In the demanding world of aerospace, where precision and performance are paramount, even the smallest deviations can have significant consequences. Maintaining the intricate internal components of aircraft has long presented a challenge, often requiring extensive and costly disassembly.
However, UK-based honing expert Delapena says it has introduced a paradigm shift with its innovative Tandem Alignment Honing Tools, redefining the landscape of aerospace repair.
For decades, Delapena has been a cornerstone of the honing market, providing comprehensive solutions for a diverse range of industrial needs, both domestically and internationally. The company’s expertise spans the entire spectrum, from the design and manufacture of standard and bespoke honing machines and abrasives to a comprehensive suite of support services. This includes feasibility studies, precise specification, new machine development, specialised tooling, and invaluable consultancy, tooling refurbishment, application development, process engineering, honing reviews, and tailored training packages.
With a decade of continuous innovation under its belt, Delapena has consistently pushed the boundaries of honing technology. Looking ahead, the integration of Industry 4.0 principles will see the development of intelligent, automated loading machines designed for optimal productivity.
The aerospace sector’s relentless pursuit of lighter, higher-performing components – demanding greater power densities, tighter control, enhanced sealing, and reduced noise and vibration – places immense pressure on manufacturing and maintenance processes. Honing, renowned for its ability to achieve exceptionally tight bore diameter tolerances, plays a crucial role. Beyond mere sizing, honing perfects the roundness, straightness, and overall surface finish of critical bores.
Maintenance gamechanger Traditionally, the maintenance of intricate and often inaccessible aircraft components has been a cumbersome affair. Removing landing gear elements, engine cylinders, and other vital parts was commonplace, leading to significant operational disruptions and substantial maintenance expenditures. Enter Delapena’s Tandem Alignment Honing Tools – a development the company confidently labels a ‘gamechanger’ in aerospace repair.
This effective tooling has revolutionised the maintenance of twin bores in aircraft. By directly addressing the challenge of honing these crucial bores – essential for proper alignment and peak performance – Delapena’s innovation eliminates the need to dismantle surrounding structures, drastically reducing costly and time consuming disassembly
These seemingly simple yet highly effective tools enable the in-situ remachining of major structural elements. This ensures perfect alignment and significantly extends the lifespan of critical components, contributing to safer, more efficient, and ultimately more sustainable aerospace operations. The elimination of expensive dismantling and reassembly further amplifies the benefits.
More than just a matter of convenience, Delapena’s Alignment Honing Tools represent a true revolution in aerospace repair. They redefine efficiency, enhance safety protocols, and contribute to the longevity of vital aircraft components, paving the way for a safer and more sustainable aviation industry as global air traffic continues to grow.
Beyond their technical prowess, Delapena distinguishes itself through an unwavering commitment to customer support. Its team of seasoned engineers provides comprehensive Honing Training, expert Honing Consultancy, responsive on-site assistance, and tailored bespoke tool design solutions, ensuring seamless integration of their alignment hones into existing maintenance workflows.
Delapena’s Tandem Alignment tools are more than just instruments; they embody a commitment to innovation, precision engineering, and a deep understanding of the unique demands of the aerospace sector. Their impact transcends mere efficiency and cost savings, directly bolstering the safety and reliability of the aircraft that connect our world.
“Delapena has not just reinvented honing; they have redefined the future of aerospace repair,” states a company spokesperson. The widespread adoption of Delapena honing tools by major aerospace manufacturers and maintenance organisations worldwide underscores their proven reliability, exceptional precision, and unmatched impact on the evolution of aerospace repair methodologies.
Delapena Grinding has been the sole UK agent for E-Tech grinding machines since 2023, a Taiwanese machine tool company that can trace its roots in grinding back to the 1950s. The company sells machines around the world and prides itself on manufacturing models that offer high levels of repeatability, guaranteeing consistent quality for even the most challenging applications. With iGrind programming software the machines are also easy to operate; designed from the ground up to be intuitive and operator-friendly, minimising training time and maximising productivity.
Delapena Honing Equipment has been in business for 98 years. During this time Delapena has manufactured over 10,000 honing machines to the global honing market. The honing process is critical to precision engineering as it enhances the accuracy, surface finish and functional performance to machined components. Today the honing process can achieve tolerances down to an accuracy of 0.0005mm and surface finishes less than 0.05Ra
There are a lot of synergies between honing and grinding: progressive material removal; surface finish enhancement; correction shape and roundness and reducing internal stresses, to name a few. Delapena researched many grinding machine manufacturers and wanted to partner with a company that had innovation as one of its key objectives. E-Tech is constantly developing new grinding machines that are not manufactured by the competition and together with the conversational programming capability of the control systems make them very attractive to precision grinding customers.
