Fundamental Investigations of Honing Processes Related to the Material Removal Mechanisms

Tilger, M.1, a; Siebrecht, T.1, b; Biermann, D.1, c

Institut für Spanende Fertigung, Technische Universität Dortmund, Baroper Str. 303, 44227 Dortmund

a); b); c)


Honing processes are commonly used for the machining of functional surfaces for tribological applications such as bearings of connecting rods and cylinder liners. Plateau-structured surfaces featuring a cross-grinding pattern and a high bearing area ratio can be generated by honing processes. As a simplification, honing is commonly considered as similar to grinding processes regarding tool-workpiece interactions although the kinematics, contact relations and, especially the resulting material removal are quite different. Therefore, the material removal mechanisms cannot be compared with those of a grinding process. The initial surface topography generated by grinding, turning or milling, has a strong influence on the resulting workpiece topography as well as the machining time using honing because of the small material removal rate. In order to investigate the material removal mechanisms arising during honing, a special experimental setup has been developed to investigate the fundamental mechanisms. In this context, small honing tools with a total contact area of 5 mm 2 are used to simplify the influence of the entire honing process on single grain engagements in a feed-controlled flat-honing process. The influence of the varying depth of cut and different rotational speeds on the single grain chip thickness is analysed, focusing on the material removal mechanisms and process forces and, finally, the generated surface structure. Ploughing with its plastic deformation and the associated lateral bulging along the width of the grain as well as micro cutting are observed as dominating material removal mechanisms in the initial process phase. Additionally, the surface formation progress, especially the gaining amount of honing grooves and the surface smoothing are investigated considering the process time and the corresponding increase of the accumulated material removal.


Honing, Material removal, Surface analysis


In: 7. WGP-Jahreskongress, 5.10.-6.10. 2017