Sunnen Honing Techniques: Above and Beyond Honing

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A B OV E A N D B E YO N D H O N I N G

®
Sunnen Honing Techniques
data file: #108
fixturing parts for power stroking

www.sunnen.com
SUNNEN HONING TECHNIQUES

CONTENTS
Part Fixturing Categories
Most parts that you would hone on a Sunnen Power Stroker fall into 10 categories as far as fixturing is
concerned. They are:
1. Parts which have a round outer surface and a substantial wall thickness . . . . . . . . . . . . . . . . . . . 3
2. Parts with thin walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Parts with projections on the outer surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. Parts with a hole on the outer surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5. Parts with irregular outer surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6. Parts which are too short to be honed one at a time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
7. Parts with short bores which must be held square to the face . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8. Parts with blind holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
9. Long parts to be honed on one end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
10. Parts which appear to have no easy way to hold them . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
11. Parts to be externally honed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Standard off-the-shelf fixturing Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
The examples shown in this data file show how parts from each of these categories have been successfully fixtured. With
this information, you should be able to apply the principles shown here to the fixturing of your own parts, when necessary.

INTRODUCTION
This book is a general guide on fixturing that may be used with the Sunnen Power Stroker. The
photographs and fact sheets provide sufficient information for most shops to design and make a
successful fixture in those cases where standard Sunnen off-the-shelf fixturing will not do the job.

Primary Design Considerations


1. The fixture must absorb the honing torque.
2. The bore must be free to align itself with the mandrel.
3. The fixture must not distort the part.
4. The fixture should permit quick, easy loading and unloading.

2
SUNNEN HONING TECHNIQUES
POWER STROKING FIXTURING
1. Parts which have a round outer surface 2. Parts with thin walls . . .
and a substantial wall thickness . . . Use a Sunnen HF- Loop-Grip Workholder to keep
Use a Sunnen HF-____ Loop-Grip Workholder to the workpiece from turning. This type of holder is
keep the workpiece from turning. Workholders are essential to avoid distortion of thin wall parts.
available in three sizes; select the size that best Workholders are available in three sizes; select the
accommodates the length and diameter of your part. size that best accommodates the length and diameter
of your part.
On heavy stock removal operations, end thrust from
stroking can be absorbed with a KKN-700 Universal End cap must be fabricated and put over the ends of
Honing Fixture, as shown. the workpiece to give the fingers or face plate a
surface to bear upon, as shown.
On light honing operations, end thrust from stroking
can be absorbed with a KKN-600 Adjustable Finger On heavy stock removal operations end thrust from
Fixture and KKN-720A Fingers (see Category 5). stroking can be absorbed with a KKN-700 Universal
Honing Fixture, as shown.
On light honing operations, end thrust from stroking
can be absorbed with a KKN-600 Adjustable Finger
Fixture and KKN-720A Fingers (see Category 5).

Figure 1, Thick Wall Parts Figure 2, Thin Wall Parts

3
SUNNEN HONING TECHNIQUES
3. Parts with projections on the outer 4. Parts with a hole on the outer surface . . .
surface . . . To keep the workpiece from turning, merely stick a
Category 3 parts usually require no workholder; a rod into the hole.
projection on the part is used to keep the workpiece On heavy stock removal operations end thrust from
from turning. stroking can be absorbed with a KKN-700 Universal
On heavy stock removal operations end thrust from Honing Fixture, as shown.
stroking can be absorbed with a KKN-700 Universal On light honing operations, end thrust from stroking
Honing Fixture, as shown. can be absorbed with a KKN-600 Adjustable Finger
On light honing operations, end thrust from stroking Fixture and KKN-720A Fingers (see Category 5).
can be absorbed with a KKN-600 Adjustable Finger
Fixture and KKN-720A Fingers (see Category 5).