E-Tech covers the whole range of conventional grinding machines including surface, cylindrical, centreless, tub/ ring grinders as well as some less conventional offerings, such as large vertical grinders and eccentric/non-round grinders. They comprise proven construction methods such
as hand scraped ways and hydrodynamic spindles, where appropriate, combined with modern technology such as linear motors and CNC controls for improved performance and capability. They also include features that help to plug the skills gap. Skills and staffing are probably the biggest issues that everyone from OEMs to subcontractor shops are facing on multiple fronts, but most of these facilities still use grinding machines that require constant operator input for traverse, infeed or both. Not only can we resolve this issue with the machines being fully CNC, but we can also offer a host of options from automatic wheel balancing, in process gauging, as well as automation systems such as robots, gantry systems etc. to increase productivity. E-Tech machines are found in all industry sectors: aerospace; defence; medical; automotive; motorsport; construction equipment; machine tool production; toolmaking and power generation.
Training will be delivered by us here at Delapena. The beauty of the conversational control means that operators should be comfortable with the machine in minimal time. Delapena is a machine tool company, not just a sales agency. We build machine tools here in the UK and have a team of skilled engineers used to building, maintaining and servicing high precision machines to hold exacting tolerances. Furthermore, E-Tech has designed its machines based on the global market, so all bearings are from NSK, ball screws are from Hiwin, the pneumatics are provided by SMC and controls are all from global providers, be that Mitsubishi or FANUC. The major benefit of this for our customers is that all of these components are available locally.
Automation of machine tools has become vital in a market where there is a shortage of engineers. Both the Delapena Honing machines and E-Tech grinding machines have lots of options for automation that can be customised for the customers’ requirements. Delapena and E-Tech can offer cobots, robots and pallet loaded machines that integrate with control systems that maximise optimise workforce productivity. Delapena is also developing machine tools with integrated AI that can handle batch production with minimal set up times.
For decades, nestled in the UK's engineering heartland, delapena has been synonymous with precision honing technology. Its journey, rooted in a vision to redefine industry standards, has seen it evolve from pioneering honing machinery to crafting advanced automated systems. This unwavering commitment to quality and a profound understanding of surface finishing intricacies have established delapena as a trusted partner across diverse sectors, including aerospace, automotive and hydraulics. This rich heritage forms the bedrock of delapena's forward-thinking approach to honing training.
Recognising the critical need to cultivate future expertise, delapena emphasises training the next generation of engineers. This investment is not merely about replacing an experienced workforce, it is about ensuring continuous innovation by effectively transferring invaluable knowledge. In an era of rapid technological advancement, a highly skilled engineering workforce is indispensable for driving breakthroughs. By providing robust education and practical experience, delapena empowers these future engineers to conquer the complex honing challenges of tomorrow.
In today's fiercely competitive landscape, achieving superior surface finishes and dimensional accuracy is paramount. Effective honing is no longer a superficial step but a crucial process directly influencing component performance, longevity and overall quality. Acknowledging this, delapena provides bespoke honing training packages meticulously tailored to the unique needs and operational contexts of individual businesses, equipping teams with the skills and understanding essential to maximise their honing operations.
Delapena's training seamlessly integrates comprehensive theory with practical application, always customised to client needs. Key areas covered include the fundamentals of honing, encompassing material removal, abrasives and machine types, alongside its inherent advantages. Participants receive thorough guidance on abrasive selection, ensuring optimal choices for diverse materials and applications. Machine operation and maintenance training emphasises safe, efficient utilisation and preventative care for extended equipment lifespan. In addition, the training delves into process optimisation and troubleshooting techniques to achieve stringent tolerances and resolve common issues, thereby minimising downtime.
By prioritising the specific needs of each business, delapena's training empowers teams with the knowledge and skills vital for maximising their honing operations and contributing significantly to overall manufacturing success.
Ready to elevate your competitive edge?
Contact delapena at sales@delapena.co.uk to discuss your specific training needs and allow it to craft a bespoke honing training package that will sharpen your team's skills and amplify your company's performance
The journey began decades ago with a simple yet powerful vision: to engineer and deliver honing solutions that redefine industry standards.
From its early innovations in honing machinery to the development of advanced automated systems, delapena has consistently been at the forefront of innovation. A commitment to quality and a deep understanding of the intricacies of surface finishing have made the company a trusted partner for businesses across aerospace, automotive, hydraulics, and beyond. This heritage provides a solid foundation for delapena’s approach to honing training.
Training the next generation of engineers is paramount for ensuring continued innovation and for seamlessly replacing an ageing workforce whose experience and knowledge must be effectively transferred. As technology evolves at an unprecedented pace, a well-educated and skilled engineering workforce is essential to drive technological breakthroughs across industries. Investing in education and providing staff with practical experience will empower these future engineers to tackle the intricate honing problems of tomorrow.
