Honing Troubleshooting Tips

Oval Bores

  • Verify that the tool is correctly sized for the bore.

  • Ensure the honing stones are properly trued, ideally to the exact bore diameter.

  • For thin-walled parts, reduce cutting pressure. If the stone stops cutting at reduced pressure, use a softer stone.

  • For bores with cutouts or large cross-holes, utilize keyway-type tooling.

Bellmouth Bores

  • Properly true the stones to match the exact bore diameter.

  • Reduce stroke length and use a tool with shorter stones if available.

  • If the bore length is less than 50% of the stone length, reduce the stone length to 1.5 times the bore length.

  • If bellmouthing persists, continue shortening the stone or switch to a softer stone. Be cautious—overcorrection can cause barrel-shaped bores.

Barrelled Bores

  • True the stones accurately to the bore diameter.

  • Increase stroke length and, if possible, use a tool with longer stones.

  • If the issue persists, shorten the stone at both ends. Overcorrection can lead to bellmouthing.

Combined Bellmouth/Barrel Bores

  • Common in bores with multiple cross-holes, such as valve spools.

  • Reduce stone length while increasing stroke length.

  • If the problem persists, use a softer stone.

Rainbow Bores & Waviness

  • Use long-series tooling with stone length at least 1.5 times the bore length.

  • Correcting bent bores may introduce bellmouthing—address this after the bend is corrected.

Tapered Bores

  • Ensure stones are properly trued to the bore diameter.

  • In manual honing, frequently reverse the component.

  • In automatic honing, adjust the stroke position to allow more of the stone to pass through the tight end of the bore.

Taper in Blind Bores

  • True stones to the exact bore diameter and reduce stone length to 2/3 of the bore length.

  • If the bore lacks sufficient relief at the blind end, start with a short stone to hone the bottom.

  • Use stones with a hardened tip.

  • Ensure an adequate supply of honing fluid reaches the blind bore.

Bent Bores

  • Use the longest available stone length, ensuring it is at least 1.5 times the bore length.

  • Straightening the bore may cause bellmouthing—address this issue once the bore is corrected.

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Honing - The Hole Story