Engine Manufacturer Case Studies

Case Study # 1

Part Name               General Bore Size          Dimensions

V-8 Diesel Engine Block 95.00mm 380mm Tall, 560mm Height, 610mm Length

Material Hardness

Cast Iron       HB156-228

Bore Diameter Surface Finish Cylindricity

94.91 +/-.025mm 10 to 20um Ra .016mm

Model                                     Honing Work Stations Honing Tool Abrasives Coolant

MV-7000 12 (4-Micro-size, 8 Micro-hone) D252 -D35 –Stones Castrol Syntila 9974

Bore Diameter       Roundness Surface Finish Cross-Hatch Cylindricity

95mm +/- 0.0095mm .008mm .4 - .8 um Ra 27 +/- 5 degrees .0125mm Max

Final Tolerances Achieved: 

Step #1 (Micro-size)               Step #2 (Semi-Finish) Step #3 (Finish) Roundness Surface Finish Other Cylindricity Processing Time

94.960 +/-0.015mm  94.995 +/-0.0095mm 95.000 +/-0.005mm < .007mm .4 - .8 um Ra 0.1–1.4Rpk, 0.28-1.32Rk, 0.51-4.3Rvk  < .011mm 140 blocks (1,120 bores)/hour

Case Study # 2

Part Name                   General Bore Size      Dimensions

3.2 liter V6 Al Block (Cast liners) 92mm bore size 315mm Height, 400mm Width, 400mm Length

Material                                  Hardness

Cast Iron Liner (Cast in Aluminum)    180 – 250 BHN

Bore Diameter Surface Finish Cylindricity

91.9 +/- .025mm      3.0 – 5.0 um Ra .016mm

Model                                     Honing Work Stations Honing Tool Abrasives Coolant

MV-7000 12 (4-Microsize, 8-Microhone)         D181, D91, D30 Castrol Syntica 9974

Bore Diameter       Roundness Surface Finish Cross-Hatch Cylindricity

Target 92mm +/-.0076    .008mm .8 um Ra max  40 to 60 deg included  .013mm

Bore Diameter

Step #1 (Micro-size)               Step #2 (Semi-Finish) Step #3 (Finish) Surface Finish Cylindricity Processing Time

91.95 +/- .010mm 91.987 +/- .0076mm 92.000 +/- .0076mm < 0.6 um Ra < .012mm 71 blocks (426 bores)/hour

Case Study # 3

Part Name                          Overall Dimensions

4-Cylinder, In-Line Engine Block 173mm Height, 170mm Width,351mm Length

Material                         Hardness

Cast Iron                                      HB 179-248

Bore Diameter  Bore Lengths Roundness Surface Finish Straightness

65.932-65.982mm 118.0mm (blind hole) 0.015mm 2.0-3.0um Ra 0.015mm

Model                                     Honing Work Stations Honing Tool Abrasives Coolant

HV-2000-L2 2 D46 Stone, SiC Brush                             Oil

Bore Diameter Roundness Surface Finish (plateau) Cross-Hatch Finish Straightness

65.000-65.015mm                            0.015mm 1.0-3.0um Ra 140-160º 0.013mm

Bore Diameter                 Roundness Surface Finish Cross-Hatch Finish Straightness Processing Time

65.000-65.009mm < 0.011mm 1.0-3.0um Ra 150º < 0.011mm 18 blocks/hour (72 bores/hour)

Case Study # 4

Part Name                          Overall Dimensions

V-6 3.0L Engine Block 249mm Height, 432mm Width,505mm Length

Material                         Hardness

Gray Cast Iron                            HB180-220

Bore Diameter  Bore Lengths Roundness Surface Finish Straightness

92.0-92.024mm          56.180mm 0.018mm 1.5-2.5um Ra 0.018mm

Model                                     Honing Work Stations Honing Tool Abrasives Coolant

HV-2000-L2    2 D38 – D252 Stones                               Oil

Bore Diameter Roundness Surface Finish (plateau)       Straightness

92.075-92.100mm 0.013mm Rk  0.75-3.0, Rvk 3.0-5.0, Rpk 0.5-1.5 0.013mm

Bore Diameter                 Roundness Surface Finish Straightness Processing Time

92.083-92.093mm < 0.011mm  Rk  0.75-3.0, Rvk 3.0-5.0, Rpk 0.5-1.5 < 0.011mm 7 Blocks (42 bores) per hour

Case Study # 5

Part Name                          Overall Dimensions

4.0L Engine Block In-Line 6 Cylinder 305mm Height, 406mm Width,711mm Length

Material                         Hardness

Cast Iron HB190-220

Bore Diameter Bore Lengths Cylindricity Surface Finish

928.27-98.32mm     139.70mm 0.038mm  2.5-3.0um Ra

Model                                     Honing Work Stations Honing Tool Abrasives Coolant

MV-7000 15 D76 – D107 Stones Water-Soluble Emulsion

Bore Diameter Cylindricity Surface Finish (plateau)

98.425-98.475mm                        0.013mm 0.68-1.13um Ra

Bore Diameter Cylindricity Surface Finish Processing Time

98.438-98.448mm < 0.011mm 0.68-1.13um Ra 150 Blocks (900 bores) per hour

Case Study # 6

Part Name Bore Diameter Operation

Cylinder Liner – Diesel Engine 124.948mm Semi-finish/Plateau Hone

Material                         Hardness

Cast Iron                                 180 – 240 HB

Stock to be Removed Bore Length

.305mm                                  245.3mm

Model                                     Honing Work Stations Honing Tool Abrasives Coolant

HV-8000                                           1 D126, C320 Oil

Bore Diameter Roundness Max. Straightness Max Surface Finish Cross Hatch

+0.02mm 0.04mm 0.04mm Plateau 30 degrees

Bore Diameter Roundness Straightness Surface Finish Cross Hatch                           Processing Time/Bore

30 degrees <0.015mm <0.015mm  Plateau 30 degrees 110 seconds/bore average

Case Study # 7

Part Name Bore Diameter Operation

Cylinder Liner – Diesel Engine 109.24mm Semi-finish/Plateau Hone

Material                         Hardness

Cast Gray Iron                         217 – 277 BHN

Stock to be Removed Bore Length

.102mm                                    239.3mm

Model                                     Honing Work Stations Honing Tool Abrasives Coolant

HV-5000                                              2 D151, C400 Oil

Bore Diameter Roundness Straightness Surface Finish Cross Hatch

0.0254mm                 0.0254mm 0.0254mm Plateau 30 degrees

Bore Diameter Roundness Straightness Surface Finish Cross Hatch                           Processing Time/Bore

0.0125mm 0.015mm 0.015mm Plateau 30 degrees 40 seconds/bore average