A final diameter of Ø16.002 to Ø16.005 mm was specified for a long hydraulic bore in EN-GJS-500-7. Pre-machining provides the bore at Ø15.94 +0.03 mm. The honing operation must therefore ensure both the narrow diameter range and uniform machining over the entire bore length.
DIAHON developed the 1L16/120-T170/240 KB17 single-ledge honing tool for this purpose. The combination of one expandable honing stone and two guide shoes supports the tool at three points. This single-ledge honing tool principle is particularly suitable for long bores with a narrow size window.
| Characteristic | Requirement |
|---|---|
| Application | long hydraulic bore |
| Material | EN-GJS-500-7 to EN 1563 |
| Initial diameter | Ø15.94 +0.03 mm |
| Final diameter | Ø16.002 to Ø16.005 mm |
| Machining length | 120 mm |
| Machine | KADIA honing machine |
| Tool | DIAHON 1L16/120-T170/240 KB17 |
| Tool principle | one expandable honing stone and two guide shoes |
The slender tool has one working honing stone and two opposing guide shoes. During expansion, the honing stone presses against the bore wall while the two guide shoes support the tool and guide it in the already machined area. The long contact zone supports uniform machining over 120 mm.
The 1L16/120-T170/240 KB17 version is matched to the nominal Ø16 mm range. The tool concept uses the existing interface of the KADIA honing machine and combines a compact design with defined mechanical guidance in the bore. Further information is available on the DIAHON page about single-ledge honing tools.
Pre-machining: The bore is provided at Ø15.94 +0.03 mm. The resulting stock forms the basis for the honing operation.
Entry: The guide shoes align the slender tool as it enters the bore and establish stable three-point contact.
Machining: The expandable honing stone removes the material. The guide shoes stabilise the tool position and support uniform machining of the long bore.
Final size: The tool is designed for the narrow size window of Ø16.002 to Ø16.005 mm. The honing stone, guide shoes and expansion mechanism are therefore treated as one interacting system.
The assessment of existing single-ledge honing tools focuses on runout, the expansion cone, the honing stone and the guide shoes. Deviations in the shank or cone affect the position of the honing stone, while worn guide shoes change the support conditions in the bore.
For the tools examined, the refurbishment concept included straightening the tool shank, reworking the expansion cone and lapping the guide surfaces. The honing stone and guide shoes are replaced to match the tool. DIAHON tool repair therefore brings the geometric and functional elements of the system back together.
Why is a single-ledge honing tool used? The honing stone removes the material while two guide shoes support the tool in the long bore. With its long, defined three-point guidance, this tool concept is particularly suitable for ensuring bore straightness and roundness while machining within a narrow final-size window.
What is the function of the guide shoes? Together with the honing stone, they form a three-point guide, stabilise the tool position and guide the tool along the machined bore surface.
Which areas are critical during refurbishment? Runout, the expansion cone, honing stone and guide shoes must be inspected and coordinated as an interacting system.
Why is pre-machining important? The initial diameter determines the available stock. A defined range of Ø15.94 +0.03 mm provides the basis for a controlled approach to the final size.
The DIAHON 1L16/120-T170/240 KB17 single-ledge honing tool combines one expandable honing stone with two guide shoes for machining a 120 mm long bore in EN-GJS-500-7. The tool concept is matched to the final size of Ø16.002 to Ø16.005 mm and the existing KADIA honing machine. For existing tools, targeted refurbishment of the shank, cone and guide surfaces complements the application concept.
Related DIAHON sections: Single-ledge honing tools and Tool repair.