Honing is an edge preparation that increases the cutting edge strength. Regularly used honing methods include round and chamfer types.
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Effect of honing geometry
With the same honing width, round honing has higher cutting edge strength than chamfer honing. For chamfer honing, the cutting edge strength changes according to the angle of the honing. In general, larger honing angles give higher cutting edge strength.
However, when the honing width is the same, chamfer honing provides greater sharpness than round honing, due to lower cutting resistance.
Cutting edge strength
Effect of honing size
Honing is necessary for increasing cutting edge strength, even though the sharpness decreases. Therefore, it is important to use the smallest honing possible but with enough width to maintain cutting edge strength. The ideal honing width is generally about 50% of the feed rate. However, for soft workpiece materials such as aluminium alloys, a sharp cutting edge without honing needs to be used.
Effects of increasing the honing width
- Cutting edge strength increases and thereby the fracture rate lowers and tool life is extended.
- Cutting resistance increases and vibration can occur.
- Flank wear tends to develop and lowers tool life.
- The amount of crater wear is not affected by the size of the honing.
Large impacts on the cutting edge during interrupted cutting and surface scale machining etc.
Small depths of cut and low feed rate when finishing.
Workpiece and machine rigidity
Lack of rigidity
For inserts with chip breakers, to maintain cutting edge strength a flat portion can be designed on the rake face. This is called a land, and is different from honing.