Sunnen Honing Techniques: Above and Beyond Honing
Sunnen Honing Techniques: Above and Beyond Honing
Sunnen Honing Techniques: Above and Beyond Honing
®
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.
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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).
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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).
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.
5
SUNNEN HONING TECHNIQUES
ROD SOLDERED
TO HOSE CLAMP
KKN-700 TO ABSORB FACE-
FIXTURE TORQUE PLATE
FACEPLATE
HOSE
CLAMP
WORKPIECE
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.
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)
ENCLOSED FIXTURE FOR PRODUCTION HONING - DESIGNED OPEN FIXTURE FOR TOOL ROOM HONING - DESIGNED
FOR A PARTICULAR PART. TO ACCOMMODATE MANY DIFFERENT PART.
TO MAKE ROOM
FOR TORQUE
ROLLER
BARCKET
TORQUE TAKEN
HERE BY HF-75
HOLDING FIXTURE
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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).
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
KKN-723A
10
1 4¼ 4¼ 1
11/16
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
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