BRM - A Study of Cylinder Wall Micro Structure

8/4/2019 BRM - A Study of Cylinder Wall Micro Structure

1/26B R U S H R E S E A R C H M A N U F A C T U R I N G C O . , I N C .

A STUDY OF A CYLINDER WALL

MICRO-STRUCTURE


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When it was frst introduced the Flex-Hone was considered a sort o brushthat was a simple and ool proo way o deglazing engine combustion andbrake cylinders. It gained quick acceptance in the trade.

Then came reports rom all over o rapid ring seating and great savings in

oil consumption. We put out a booklet called An Observation o SomeCommon Practices in Cylinder Boring, Honing and Wall Finishing. The rontcover emphasizes that Nothing improves until someone stops and questionsan accepted assumption. This gold book subsequently was translatedinto fteen languages and had over 00,000 copies printed. Most schoolsuse it as a text reerence book. In rapid succession we obtained ServiceApprovals rom John Deere, International Harvester, Perkins, MasseyFerguson UK, Caterpillar, Burmeister Wain, Klockner-Humboldt-Deutz,S.E.M.T. Pielstick, OMC, Saviem, Citroen, Peugeot, Mercury Marine, andCountless others.

We had learned by this time using comparison profles that the Flex-Honedeburred the fnish let by either boring or rigid honing and greatly increasedthe plateaued area. Feeling that this was probably the answer to thesecret o its perormance we produced a second booklet on The Necessityo a Plateaued Cylinder Wall Finish. In it we showed in detail the resultso two perormance tests, one on a gasoline powered auto engine, and thesecond on a Detroit Diesel. This booklet with over 40,000 now distributedhas had a great impact in the engineering feld and has resulted in our doing(in cooperation), a great many more tests into problem areas. We still didnot know the real why o its unique perormance qualities.

We think, now, that we have come a lot closer to the answer by studyingthe micro-structure with a Scanning Electron Microscope and by taking beoreand ater photographs o dierent suraces. That is what this booklet is allabout. And we would like you to study this subject with us and help us inour continued search or the reasons why the results turn out the way theydo. We used to say that the only way you could tell, was to perormancetest. And that is still true. But now perhaps we can have a little betterunderstanding o what it is we are testing.

We are not a large company and we do not operate on grants or fnancial

assistance rom the government. Most o our work in this feld is done withthe cooperation o interested customers and/or our very capable distributorsrom around the world. You will recognize the many renowned companiesthat have worked with us or approved our products as they are listed ormentioned in our previous publications. Our reward or our extensive servicein this area is the reception that we have received rom you and we arededicated to pursue the technology o cylinder wall fnishing so as to providethe most up-to-date inormation to the industry.

O equal importance is the fnishing o hydraulic and Pneumatic Cylinders.Under heavy pressures, with dierent types o seals, fnish is vital to theirperormance. Too common is the all-consuming mania o cost reduction,so the continuance o roller-burnishing or pre-fnished rigid honed tubingbecause o speed and cost. Like a lot o products today, make it acceptable

or selling. Let the consumer worry about the resultant problems. But thepicture today is slowly changing. Competition by quality, or mandatedperormance levels, will demand changes in improved methods.

I you havent read our Plateaued Booklet recently then we urge you to doso now. Most top engineers consider it to be the best presentation in itsfeld. Pages 0-, , and 3 deals with our patented concepts in thetheory o the sliding suraces and co-acting metals. We continue its study.

Footnote:The Flex-Hone tool is a patented or has patents pending in all major

industrial nations o the world and the name Flex-Hone is a Registeredtrade mark o Brush Research Manuacturing Co., Inc o Los Angeles and isregistered or has registrations pending in almost every trading area o theworld. Use o the name o Flex-Hone must show that it is a Brush ResearchManuacturing Co., Inc. Trademark. Exclusive distributors in almost everycountry are equipped or your immediate service.

BAUDOUINS STRIVE FOR QUALITY

The frst presentation is rom our distributor or France, SEDIMAT, Baudouin

have been purchasing their liners rom Associated Engineering o Franceand they had discovered that by Flex-Honing the liners ater receipt romA.E.F. that they eliminated many problems o oil consumption and scufng.Baudouin had issued a service approval or the Flex-Hone back in 975.

Baudouin asked A.E.F. to Flex-Hone all liners beore fnal anti-rust coatingand delivery to eliminate the problem o doing the Flex-Hone operation aterreceipt. These normal liners are shown in the ollowing profles, labeled No.3003, beore and ater the Flex-Hone Process.

