Modelling of tool behaviour for long stroke honing of bores

The honing tool is often assumed to have an ideal behaviour, meaning that there is no difference between the forces or positions measured at the honing spindle and those measured directly at the honing tool. In reality the normal force at the honing stone is influenced by the behaviour of the honing tool: a tangential tolerance at the honing stone can enable a yawing of the stone. Friction between the tool components influences the forces at the tool and can lead to self-locking. Also the outer diameter of the honing tool can be influenced by several perturbations: elastic deformation of the tool can cause a difference between the feeding position at the honing spindle and at the honing stone. Axial tolerance at the honing stone can make the feeding position dependent on the direction and value of the axial stroke velocity. Varying feeding positions of the honing stone influence the process forces and consequently the material removal mechanism during the honing process. In this paper an analytical model of the honing tool will be used to investigate and estimate the real tool behaviour. The model uses geometric and algebraic methods to estimate the state, forces and lengths during the honing process. Two different tools from the industrial application will be used as an example to show the impacts on the process forces.