Analysis of Process Forces for the Precision Honing of Small Bores

For the honing process the chip removal and therewith the material removal rate and the surface of the part after honing depend on the cutting pressure between the honing stone and the workpiece. In this paper an analytical model of the honing tool is used to make the contact surface between honing stone and workpiece as well as the in-process forces at the honing stone accessible from the geometry, positions and given process loads at the honing unit over different approaches without additional sensors. Exemplary paths of the cutting pressure dependent on the stroke position are then given for an assumed constant axial feeding force on the cone including friction as well as for an assumed constant torque along the axis of the honing tool. It is found that for active movement of the feeding cone the calculations from the feeding force and the torque along the tool are approximately equal. For reactive feeding movement because of high normal forces at the honing stone self-locking can occur for the given tool with small cone angle because of friction at the cone.