A.E.F. said they would plateau hone them by their own methods and the

fnish would be the same as with the Flex-Hone. This type o liner is shownby SEM photographs labeled No. 300. A.E.F. said that liner No. 300had been rigid plateau-honed so it was not necessary to apply the Flex-HoneProcess. Mr. Faure oered to have the fnishes analyzed or Baudouin andthe results are presented on the ollowing pages. Needless to say, Baudouinagain requested that all linersbe Flex-Honed beore delivery. A.E.F. hasagreed to Flex-Hone all Baudouin liners at normal price.

EVOLUTION OF A STUDY IN THE MICRO-FINISHING OF CYLINDER WALLS

Copyright March, 006 by Brush Research Manuacturing Co., Inc. Printed in U


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The above two profles represent the same areas but have been FLEX-HONED with an 80 grain or 60 seconds. Finish has been refned to Ra:0.6 andRa:0.59 and the PLATEAUED AREA 77% and 78%.

Zone A and Zone B represent an area approximately 5 CM in rom the top and bottom o the cylinder liner. The above show the profle in the As Receivedcondition. A.E.F. said they had been rigid normal honed. Finish top was Ra:.09 and bottom Ra:0.99. PLATEAUED AREA 34% AND 49%


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These are SEM photos o Liner 300, Plateau-Rigid Honed by A.E.F.

Let side are sections o the A.E.F. Plateaued Rigid Honed liner. On the Right Side the same sections Flex-Honed with an 80 grain SC.

We eel that an 80 grit is too course or the average application, but manuacturers o large diameter heavy duty engines still want the courser fnishes. Aew seconds with a fner grit should remove any remaining proud metal.

No 6 X00 AE PLATEAU No 4 X00 FLEX-HONE 80

No 6 AE PLATEAU X000 No 4 X000 FLEX-HONE 80


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Two more SEM photos o Liner 300 with the 000 magnifcation.

The Baudouin Liner as supplied by A.E.F.,Plateau-Rigid Honed Finish. Liner wassectionalized and shows the piece removedor the SEM photo-graphs.

The lower section has been Flex-Honed. Thevast dierence in the fnish and the crosshatch is very evident to the naked eye. Notethe over-all consistency is a eature o theFlex-Hone fnish.

No 6 X000 AE PLATEAU No 4 X000 FLEX-HONE 80


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With minimum uel economy regulations becoming increasingly difcultto achieve, internal FRICTION plays a very important part. Reduction opiston ring to cylinder wall interace riction will measurably add to theengines efciency.

The oil contamination actor o converters is also VERY important.Emission Control Devices may soon have a mandated mileage warrantyand they are very adversely aected by excess oil in the emission. Too,i the oil actor is lower, then the manuacturer can start with higheremissions.

With some o these problems in mind, and with the possibility ocontributing to the solution o them, we received two V-6 engine blocksrom Buick o the assembly line or experimentation and reports. Oneengine was a new acceptable block which had been double honed,frst or size and second or fnish. The second engine block had beenre-honed and was rom the rework acility. The blocks were identifed,cylinders marked and the blocks cut into individual cylinders.

To assure a true comparison o beore and ater Flex-Honing, the individualcylinders were cut into our short sections. One o these was let As-Is.

Only one grit size was used on each section and grits 80, 0, 80,40, 30 silicon carbide were used in GBD 4 Flex-Hones. A randomselection o fve cylinders was made or test procedures.

Ater Flex-Honing, the sections were cut yielding one inch squares in orderto ft into the vacuum chamber o a Scanning Electron Microscope (SEM).SEM photos were taken by Scanning Electron Analysis Laboratories oLos Angeles. SEM photos o 00 and 000 times magnifcation weretaken at an angle o 45 degrees to give a three-dimensional eect.Suranalyzer profles were taken by BRM.

When examining the photographs, it will also help to use a handmagniying glass and to realize that the 00x photos represent an area o.03 x .035 (.8 x .89 mm). The 000 magnifcation photos cover anarea o .003 x .0035 (.08 x .089 mm).

Profles and Fax Films do not show the whole story o MICRO-STRUCTURE,the part you cannot see with the naked eye. The common cold virus cantbe seen either, but it creates lots o havoc and costs millions o dollarsyearly through reduced perormance.

While you are studying these comparisons, note the typical rigid honedfnish, and in the photographs o 00x the unidirectional cuts, and in the000x photos the debris let on the surace. Notice how the Flex-Honeprocess has cleaned it up and or the most part, has removed it. Noticethe appearance o the cross hatch pattern o the Flex-Hone fnish.

