The influence of honing process parameters on surface quality, productivity, cutting angle and coefficients of friction

Purpose ‐ The purpose of this paper is to explore the influence of tool kinematics parameters on surface roughness, productivity and cutting angle for grey cast iron cylinder liners machined by normal honing. Design/methodology/approach ‐ For experimental investigation, a long stroke honing system was used. Diamond and SiC tools were used, for pre- and finishing, respectively. The values of cutting parameters were varied within the following limits: cutting speed vs=0.931-1.11?m/s; specific pressure of pre-honing process pd=1.0-1.4?N/mm2 and specific pressure of finishing honing process pz=0.2-0.5?N/mm2. The analysis of dispersion was conducted for determining the mathematical model for cutting parameter influence on surface roughness and productivity. Findings ‐ Dispersion analysis proved that the most influential parameters on maximum roughness depth are cutting speed for D181 tool and specific pressure of finishing honing for D151 tool. The most influential parameter on productivity in the honing process with D181 and D151 tool is cutting speed. Originality/value ‐ The paper gives new information related to the normal honing optimization process. Normal honing offers the highest surface quality which is achieved by a low speed machining. However, that means also a relatively low productivity, demanding a thorough process optimization. Furthermore, normal honing is usually done by ECH pre-honing and mechanical finishing honing, but in this paper, all-mechanical honing was used for the same result, at a lower lost.