we do everything and everybody in the shop does everything they can to meet those needs.

We’re always looking for those things we can do that make us better, faster, quicker.  We have a very rigorous quality process ISO certified of course.   But more important than just the process is the environment in which we have that process working.  We have quality equipment, we have a clean and well organized environment, we have empowered employees, we have teamwork.   All that allows us to deliver quality to the customer.

You know, I often hear people say, “what’s a facility like this doing in Fredericksburg?”