Profles have been shown using the various grits with the resultant AAfnishes as compared to the original. Compare these to the photos to seewhat the various grit sizes also do to the surace texture. Courser proflesare normally required on a standard rigid honed surace as the smeared-over metal and covered-up graphite needs extra lubrication grooves. Inthe running-in process with hard and peaky ring suraces the wholesurace gets abraided and except or the deep scratches, the cross hatchfnish disappears.

In the Flex-Hone Finish, the ring seating is rapid in comparison, and theabrasive attrition o cleaning up the cylinder wall is greatly reduced oreliminated, so the Flex-Hone fnish generally remains. Please turn to ourBooklet on the Necessity o a Plateaued Finish and look at Comparisonphotos o the cylinders, (page 4), an OEM, a Rigid Honed, and a Flex-Honed cylinder, run under identical conditions and see the dierence. The

Flex-Hone fnish retains its almost dull-matte look, open and clean.

A COMPARISON STUDY ON TWO V-6 BUICK ENGINES


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A cylinders were rom production rigid honed engine block. B cylinders were rom rehoned engine block by actory rework section.As you are analyzing the ollowing SEM photographs and the corresponding profles, Please Note:The cut, torn and olded-over metal that is quite evident on the surace. This is what sometimes is reerred to as the Deormed Layer or the StressLayer, or the Plastically Deormed Surace Layer, all o which is dierent rom the basic structure o the metal. The surace should ully represent themicrostructure as it existed in the metal beore working. You will note that the Flex-Hone Process has removed the ragmented, damaged, deormed slipbands and in the removal o the common cut, torn and olded metal has opened up the surace structure to a condition that will allow oil retention, reduceriction and abrasive wear on the rings and urther damage to the wall surace. This also allows the ree graphite (provided that particles have not beentorn out by the boring tool or the rigid hone) to appear on the surace to aid in the important role o adding to the lubrication. It is also possible that anyhardened martensitic layers may also be removed to assist in ring seating and to cut down excessive ring wear and ring surace confgurations. With suchsuraces as the Flex-Hone Surace now being possible, then perhaps it may no longer be necessary or piston rings to have the original heavy peaky fnish ormutual attrition.

ANOTHER SHOCKER!O the subject o this booklet, we would like to present a small sample o some developmental work in progress on O.D. Finishing o shats with the Flex-Hone Process. These two SEM photos were taken o a C-045 ground and polished steel shat in the beore and ater Flex-Hoe conditions.

Continuing on the consideration o Co-Acting Metals-the two felds o motion and rest-can you visualize the As Is fnish rotating at high speed under pressureon a sliding bearing (including journals, thrust and guide bearings), and the attempt to keep these two metals separated by lubricant, a liquid or a gas? A

comprehensive study is to be presented at a later date.

The ollowing operations were carried out as previously explained and a study is possible o the dierent fnishes achieved by the dierent grit or grain sizes.

A-2A-2A-2

A-3A-3A-3A-3

A-6A-6A-6A-6

B-1B-1

B-2B-2

As ReceivedFlex-HonedFlex-Honed

As ReceivedFlex-HonedFlex-HonedFlex-Honed

As ReceivedFlex-HonedFlex-HonedFlex-Honed

As ReceivedFlex-Honed

As ReceivedFlex-Honed

-----80 SC

120SC

-----80 SC

120 SC180 SC

-----180 SC240 SC320 SC

-----180 SC

-----180 SC

-----3030

-----303030

-----303030

-----30

-----30

20 - 2530 - 4020 - 25

20 - 2530 - 4020 - 2520 - 25

20 - 2520 - 2512 - 18

7 - 10

40 - 5020 - 25

25 - 3520 - 25

.51 - .63

.76 - 1.02

.51 - .63

.51 - .63

.76 - 1.02

.51 - .63

.51 - .63

.51 - .63

.51 - .63

.30 - .46

.18 - .25

1.02 - 1.27.51 - .63

.63 - .89

.51 - .63

Peaky saw-toothPeaky semi- plateauSemi- plateau

Saw- toothPeaky semi- plateauSemi- plateauSemi- plateau

Peaky saw-toothSemi- plateauSemi- plateauSemi- plateau

Very PeakySemi- plateau

Very PeakySemi- plateau

ACE

G HI J

K LM N

O PQ RS TU V

WY

A AC C

Cylinder Condition Grit & TypeHoning TimeIn Seconds Finish AA Finish m Profile Characteristics SEM Photos


8/26

AS RECEIVED, PRODUCTION RIGID HONED, A photo taken at 000x.Unidirectional cut pattern rom hone operation. Torn, jagged, olded andsmeared metal on surace. Pieces o smeared metal loosely adhearedto surace. 0 to 5 fnish. Peaky saw tooth appearance to profle.#A- cylinder.

