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Electrical discharge dressing of honing stones

: Uhlmann, E.; Yabroudi, S.; Zimmermann, S.; Gerlitzky, G.; Polte, M.; Klink, U.; Sihling, B.


Precision engineering 62 (2020), S.151-161
ISSN: 0141-6359
ISSN: 0401-6459
Fraunhofer IPK ()

Honing processes require a systematic preparation and a regeneration of the honing tool to guarantee a sufficient cutting behaviour and prevent unintended wear of the tool. These dressing processes are particularly important for the regeneration of the macro- and microscopic topography of the honing stones. The established method of manual shaping subsequent to a cylindrical grinding process demands a high skill level, a great amount of non-productive time and is not reproducible.
In this paper the preparation of honing stones by use of electrical discharge machining (EDM) is presented. The aim is to ensure an automatic, systematic and reproducible process of resetting the bond of honing stones. Different tool electrode materials were analysed systematically for two different bond specifications of the honing stones. EDM process parameters were studied within a design of experiments (DoE) strategy and a subsequent effect analysis to assure the identification of most appropriate EDM process parameters. After this procedure various cycles of long-stroke honing processes were carried out. As a result, the new approach makes it possible to prepare honing stones with reproducible sharpness and macroscopic topography within an automated process. The dressing time td was reduced by 88 % compared to the established method.