How Manufacturers Use Flexible Honing Tools

As visitors to IMTS 2014 learned, Brush Research Manufacturing (BRM) supplies a full line of surface finishing solutions to a wide range of industries. From flexible honing tools to industrial brushes, BRM helps part and equipment manufacturers to improve quality and consistency. By removing burrs and improving surface finish at the same time, BRM technologies such as Flex-Hone® tools are also enabling manufacturing companies to increase efficiency and boost productivity.

ID Surface Finishing and Deburring

BRM Flex-Hone® tools are the industry standard for inner diameter (ID) surface finishing and deburring. Known also as ball hones, these flexible cylinder hones feature abrasive globules that are permanently laminated to flexible nylon filaments. Self-centering, self-aligning to the bore, and self-compensating for wear, these deburring tools remove cut, torn, and folded metal while imparting a plateau finish with oil-retaining grooves for optimum lubrication.

Flex-Hone® tools are also built with a stiff, double-wire metal stem for easy mounting. Manufacturers can use these surface finishing and deburring tools during machine tool applications (on-line), or during secondary operations (off-line). Regardless of how they’re used, flexible cylinder hones always require the use of a lubricant. Choose a high-quality honing oil (such as Flex-Hone® oil), or other good-quality lubrication (such as machine oils). Lubricate the ball hone generously, and never use solvents.

On-Line and Off-Line Operations

For on-line operations, flexible honing tools mount in most machine spindles. Examples include drill presses, lathes, and milling machines as well as robotic cells, transfer lines, and CNC equipment. With CNC machinery, a Jacobs-style chuck or CAT 40 collet is recommended. The Flex-Hone® In-Machine Setup video shows how BRM’s cylinder honing tools are mounted and used. For off-line use, flexible hones can be used with a handheld power tool such as an electric drill.

As the Flex-Hone® Resource Guide explains, BRM’s surface finish improvement and burr removal tools come in 10 different abrasive types, 11 grit sizes, and in standard diameters ranging from 4-mm to 36”. The base material determines which abrasive to select. The amount of work to perform and the degree of surface improvement to achieve govern the grit selection. Available grit sizes vary by abrasive type, and some options are available by special order.

Diamond Hones

Diamond Flex-Hone® tools feature diamond abrasive for finishing carbide wear parts, ceramic cylinders, chromed and plated bores, electrical discharge machining (EDM) layers, and guide and drill bushings. Precision-engineered for rapid cut rates, BRM diamond hones also offer excellent heat dissipation. The self-sharpening, resin-bonded crystals in each diamond honing tool are ideal for hard materials such as heat-treated steel, titanium, stainless steel, and space age alloys.

Industries and Applications

Flex-Hone® tools that use other abrasives (such as AO and SC) are used to deburr and improve the surface finish of manufactured parts such as engine cylinders and pneumatic cylinders. In fluid power applications, flexible cylinder hones are ideal for hydraulic cylinders, ram cylinders, valve bodies, and valve guides. Flex-Hone® tools are used with the valve housings and pump housings on industrial enclosures, too. General industry applications include surface preparation and decontamination.    

BRM Flex-Hone® tools are also used in industries and applications such as aerospace, automotive, earth moving equipment, marine, oil and gas, aluminum extrusion, brass instruments, firearms, fluid power, hydraulics, and military/defense. For more information, visit the applications page on the BRM website. The Brush Research Manufacturing YouTube channel is also a great source of information, and includes a Flex-Hone® Tools Application video  that describes the BRM ball hone’s versatility and benefits.