AFTER FLEX-HONE, 0 grit silicon carbide, E photo at 000x. Uniormcross-hatch fnish. Most o torn, olded and smeared metal removed.Profles show good semi-plateaued fnish. Surace has clean open appearance. 0 to 5 fnish. Section o #A- cylinder.

AFTER FLEX-HONE, 80 grit silicon carbide, C photo at 000x. Uniorm cross-hatch pattern. Most o torn and olded metal removed. Profle shows somewhat peaky semi-plateau fnish. Profle also reveals that some o original boring operation grooves were opened up by the Flex-Hone operation (deeper

grooves on let hand side o profle. 30 to 40 (.76 to .0 m) fnish. Section o #A- cylinder.

A E

C


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AS RECEIVED, PRODUCTION RIGID HONED, G photo at 000x, H at 00x. Cross-hatch not uniorm with skips in pattern. Torn, jagged, olded andsmeared metal. Some o smeared metal loosely attached to surace. 0 to 5 (.5 to .63 m) fnish. #A-3 cylinder

AFTER FLEX-HONE, 80 grit silicon carbide, I photo at 000x, J at 00x. Uniorm cross-hatch pattern. Surace has a very clean, open appearance with

the torn, olded and smeared metal removed. Profles somewhat peaky due to coarser grit size. 30 to 40 (.76 to .0 m) fnish. Section o #A-3cylinder.

G H

I J


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AFTER FLEX-HONE, 0 grit silicon carbide K photo at 000X, L at 00X. Uniorm cross-hatch pattern. Surace has clean open appearance with mosto torn, olded, and smeared metal removed. Excellent semi - plateaued profle. 0 to 5 (.5 to .63 m) fnish. #A-3 cylinder.

AFTER FLEX-HONE, 80 grit silicon carbide M photo at 000X, N at 00X. Uniorm cross-hatch fnish. Surace has clean open appearance with mosto torn, olded, and smeared metal removed. Excellent semi - plateaued profle. 0 to 5 (.5 to .63 m) fnish. #A-3 cylinder.

K

NM

L


11/26

AS RECEIVED, PRODUCTION RIGID HONED, Ophoto at 000X, P at 00X. Undirectional cut pattern rom rigid hone operation. Peaky profle withtypical saw tooth appearance. 0 to 5 fnish. #A-6 cylinder.

AFTER FLEX-HONE, 80 grit silicon carbide Q photo at 000X, R at 00X. Uniorm cross-hatch pattern. Surace has clean open appearance with mosto torn, olded, and smeared metal removed. Excellent semi - plateaued profle. 0 to 5 (.5 to .63 m) fnish. #A-6 cylinder.

O P

RQ


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S T

U V

AFTER FLEX-HONE, 40 grit silicon carbide S photo at 000X, T at 00X. More refned fnish with uniorm cross-hatch pattern. Surace has clean openappearance with most o torn, olded, and smeared metal removed. Excellent semi - plateaued profle. to 8 (.30 to .46 m) fnish. Section ocylinder #A-6.

AFTER FLEX-HONE, 30 grit silicon carbide U photo at 000X, V at 00X. More refned fnish with uniorm cross-hatch pattern. Surace has cleanopen appearance with most o torn, olded, and smeared metal removed. Excellent semi - plateaued profle. 7 to 0 (.8 to .5 m) fnish. Section ocylinder #A-6.


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CC

W Y

AA

AFTER FLEX-HONE, 80 grit silicon carbide Y photo at 000X. Uniormcross-hatch pattern. Surace has clean open appearance with most otorn, olded, and smeared metal removed. Excellent semi - plateauedprofle. Small dust particles visible on surace in Y photo. 0 to 5 (.5 to .63 m) fnish. Cylinder #B-.

AFTER FLEX-HONE, 80 grit silicon carbide CC photo at 000X. Uni-orm cross-hatch pattern. Surace has clean open appearance with mosto torn, olded, and smeared metal removed. Excellent semi - plateaued

profle. 0 to 5 (.5 to .63 m) fnish. Cylinder #B-.

AS RECEIVED RIGID HONED BY FACTORY REWORK SECTION. W photoat 000X. Cross-hatch has majority o cut in one direction. Smeared,torn, jagged and olded metal on surace. Smeared metal looselyattached to surace. Very peaky profle fnish. 40 to 50 (.0-.7m) fnish. Cylinder #B-.

AS RECEIVED RIGID HONED BY FACTORY REWORK SECTION. AA photoat 000X. Uniorm cross-hatch pattern. Smeared, torn, and olded metal,smeared metal loosely attached. Very peaky profle.. 5 to 35 (.63

to .89 m) fnish. Cylinder #B-.


