A study on the influence of bond material on honing engine cylinder bores with coated diamond stones

A consistent increase in demand for special tools designed to enhance an efficient honing of engine cylinder bores is observed. Metallic Bonded Diamond Stones (Dia-M) are more and more used for their wear resistance and their high tool life. However, the hardness of this Metallic Bond leads to the degradation of the honed surface aspect by the formation of smudgy grooves edges (blechmantel). This torn and folded metal affects the required functional performances of the cylinder bore. In this study, two new diamond coated abrasive stones with Vitrified and Resinoid Bonds (respectively Dia-V and Dia-R) are tested and compared to the Dia-M sticks. The influences of bond material on the honing reliability are studied in terms of honed surface aspect, material removal rate and wear properties. Results reveal that the stiffness and the openness structure of the Resinoid Bond leads to a better trade off between surface aspect and tool life.