Figure 3, Parts w/Projections Figure 4, Parts w/Holes

4
SUNNEN HONING TECHNIQUES
5. Parts with irregular outer surfaces . . . 6. Parts, which are too short to be, honed
Best method of holding this type of part is to find a one at a time . . .
flat, a protrusion, a slot, or an indentation on the OD, Make a pot fixture to accommodate as many parts as
and fabricate a wrench-type holder to engage the part can be efficiently honed with the mandrel you will
to keep it from turning, as shown, use. A combined part length equal to or longer than
On heavy stock removal operations end thrust from stone length is a good place to start. The pot fixture
stroking can be absorbed with a KKN-700 Universal must be open at both ends and should have a screw
Honing Fixture (see Category 4). cap, bayonet, or clamp to contain the parts. A rod is
used to keep the pot fixture from turning.
On light honing operations, end thrust from stroking
can be absorbed with a KKN-600 Adjustable Finger
Fixture and KKN-720A Fingers, as shown.

Figure 5, Parts w/Irregular Surface (1 of 2) Figure 5, Parts w/Irregular Surface (1 of 2)

5
SUNNEN HONING TECHNIQUES

CAUTION 7. Parts with short bores, which must


End faces of parts must be flat, parallel, and be held, square to the face . . .
reasonably square with the bore. I. D. of parts should When the diameter of a bore is more than three times
be lined up sow as closely as possible with a plug or its length, and the workpiece has a flat face, Sunnen
expanding mandrel. (A long Sunnen mandrel of the Power Stroking can create or maintain squareness
same diameter as you're honing with would be ideal.) between the bore and the face. In some cases, this
Part-to-part variation of rough size should be can even be achieved when the diameter of the bore
minimized. is only twice its length.
If the parts are shaped so that a convenient way can
be found to keep each part from turning individually, Use a Sunnen KKN-____ faceplate to absorb forward
lining up and clamping is not necessary. But the stroke end thrust while keeping the bore square to the
stroke must be adjusted so no more than 1/2 the face. Configuration of the workpiece will dictate the
length of the end parts extends beyond the end of the method to use to keep it from turning.
stone at each extreme position of the stroke. End thrust on the backstroke can be absorbed with a
KKN-700 Universal Honing Fixture, as shown, or
On heavy stock removal operations, thrust is taken
with a KKN-600 Adjustable Finger Fixture, (see
on the pot fixture with a KKN-700 Universal Honing
Category 5). The important thing is that the
Fixture (see Category 8).
workpiece must be held flat against the faceplate in
On light honing operations, thrust is taken on the pot order to create or maintain squareness. KKN-615A
fixture with a KKN-600 Adjustable Finger Fixture Flex Pads (available from Sunnen) can often be used
and KKN-720A Fingers, as shown. to hold the workpiece flat against the face plate, as
shown pads should exert pressure on workpiece.

ROD SOLDERED
TO HOSE CLAMP
KKN-700 TO ABSORB FACE-
FIXTURE TORQUE PLATE

FACEPLATE

HOSE
CLAMP

ROD SOLDERED TO KKN-720A


HOSE CLAMP TO FINGERS
ABSORB TORQUE

WORKPIECE

KKN-615 FLEX KKN-615 FLEX WORKPIECE HOSE


PADS PADS
CLAMP
(COMPRESSED
BETWEEN WORKPIECE
AND FINGERS)

Figure 7, Short Parts w/Sq. Face (1 of 2)

6
SUNNEN HONING TECHNIQUES
8. Parts with blind holes . . .
If at all possible, provide a relief (undercut) at the 2/3 BORE
closed end of the hole to permit the stone to LENGTH
overstroke the honed surface. The relief does not
have to be more than a few thousandths deep and can
actually blend in with the bore when finish honed,
but it should be as long as possible, preferably 1/3 ALTERATION OF
the length of the stone. INTERGRAL SHOE MANDREL

