Cylinder Hones for Automated Bore Finishing and Blending

The Flex-Hone® tool from Brush Research Manufacturing (BRM) is a flexible, resilient honing tool that’s used to improve the surface finish inside of cylinders. Self-centering and self-aligning to the bore, BRM cylinder hones use a low-temperature, low-pressure abrading process to remove cut, torn, and folded metal from cylinder walls. Flexible honing tools also produce a long-wearing plateau finish that aids in lubrication.

By removing the sharp, jagged peaks produced by prior machining operations, flexible honing allows piston rings to seat and seal without damaging their edges. The substantially flat surface that cylinder honing imparts also promotes longer seal life, increases bearing area, and reduces wear. By creating a series of uniformly-spaced, oil-retaining grooves, cylinder hones also help to reduce seepage in hydraulic applications.

Automated Deburring and Surface Finishing

Built with a stiff metal stem and flexible nylon abrasive filaments, BRM cylinder hones mount in lathes, mills, drill presses, and electric hand drills. As BRM’s new Flex-Hone® In-Machine Setup video explains, manufacturers can also automate surface finishing operations by using flexible honing tools in machine centers. Automated honing with the Flex-Hone® tool is ideal for cross-hole deburring and port radiusing, as well as bore finishing and blending.

Unlike other automated deburring tools, BRM cylinder hones are easy-to-use and do not require rigid setups. As the Flex-Hone® In-Machine Setup video shows, cylinder hones can be used to surface finish bores made of various metal materials, including 6061 and 7075 aluminum. By reversing the direction of the machine spindle, burr removal can be performed quickly and efficiently in both directions.

Cylinder Honing and Plateau Fishing

Flex-Hone® tools follow existing bore geometry and will not affect size, ovality, or concentricity. Unlike traditional honing stones, BRM cylinder hones are not designed for heavy-duty or high-precision material removal. As a technical article called Evaluating the Cylinder notes, rigid hones are recommended for out-of-round cylinders, but cannot match the Flex-Hone® tool’s plateau finish.

Since rigid hones can create uneven valleys, quality-conscious manufacturers prefer flexible honing tools for applications that require a superior surface finish. Available in a 10 different abrasive types and a wide range of grit selections, the Flex-Hone® comes in standard diameters ranging from 4-mm to 36 inches.

Applications and Industries

As BRM’s Gold Booklet confirms, Flex-Hone® tools are used in a wide range of industries and applications to solve surface finishing challenges. Examples include automotive, aerospace, earth moving equipment, marine, oil and gas, aluminum extrusions, brass instruments, fluid and power, hydraulics, and military and defense. Engine builders and gunsmiths also use Flex-Hone® tools.

So what’s your cylinder honing application? Would you like to automate deburring and surface finishing operations to save time, increase efficiency, and improve quality? For more information, watch the Flex-Hone In-Machine Setup for Surface Finishing video and comment on this blog entry with your questions.