Brush Research Manufacturing (BRM) supplies flexible honing tools for surface finishing and deburring the bores of any type or size of cylinder. Standard Flex-Hone® tools are available for bores with diameters as small as 4mm to as large as 36”.

To produce a soft cutting action, BRM’s flexible cylinder hones are always used in an oversized condition. This means that a flexible hone for a 3” bore has a diameter that’s slightly larger than 3”.  Tool diameters also determine operating parameters, which can affect surface finish.

Tool Diameters

As a full-line supplier of surface finishing and deburring solutions, BRM works with a global distributor network and maintains a robust website where users can order Flex-Hone® tools on-line anytime. In terms of product selection, Flex-Hone® tools can be categorized in terms of tool diameter.

• Standard Duty Small-diameter tools (BC Series) are for bores ranging in diameter from 4mm to 3”.
• Standard Duty Medium-diameter tools (GB Series) are for bores ranging in diameter from 3-1/4" to 4-5/8".
• Heavy Duty Medium-diameter tools (GBD Series) are for bores ranging in diameter from 3” to 8”.
• Heavy Duty Large-diameter tools (GBD Wood Core Series) are for bores ranging in diameter from 8” to 18”.
• Extra Heavy Duty Large-diameter tools (GBDX Series) are for bores ranging in diameter from 19" to 36".

Again, always order and use Flex-Hone® tools in an oversized condition. If a cylinder bore is in-between tool sizes, then order the next largest flexible cylinder hone.

Speeds and Stroke Rates

Tool diameter is also important because it helps determine the recommended revolutions per minute (RPM). Flexible cylinder hones can be used with most any rotating spindle, and in equipment ranging from handheld power drills or drill presses to CNC machines or robotic cells. The Flex-Hone® is a low RPM tool, but speed is a function of tool diameter. As a rule, larger tools run at slower speeds and smaller tools run at faster speeds.

The Flex-Hone® Resource Guide provides general speed ranges, but users should perform machine trials to test their own equipment against BRM’s guidelines. Tool diameter also affects stroke rate, another key operating parameter. Stroke rate is the number of inches per minutes (IPM) that are fed or stroked during flexible honing. Depending on your Flex-Hone® configuration, stroke rate is controlled either by machine parameters or by a human operator. Cross-hatch angle is also important to consider.

Stroke Rates and Cross-Hatch Angles

Flex-Hone® tools improve surface quality by imparting a uniform, cross-hatch pattern that promotes oil retention. The angle at which cross-hatch lines intersect can vary, and is a function of Flex-Hone® stroke rate. In other words, stroke rate determines whether users produce 20° to 23° cross-hatch angles or 45° cross-hatch angles. Use a lower stroke rate to achieve a smaller cross-hatch angle. Use a higher stroke rate to achieve a larger cross-hatch angle.

Tool diameter is also related to stroke rate and cross-hatch angle. As a rule, smaller-diameter Flex-Hone® tools require faster stroke rates to achieve the same cross-hatch angle as larger-diameter tools. For example, to achieve a 45° cross-hatch angle, a Flex-Hone® tool with a small diameter has a recommended stroke rate of 250 IPM.  Flex-Hone® tools with large diameters have a recommended stroke rate of 100 to 120 IPM to achieve this same 45° cross-hatch angle.

Time to Talk about Flex-Hone® Tools?

Are you ready to learn more about flexible honing for cylinder deburring and surface finishing? Then visit BRM at WESTEC 2015 in Booth #2309. Even better, request a meeting in advance. Talk to the BRM Technical Team about your specific surface finishing and deburring challenges. Ask questions, get answers, and find the Flex-Hone® that you need.