Sunnen honing units in the K, J-K, AK, J-AK, BL, L, Alteration For Blind Holes
BAL, AL and P28 groups can be utilized for honing
bores that have one end closed. (Special Y mandrels
can also be made.) In honing blind holes, it is
necessary for the stone and guide shoes to extend
flush with the tip of the honing unit. If your
application utilizes one of the P28 groups of honing
units, install the blind hole wedge, blind hole guide
shoe and R28 Honing Stones. The remaining
mandrel groups have a tip, which extends slightly
beyond the front end of the stone and guide shoes.
For all blind hole work this tip must be cut off, as
illustrated. Mandrels, which have been altered in this
manner, can still be used for honing open holes using
a full length stone and guide shoes.
The most important thing to remember in fixturing
blind-hole parts for power stroking is that the stroke
must be longer than the travel of the stone. This
sounds incongruous at first, but is accomplished by
using a spring in your fixturing . . . the spring permits
the stroker arm to continue moving for a short
distance after the mandrel has bottomed out in the
bore. During this period, the bottom of the bore
receives extra honing, called "dwell".
It is necessary to dwell in order to minimize the
tightness that results from the inability to overstroke
the part at the blind end.
Illustrated on this page is one method of fixturing a
blind-hole part . . . note especially the spring, which
is the one element that must always be present for
successful blind-hole honing.

Figure 7, Short Parts w/Sq. Face (2 of 2) Figure 8, Parts w/Blind Holes

7
SUNNEN HONING TECHNIQUES
9. Long parts to be honed on one end . . . Dimensions on the drawings are for typical fixtures;
Long parts which have a short land to be honed on vary as needed to suit your particular job.
one end must be supported so they don't sag or whip.
The fixtures illustrated on this page are designed to
clamp onto one of the rods on the KKN-600 Finger
Fixture. A rod can be inserted into the clamp on the
bottom of the stroking arm if the KKN-600 is not used.
The Enclosed Fixture is recommended for product
ion honing, or for high-speed honing where there is a
chance for the part to whip.
The Open Fixture is more versatile, accommodating
many different ODs. It is very handy to have around
a tool room, or-wherever short runs of various parts
is the rule. Figure 9, Long Parts (1 of 4)

1/2 in. 1/2 in.


.005 in. LARGER
THAN OD OF PART 1-1/2 x 1-1/2 x 1/8 in.
ANGLE IRON
HEIGHT
WELD
ADJUSTMENT
NUT
5/16 in. .24
BOLT x 2-1/4 in. LONG
DRILL HOLE FOR
LOOSE FIT OF BOLT
1 in. BAR STOCK 1 in. BAR STOCK

#7 DRILL THRU TAP


1/4-20 USE 1/4-20 #7 DRILL THRU TAP
1/2 in. SETSCREW 1/4-20 USE 1/4-20
1/2 in. SETSCREW

ENCLOSED FIXTURE FOR PRODUCTION HONING - DESIGNED OPEN FIXTURE FOR TOOL ROOM HONING - DESIGNED
FOR A PARTICULAR PART. TO ACCOMMODATE MANY DIFFERENT PART.

Figure 9, Long Parts (2 of 4) Figure 9, Long Parts (3 of 4)


WASHERS
ENCLOSED BETWEEN
FIXTURE FINGERS AND
CARBIDE PADS

TO MAKE ROOM
FOR TORQUE
ROLLER
BARCKET

TORQUE TAKEN
HERE BY HF-75
HOLDING FIXTURE

Figure 9, Long Parts (4 of 4)

