The machining principle of honed cylinder tubes is based on micro-cutting achieved through a combined rotational and reciprocating motion of the honing tool. This process utilizes abrasive stones mounted on a honing head to interact with the inner surface of the workpiece, forming a cross-hatched pattern that improves geometric accuracy and reduces surface roughness. The following sections detail the core principles and mechanisms involved:
I. Basic Motion Mechanism
The honing head drives abrasive stones (honing sticks) to perform two simultaneous motions:
Rotational Motion: The honing head rotates around its axis, generating circumferential cutting traces.
Reciprocating Motion: The honing head moves axially back and forth, producing linear cutting traces.
Combined Effect: The superposition of these motions creates a cross-hatched pattern with a typical angle of 30°–60° (adjustable based on requirements). This pattern enhances oil retention, reduces friction, and improves wear resistance.

II. Material Removal Mechanism
Micro-Cutting Action:
Abrasive grains remove material at a micron-level depth, ensuring minimal heat generation and avoiding thermal damage to the workpiece.
The large contact area between the abrasive stones and the bore wall results in low unit pressure (typically 1/50–1/100 of grinding processes), reducing cutting forces and preventing workpiece deformation.
Self-Sharpening of Abrasive Stones:
Initial Phase: High unit pressure rapidly removes irregularities on the bore wall, while worn abrasive grains break away to expose fresh, sharp grains.
Stable Phase: As the surface becomes smoother, the cutting action transitions to a finer material removal process.
Clogging Prevention: Continuous coolant flow removes chips and prevents abrasive stone clogging, maintaining cutting efficiency.

III. Characteristics of Cross-Hatched Patterns
Oil Retention: The grooves store lubricating oil, forming a protective film that reduces friction and wear.
Noise Reduction: The pattern disrupts sound wave propagation, reducing operational noise.
Stress Distribution: The increased surface area distributes loads more evenly, extending component life.

IV. Honing Head and Tooling
Abrasive Stones: Designed with specific grit sizes and bonding materials to suit different materials (e.g., cast iron, steel, or aluminum).
Expansion Mechanism: Allows radial adjustment of abrasive stones to maintain consistent contact pressure with the bore wall.
Floating Connection: Compensates for misalignment between the tool and workpiece, ensuring uniform material removal.

V. Advantages of Honing
High Precision: Achieves tight tolerances (IT6–IT7), cylindricity ≤ 0.005 mm, and surface roughness as low as Ra 0.025 μm.
Geometric Correction: Corrects deviations from previous machining steps (e.g., boring or grinding errors).
Enhanced Performance: The cross-hatched surface improves lubrication, reduces friction, and increases service life.
Efficiency: Suitable for mass production due to short cycle times (2–3 minutes per bore) and minimal material waste.

VI. Applications
Honed cylinder tubes are widely used in:
Hydraulic Cylinders
Engine Cylinders
Precision Pneumatic Systems
Industrial Machinery