Technical training manager Paul Lane explains: “We share the practical knowledge and hard-earned expertise that comes from years of hands-on experience in designing, manufacturing, and applying honing processes. When you choose delapena for your training needs, you are tapping into a legacy of precision and insights derived from realworld applications while understanding the process that comes with it.
“In today’s competitive landscape, achieving superior surface finishes and dimensional accuracy is paramount. Effective honing is no longer just a finishing touch; it’s a critical process that directly impacts the performance, lifespan, and overall quality of your components. With this in mind, we offer bespoke honing training packages tailored to address the specific needs and operational contexts of individual businesses, designed to empower your team with the skills and understanding needed to maximise the potential of your honing operations.”
He continues: “Forget generic, off-the shelf courses – we understand that every business has unique needs, equipment, and skill levels. Our bespoke approach means that your training program is meticulously tailored to your specific requirements. Whether you are looking to upskill experienced operators, onboard new team members, or deepen the knowledge of your engineering staff, we will work closely with you to develop a course that hits the mark.
“Our training blends comprehensive theory with practical application, always customised to customer needs. Key areas include the fundamentals of honing, covering material removal, abrasives, and machine types, highlighting its advantages. We guide you through abrasive selection, ensuring optimal choices for varied materials and applications.
“Machine operation and maintenance training focuses on safe, efficient use and preventative care for longevity. Learn process optimisation and troubleshooting to achieve tight tolerances and resolve common issues, minimising downtime,” he explains. “Dimensional control and metrology instruction covers accurate measurement for quality assurance. Crucially, we emphasise safety best practices for a secure working environment. Optionally, we offer training in advanced honing techniques like plateau honing and bore sizing, tailored to your specific requirements.
“Ultimately, investing in specialised honing training, such as that offered by delapena, represents a commitment to operational excellence. The benefits extend to tangible improvements in component quality, enhanced process efficiency, reduced equipment downtime through proactive maintenance and effective troubleshooting, increased operator competence, and a stronger return on investment.
This article highlights Delapena Group’s groundbreaking ProductionHone machine, an innovative solution set to transform the honing process. With a strong legacy in honing technology, Delapena has developed an all-in-one automated system that integrates honing and gauging, significantly reducing processing time from 60 minutes to just three. Designed for precision and efficiency, the machine addresses Industry 4.0 requirements, offering seamless automation, real-time data tracking, and exceptional accuracy. With its expertise in abrasives and tooling, Delapena ensures superior performance, making the ProductionHone a game-changer for industries requiring high-precision machining.
In precision engineering, where even the slightest imperfections can have significant consequences, the choice of honing oil is critical. Delapena honing oil stands out due to its exceptional performance, contributing to superior results and enhanced efficiency across various industrial applications.
A key advantage of Delapena honing oil lies in its cooling and lubricating properties. During the honing process, friction generates heat, potentially leading to tool wear and dimensional instability. Delapena oil effectively dissipates this heat, maintaining optimal operating temperatures and preventing premature tool failure. Simultaneously, its lubricating properties minimise friction between the honing tool and the workpiece, reducing wear on both components.
Furthermore, Delapena honing oil flushes away excess particles and debris generated during the honing process. This ensures a clean working environment and prevents the accumulation of particles that can interfere with the honing process and compromise the quality of the finished surface. The oil's effective flushing action also maintains consistent honing performance and extends the life of honing stones.
Delapena honing oil provides rust and corrosion protection. This is crucial in environments where moisture or other corrosive elements may be present. By forming a protective film on the workpiece, the oil safeguards against rust and corrosion, ensuring the longevity and integrity of the finished product.
Beyond its technical benefits, Delapena honing oil is formulated using the latest additives and technology, minimising its odour compared to other products using heavy sulphurised and chlorinated additives.
By choosing Delapena honing oil, manufacturers can achieve optimal results, and elevate the quality of their products Delapena Extra Honing Oil, Light and Heavy-duty Honing Oil are available in 20L and 205L drums from: www.delapenaonline.com
delapena group will be returning to MACH.
delapena, a leading name in the honing industry, is making waves in the aerospace sector with their revolutionary Tandem Alignment Honing Tools. These ingenious tools are rewriting the rules of aircraft landing gear maintenance, offering a faster, safer, and more sustainable approach to aircraft repair.
The aerospace sector is increasingly tightening the requirements for components to achieve lighter weight and greater performance from end products – higher power densities, more precise control, tighter sealing, less noise, and vibration.