8
SUNNEN HONING TECHNIQUES
10. Parts which appear to have no easy 11. Parts to be externally honed . . .
way to hold them . . . Hold the workpiece in an adapter chuck (available
Sometimes you run across a part which cannot be held from Sunnen) and use the KKN-700 Universal
by any of the preceding methods. The reasons could be Honing Fixture to stroke the Sunnen External Hone.
varied. In the case illustrated here, the bevel gear to be Four KKN-723A Plain Fingers without carbide pads
honed seems to defy any attempt to hold it. Cutting are included with the KKN-700 for use with the
both ends out of an empty tuna fish can and using it as External Hone.
a mold to make a fixture with Devcon Plastic Steel Fit Sunnen Honing Machine spindles. Hold Adapter Chucks
solved this particular fixturing problem. A rod was work being rotated for external
honing operations.
inserted through a slot in the side of the can and into PART NO.
MB-748
RANGE
0 - 3/8" dia.
the fixture before 'it hardened ... the rod to be used to MB-750 3/16 - 3/4" dia.
MB-770 1/8 - 5" dia.
keep the part from turning during honing.
With parts in this category, use your imagination.
Just remember that, no matter how odd it looks,
there's probably some way to hold it. If you need
some ideas, call your nearby Sunnen Man in ... he'll
MB-748
be happy to help. MB-750 MB-770
On heavy stock removal operations end thrust from
stroking can be absorbed with a KKN-700 Universal
Honing Fixture, as shown.
On light honing operations, end thrust from stroking
can be absorbed with a KKN-600 Adjustable Finger
Fixture and KKN-720A Fingers (see Category 6).

Figure 10, Special Parts Figure 11, External Honing

9
SUNNEN HONING TECHNIQUES
STANDARD OFF-THE-SHELF FIXTURING ITEMS
KKN-700 Universal Honing Fixture: Accommodates
almost any workpiece or fixture you'll ever have.
Easily and quickly installed or removed. Takes the
thrust on forward and backstrokes. Includes two pairs
of fingers with longwearing, adjustable carbide pads,
and two pairs of driving fingers for use with external
KKN-700
hones.
KKN-600 Adjustable Finger Fixture: Accommodates
most parts; especially useful on small workpieces.
Easily and quickly installed or removed. Used in
conjunction with KKN-720A Fingers. Includes
longwearing, adjustable carbide pads on fingers, two
pairs of support rods, and clamp. .
KKN-600

FacePlates: Use a face plates on parts whose bore must


be kept square to the face. Select correct faceplate
from table below. OD of workpiece should be larger
than OD of faceplate, and ID of workpiece must be
smaller than ID of faceplate. (See Table below.) .
Faceplate

KKN-720A Fingers: For fast, economical setups.


Long-wearing, adjustable carbide pads. Quick, easy to
use. Mount on Stroker Arm. Also used as replacement
part for KKN-700. Two per set. Consists of fingers,
pads, attaching screws and washers. .
KKN-720A

KKN-723A Finger Set: For external honing, included


with KKN-700 Universal Honing Fixture. KKN-723A
Finger Set includes four fingers without carbide pads,
and four screws. .

KKN-723A

Loop-Grip Workholder: Especially useful for hard-to-


hold parts such as thinwall tubes, glass barrels, small
parts with smoth surfaces, and parts with sharp
projections such as gears and milling cutters. Uses
emery cloth to hold part securely without distortion.
HF-____ Parts can be inserted and removed easily. Each fixture
handles. (See Table below.)
OUTSIDE DIAMETER MAXIMUM INSIDE FIXTURE
RANGE OF WORKPIECE DIAMETER OF FACE PART NUMBER REPLACEMENT
FACE WORKPIECE PLATE (INCLUDES 3FT. OF EMERY EMERY CLOTH
(inches) (inches) EMERY CLOTH) CLOTH (25FT. LENGTH)
.345- .380 .200 KKN-201 HF-75 3/4” WIDE HF-110
.380- .460 .230 KKN-202 HF-200 2” WIDE HF-210
.460- .575 .290 KKN-203 HF-300 3” WIDE HF-310
.575- .730 .380 KKN-204 HF-55 Set of all three fixture listed above.
.730- .925 .510 KKN-205
.925-1.160 .650 KKN-206
1.160-1.430 .820 KKN-207
1.430 - 1.740 1.030 KKN-208
1.740 - 2.090 1.270 KKN-209
2.090 - 2.480 1.540 KKN-210
2.480 - 2.820 1.850 KKN-211
2.820 - 3.190 2.190 KKN-212
3.190 -and over 2.560 KKN-213
Setup Faceplate KKN-265

10
1 4¼ 4¼ 1

11/16

1/4-20 UNC TH’D


115/16 15/16
8 PLACES
LOCATOR STUD
(REMOVABLE)
4.812 ADJUSTABLE SUPPORT BUSHING
HONE SPINDLE CENTERLINE 2.406 17/64 DIA. HOLE

.625 1/2 TYP.

