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Compressor block - 2 stage plateau honing operation

Honing of compressor block with a 2 stage plateau honing operation with coolEX® honing tools.

Component: compressor block
Diameter: 125mm
Material: GG25
Machine builder: Heller machines
Machine: H5000
Connector: DAH115/HSK-A100

2-stage honing operation of a V8-engine block (AlSi17 hypereutectic) in a machining centre

The task was the prove of concept of a 2-stage honing of a V8 engine block in an existing machining center with KomTronic® U-axis system of KOMET®. The solution is a combination of coolEX®- and Xstep ®-honing tools to gain the advantages of both honing systems.

  1. Honing operation with Xstep®-honing tools on KomTronic® u-axis-system for dimensional control of the diameter
  2. Honing operation with coolEX®-honing tools to expose the silicon crystals in the functional surface of the cylinder

Cylinder crankcase - Grey cast iron GG25, plateau honed

Honing of cylinder crankcases with a two-stage plateau honing operation with coolEX® honing tools:

  • Part: Cylinder crankcases
  • Diameter: 95mm
  • Material: GG25
  • Machine manufacturer: Heller
  • Machine: MCH 250
  • Holding fixture: DAH115/HSK-A100

The task was successfully completed using the since 2008 proven coolEX® Honing tool technology.

Plateau honing of the cylinder bore

2-stage coolEX® honing process, plateau honing of the cylinder bore in cylinder

  • Part: Cylinder crankcases
  • Diameter: 73.40mm
  • Material: GG25
  • Machine manufacturer: Hüller-Hille
  • Machine: NBH650
  • Holding fixture: HSK-A100

The task was successfully completed using the since 2008 proven coolEX® Honing tool technology.

Honing of grey cast iron on a MAKINO a81M machining centre

At the end of 2010 a concept trial of honing on a MAKINO a81M machining centre was successfully completed. The task was 2-stage honing operation on a cylinder bore in a grey cast iron block to generate a plateau surface (Rpk = 0.2-0.8μm, Rvk = 1.0-3.5μm, Rk = 0.5-1.5 μm), a cylindricity of less than 5μm and a honing angle between 30° and 40°. 

The aim of the trial was to demonstrate the prove of concept of this honing operation on a MAKINO standard machining centre without any technical modifications. 

The trial was successfully completed using coolEX® honing tool technology.

Honing the valve guides of a cylinder head on a MAKINO a100 machining centre

The requirements for this honing operation was to generate a surface roughness defined in the required tolerance of Rz=6-16μm and an improvement in the cylindricity. This was done reliabily with a DIAHON fixed diameter honing tool. The roughness was achieved at a stable Rz=7-9μm, all geometric requirements were kept, including a cylindricity of less than 1.5 μm. 

Learn more in section Fixed diameter honing tools and the options for use in machining centres.