Traditionally, maintaining the intricate and often difficult-to-reach components of aircraft involved time-consuming and expensive disassembly of key parts like landing gear and engine cylinders. This not only disrupted operations but also drove up maintenance costs significantly.
delapena’ s Tandem Alignment Honing Tools are a gamechanger. These innovative tools allow for In-Situ honing of critical twin bores, eliminating the need for disassembly. This translates to faster turnaround times, reduced costs, enhanced safety through perfect alignment and extended component life, and more sustainable practices through reduced waste.
The tool body is made such that its length matches the centre distance of the two ‘in-line’ bores. One end of the tool is fitted with abrasive stones and the other with nylon guides.
When the tool is inserted into the bores the nylon guides are expanded to pilot the tool in one bore while the honing stones are expanded to increase the diameter of the bore to be honed. When the first bore has been honed to the correct size the tool is removed and inserted from the opposite end so that the nylon guides are piloted in the honed bore while the stones increase the diameter of the second bore. If access is restricted and the tool cannot be inserted from each end of the tandem bore, then the position of the honing stones and nylon guides are reversed in the tool after the first bore has been honed.
The impact of delapena’ s tools extend far beyond mere convenience. They represent a paradigm shift in how aircraft landing gear components are maintained, prioritizing efficiency, safety, and sustainability. As air traffic continues to grow, these tools play a vital role in ensuring the smooth operation and longevity of our global fleet.
delapena’ s Tandem Alignment Honing Tools are a testament to their commitment to innovation, precision, and a deep understanding of the aerospace industry’s needs.
In the realm of precision engineering, where tolerances are measured in microns and surface finishes are paramount, the honing process could be described as prevailing in
accuracy. Among the various honing machines available, the delapena PowerHone EXL is said to be a champion, delivering exceptional performance, versatility, and ease of use.
At the heart of the PowerHone EXL lies a robust design, crafted with heavy-duty
components to ensure high stability and vibration-free operation. This translates to
consummate precision, with honed surfaces achieving mirror-like finishes and
dimensional accuracy exceeding even the most stringent requirements. The
machine’s rigid construction also means it can tackle large and heavy workpieces with confidence, making it ideal for diverse industrial applications.
In manufacturing, close working partnerships between customers and suppliers are worth their weight in gold and that’s certainly the case with Hemel Hempstead-based precision subcontractor Subcon Drilling and honing specialist Delapena who have been working together for many years, developing super abrasive to optimise their honing process. In 2019 however, Subcon Drilling threw down the gauntlet to its longstanding supplier with a specific challenge that included specialist honing super abrasive. Dave Tudor reports.
Through a combination of a delapena SpeedHone Cooper S horizontal honing machine and customised, tuned and tweaked super abrasive honing stones, not to mention extensive trialling, delapena not only managed to hit the 20 minute cycle time target they totally annihilated it, said Dean Edwards, Subcon Drilling.
Lower cost Super abrasive
delapena sintered products strive to offer the highest quality product and service to our customer, a key factor in this is value of the product. To address the high cost of super abrasives we were keen to investigate all the sintering technologies available with the intention of driving the super abrasive manufacturing costs down making it an affordable option compared to standard abrasive.
This has been achieved by investing in the best technology available as well as optimising the process flow in manufacturing using best practice lean principles. Quality, Delivery, Price, and Service targets have all been achieved with customers saving on average 30% against competitors’ products. View our brochure
In recent years Ceramics, Chrome and Carbide have provide a challenge for the honing process due to the increased surface hardness properties of the newer grade carbide abrasive.
To address these harder materials, delapena sintered products state of the art production facility, design, develop and manufacture super abrasive bonds with outstanding results.
Following extensive research and using innovative technology, delapena have developed Chomestone.
| `Honing of Hard Chrome case study` A customer of delapena was using a delapena PowerHone to resize Chrome plating in cylinder using a conventual silicon carbide abrasive. The downside to using conventual abrasive is the abrasive wear quickly and the honing machine needs constant adjustment to maintain size. The customers honing process averaged 60 minutes depending on the depth of the chrome layer. Chromestone developed by delapena sintered products was then introduced and reduced this honing process to 10 minutes. Another advantage that their customer also gained was that traditionally the worn chrome plating was stripped overnight in chemical tanks. Using a rougher Chrome bond abrasive, Chromestone, allowed the cylinder to be honed prior to the plating process in a little under 20 minutes negating the need to chemically strip the cylinder. |
Lower cost Super abrasive
delapena sintered products strive to offer the highest quality product and service to our customer, a key factor in this is value of the product. To address the high cost of super abrasives we were keen to investigate all the sintering technologies available with the intention of driving the super abrasive manufacturing costs down making it an affordable option compared to standard abrasive.
This has been achieved by investing in the best technology available as well as optimising the process flow in manufacturing using best practice lean principles. Quality, Delivery, Price, and Service targets have all been achieved with customers saving on average 30% against competitors’ products.
Find out more, visit www.delapenasintered.co.uk
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