3.032
21/32 R.
2.625

41/8

½ 1
SOLID SUPPORT BUSHING 1 ½
17/64 DIA. HOLE 27/32 5/16-18 UNC TH’D
1
1 27/32 4 PLACES

FIXTURING DIMENSIONS
SUNNEN HONING TECHNIQUES

11
data files
101 - Honing Bores With Keyways And Splines
102 - Honing Short Bores
103 - Honing Blind Holes
104 - Obtaining Specified Finishes By Honing
105 - Choosing the Right Stone
106 - Honing Tandem Holes
107 - Making Manual Honing Easier With Workholders
108 - Fixturing Parts For Power Stroking
109 - Vertical Hone Fixture
110 - Honing Small Bores
111 -
112 - External Honing
113 - Fixturing Design Considerations For Automatic Krossgrinding® Machines

SUNNEN CUSTOMER SERVICE AND TECHNICAL SERVICE CENTERS


The fully equipped Automotive and Industrial Technical Service Centers in St. Louis is available to
help with any honing problem at any time without cost or obligation. Sunnen factory-trained
Field Service Engineers cover the entire country and are always at your service - again, no cost or
obligation. Call us whenever you have a bore-sizing problem.
visit
ww.sunnen.com

“SUNNEN®, THE SUNNEN LOGO, GENERAL HONE AND THE GENERAL HONE LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY.”

SUNNEN WORLDWIDE A Legacy of Excellence since 1924.

Sunnen Products Company France – Sunnen SAS Russia – Sunnen RUS


World Headquarters Phone +33 01 69 30 0000 Phone +7 495 258 43 43
St. Louis, MO – USA Fax +33 01 69 30 1111 Fax +7 495 258 91 75
Phone 1.314.781.2100 Email info@sunnen.fr Email sunnen@sunnen-russia.ru
Fax 1.314.781.2268 www.sunnen.fr www.sunnen.ru
Toll Free 1.800.325.3670
Email sunnen@sunnen.com UK – Sunnen Products Ltd. Czech Republic – Sunnen s.r.o.
www.sunnen.com Phone +44 1442 39 39 39 Phone +420 383 376 317
Fax +44 1442 39 12 12 Fax +420 383 376 316
Switzerland – Sunnen AG Email hemel@sunnen.co.uk Email sunnen@sunnen.cz
Phone +41 71 649 33 33 www.sunnen.co.uk www.sunnen.cz
Fax +41 71 649 33 34
Email info@sunnen.ch Poland – Sunnen Polska Sp. z o.o. China – Shanghai Sunnen
www.sunnen.ch Phone +48 22 814 34 29 Mechanical Co. Ltd.
Fax +48 22 814 34 28 Phone +86 21 5813 3990
Italy – Sunnen Italia S.r.l. Email sunnen@sunnen.pl Fax +86 21 5813 2299
Phone +39 02 383 417 1 www.sunnen.pl Email shsunnen@sunnensh.com
Fax +39 02 383 417 50 www.sunnensh.com
Email sunnen@sunnenitalia.com
www.sunnenitalia.com
Sunnen® reserves the right to change or revise specifications and product design in connection with any feature of our
products contained herein. Such changes do not entitle the buyer to corresponding changes, improvements, additions, or
replacements for equipment, supplies or accessories previously sold. Information contained herein is considered to be ©2009 Sunnen Products Company Printed in USA
accurate based on available information at the time of printing. Should any discrepancy of DF-108 9/09 - POD
information arise, Sunnen recommends that user verify the discrepancy with Sunnen before proceeding.

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