Surface quality and geometric accuracy control of fuel nozzle single-pass honing

Fuel nozzle is a key part of aero-engines. Due to the particularity of fuel nozzle’s working environment, the high machining requirements for the surface quality and geometric accuracy of nozzle hole were put forward. The existing process is difficult to meet the machining requirements, so a new process is proposed, which is called the flexible single-pass honing. For the novel single-pass honing tool with diameter less than 1 mm, the laws are not very clear, so studies were carried out. Firstly, a novel cutting force model of single-pass honing was established, which explains the relationship between force and machining parameters. Based on the cutting force model, the influence laws of honing parameters on surface roughness, bore diameter, and shape accuracy were explored detailedly. Finally, according to the machining requirements of fuel nozzles, the honing process optimization was carried out, and the optimal parameters were obtained. Furthermore, precision control of surface quality and geometric accuracy for fuel nozzle single-pass honing was realized.