Diamond Honing Reamers: Precision Tools for High-Accuracy Machining
Electroplated diamond reamers (also called diamond honing reamers or honing rods) perform machining through abrasion rather than cutting teeth. This innovative process combines conventional honing and reaming, delivering exceptional precision for applications in automotive, aerospace, and general machining.
I. Materials and Types of Honing Reamers
1. Material Selection
- Diamond Honing Reamers: Ideal for FRP (fiber-reinforced plastic), cemented carbide, and superalloys.
- CBN Honing Reamers: Optimized for hardened steel, chilled cast iron, and wear-resistant alloy steel.
2. Reamer Classification
|
Type |
Key Features |
Best For |
|
Fixed Diameter |
Non-adjustable; integrated front/rear guide structure |
Blind holes, mass production |
|
Adjustable |
Tunable sleeve restores diameter after wear |
Through-holes, cost efficiency |
Pro Tip: Combine adjustable reamers (for roughing) with fixed reamers (for finishing) to maximize efficiency and accuracy.
II. How to Use Honing Reamers
1. Mount the honing rod in a compatible honing machine.
2. Process workpieces sequentially from the first (coarsest) to the last (finest) axis.
3. Achieve progressive results:
- Hole diameter gradually increases
- Surface roughness (Ra) decreases
- Dimensional/form tolerances meet specifications
Critical Factor: Success depends on selecting scientifically validated tools and honing parameters.
III. Optimizing Machining Allowance
Exceeding 1/3 to 1/4 of the abrasive grain size causes chip buildup, jamming, and reduced tool life. Recommended allowances:
|
Abrasive Grain Size |
Allowance (mm) |
|
80/100 – 100/120 |
0.02 – 0.04 |
|
170/200 – 230/270 |
0.015 – 0.005 |
|
325/400 (Fine) |
0.005 – 0.01 |
IV. Cutting Fluid Recommendations
- For cast iron: 80% kerosene + 20% sulfurized oil/mechanical oil (or 100% kerosene).
- For steel: 70% kerosene + 30% sulfurized oil.
