high finish honing machine at khushbu engineers

CNC Honing Machine

Posted On : 25-05-2022
By : Ajeet Samani

Modern engineering processes expect high quality and consistent performance. Naturally, the accuracy of the machining process required is very high and is difficult to achieve. Honing is one such highly accurate finishing operation.

The Process

Honing is a little stock-removing finishing operation that requires high dimensional and geometrical accuracies and a good surface finish. In this process, an abrasive grinding stone is rotated and reciprocated with controlled pressure on the hole's surface.

The rotation and reciprocation of the spindle are closely monitored to achieve the desired result. In short, honing is finishing a hole by removing less material. It is used for parts requiring high geometrical accuracy and good surface finish.

Typical Applications

The following are typical examples of honing applications :

Valve guide, cylinder liner, connecting rod, rocker arm, gear shifter fork, gear, yoke, sprocket, slider block, engine parts, hydraulic directional control valve, spool, hydraulic motor part, etc. The honing process is also used with great advantage in aerospace components, turbocharger components, fuel injection components, refrigeration components, and so on.

The Equipment

Khushbu Engineers initially developed the traditional manual horizontal honing machine . Manual Honing is a very highly skilled operation. Therefore, the productivity of the machine is lower in the case of conventional honing. Here, the accuracy and productivity are inversely proportionate.

Over a while, customers demanded a highly productive machine with high bore accuracy. Also, operator dependency was expected to be reduced.

Trends in Technology

The latest development in honing is single pass honing Technology. Using single-pass honing technology, extremely close tolerances can be achieved repeatedly in production at a lower per piece cost.

In the view of above, Khushbu Engineers developed a Multi-spindle, single pass progressive honing machine. The technology used was to pass a Diamond Coated, pre-fixed size tool in the bore while rotating. It removes pre-determined material in the bore. This is done 4-6 times in a row to remove 40 or 60 microns of material from the hole.

Since the tool is diamond coated, the wear is very low. Passing the tool without expansion can speed up the operation. Due to the CNC System, this process is controlled with very high accuracy and consistency. The rigidity of the machine also plays a very important role.

Establishing new concepts is always difficult. With the help of the latest drafting technology and an experienced design team, we at Khushbu were able to develop single-pass progressive honing technology in the country.

At each stage of the design, it was necessary to perform stress analysis and confirm the design. Equally important was the manufacturing part of the machine. Our first machine passed all the tests due to the selection of the right vendor who can get high specifications of manufacturing tolerance.

Key Features of the Machine

  •   Number of spindles / tools: 4,6,8.

  •   Maximum diameter: 40 mm.

  •   Maximum depth: 150 mm.

  •   Indexing accuracy: 15 seconds.

  •   AC servo motor for axis movement.

  •   Feed: 2500 mm / min.

  •   Rapid traverses 2: 5000 mm./min.

  •   Hole accuracy: 2-5 microns.

  •   Size repeatability (Cpk): 1.33.

Examples

Transmission Gear

All transmission gears are honed to get a good fit on the shaft. The result is reduced noise, improved torque transmission, and improved vehicle performance. Normally after heat treatment, the hole in the gear shrinks by a few microns and the geometric accuracy deteriorates. The honing process improves geometry such as roundness, taper, and surface finish. At the same time, the bore-to-face runout and gear PCD run out are kept intact.

diagram of transmission gear

Details

  •   Material –Case Hardened steel

  •   Stock for Honing - 0.040 mm

  •   Diameter - 38.00 mm

  •   Length- 18 mmseconds.

  •   Number of passes- 4


Parameters (mm) Required Achieved
Bore Tolerance 0.020 0.003
Ovality 0.007 0.002
Taper 0.007 0.0015
Face runout 0.1 0.070-0.08
Surface finish 0.8 Ra 0.6 Ra
Productivity - 120 parts per hour

Hydraulic Valve

Honing a Hydraulic Valve is a little difficult. The fitment of the spool in the hole of the valve body is within 4-5 microns. That is, the geometric measurements of the hole have to be within 2 microns. Also, the surface finish required is 0.2 - 0.4 Ra. Here, the input accuracy of the hole is up to 20 microns. The honing process improves the roundness and straightness of the hole up to 2 microns.

diagram of hydraulic valve

Details

  •   Material – Cast Iron

  •   Stock for Honing - 0.030-0.040 mm

  •   Diameter - 16.00 mm

  •   Length- 127mm

  •   Number of passes- 4


Parameters (mm) Required Achieved
Bore Tolerance 0.011 0.003
Ovality 0.003 0.0015
Taper 0.003 0.002
Surface finish 0.4 Ra 0.4 Ra
Productivity - 66 parts per hour

Refrigeration Compressor Body

This is the heart of the refrigeration compressor. The performance of the Air Conditioning unit depends on the accuracy and finish of the hole. Since the fitment of the piston in the hole is within 3-4 microns, the accuracy of the hole has to be in 1-1.5 microns. The Single Pass honing process not only achieves the accuracy of the hole and the surface finish of both holes but also maintains the perpendicularity between the journal bore and the piston bore.

diagram of refrigeration compressor body

Details

  •   Material – Cast Iron

  •   Stock for Honing - 0.030-0.040 mm

  •   Diameter - 19.00 mm

  •   Length- 40mm

  •   Number of passes- 6


Parameters (mm) Required Achieved
Bore Tolerance 0.005 0.003
Ovality 0.002 0.001
Taper 0.002 0.0015
Surface finish 0.15 Ra 0.15 Ra
Productivity - 360 parts per hour

Distinctive Advantages of the Honing Process

To sum up, following are the distinctive advantages of the Honing Process :

  •   High dimensional and geometrical accuracy with smooth surface finish, faster than grinding.

  •   Higher productivity with high accuracy at a moderate cost.

  •   Smaller bores of diameter 3 to 48 mm and length of 180 mm can be honed faster than grinding, with high accuracy.

  •   Less skilled operators also can operate the machine easily.

Khushbu specialize in high precision, highly productive bore finishing honing solution.
CNC Single Pass Honing Machines in India, Honing Machine Manufacturers and Exporter in India,
Honing Machine Manufacturers in India

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