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We were asked by these two manuacturers to investigate the use o theFLEX-HONE Tool on their cylinder liners as a fnal fnishing process.This report is in two parts. Part One deals with cylinder liners made by one

o the fnest producers o engines and cars in the World. Part Two deals withcylinder liners made by the biggest producers o heavy commercial vehiclesin the UK.

All cylinder liners were checked or surace fnish and surace profle uponreceipt. We decided at this juncture to cut sections Out O two liners o PartOne and one liner o Part Two in order to have them photographed by aScanning Electron Microscope. Our purpose in so doing was to see whatlevel o smeared, torn and olded metal appeared on the surace o theseliners in the as received condition. These sections were then reftted intothe liners and all liners were then Flex-Honed. Ater Flex-Honing, the liners

were then rechecked or surace fnish and profle. The sections were thenremoved rom the liners and photographed again by the Scanning ElectronMicroscope.

All surace measuring was done by our own Ferrants Surcom IOB instrumentand associated recorder. The SEM photographs were done by an indepen-dent metallurgical laboratory using a Cambridge Stereoscan 600.

All profle charts shown in this report have a vertical magnifcation o 000and a horizontal magnifcation o 50. Surace fnishes are expressed in m

(micro metres) RA. The profle charts show profles as TP (total profle).

TEST PART ONE

We received nine liners rom the manuacturer, all o which were reported to

be in the fnish honed condition i.e., they were in the condition in which theywould be installed into engines. The manuacturers specifcation or fnalfnish is 0.63 . .3 m RA (5-45 ins CLA). As can be seen rom the ol-lowing table, none o these liners was anywhere near this in the condition inwhich we received them, Further more, all had profle characteristics whichwere very peaky. We photographed two sections rom each o liners ()& (6) and these photographs are shown below. They show quite clearly thathe surace o these cylinders contained a great deal o smeared, torn andolded metal. The fnish o all liners showed a very clearly defned crosshatch through out.

Every liner was then Flex-Honed with the grade indicated in the ollowingtable. The results in terms o surace fnish are also shown in this table. Thetype o Flex-Hone used was GB 4- 5/8. The sections were removed romliners () & (6) and re-photographed by the SEM.

The results shown by these photographs are very revealing indeed. It caneasily be seen that the surace o these cylinders shows very little evidenceo smeared, torn and olded metal. Flex- Honing has cleaned and opened upthe surace. The surace has been stress relieved and the profle changedrom peaky to an excellent plateau or a semi-plateau.

PLEASE LOOK VERY CAREFULLY AT THE FOLLOWING TABLE, SEMPHOTOGRAPHS AND PROFILES.

REPORT OF A TEST PROGRAMME CARRIED OUT BY NICRO (LEAMINGTON) LTD.,STROUD, GLOS., ENGLAND

ON THE SURFACE FINISH OF CYLINDER LINERS MANUFACTUREDBY TWO OF THE MOST IMPORTANT ENGINE MANUFACTURERS IN THE UK.


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Cylinders One and Six were photographed with a Scanning Electron Microscope and these ollow:

CONCLUSION:

There can be no doubt whatsoever that the Flex-Hone has changed the whole nature o the cylinder walls rom the as received condition. The Flex-Honed sur-aces are very largely ree rom smeared, torn, and olded metal. They are o a plateaued or semi - plateaued nature and absolutely within the manuacturersspecifcation. The surace will be sympathetic to piston rings. The as received fnishes would have been decidedly unsympathetic to piston rings.

TABLE SHOWING RESULTS OF TEST PART ONE

The beore and ater surace fnishes are shown hereunder:

(1)(1)

(2)

(2)

(3)

(3)

(4)

(4)

(5)

(5)

(6)

(6)

(7)

(7)

(8)

(8)

(9)

(9)

As ReceivedFlex- Honed

As Received

Flex- Honed

As Received

Flex- Honed

As Received

Flex- Honed

As Received

Flex- Honed

As Received

Flex- Honed

As Received

Flex- Honed

As Received

Flex- Honed

As Received

Flex- Honed

-----180 SC

-----

180 SC

-----

180 SC

-----

180 SC

-----

180 SC

-----

180 SC

-----

180 SC

-----

180 SC

-----

180 SC

-----45

-----

30

-----

30

-----

45

-----

45

-----

45

-----

45

-----

45

-----

45

1.25 - 1.50

0.75 - 0.95

1.10 - 1.50

0.60 - 0.80

1.30 - 1.75

0.70 - 0.95

1.25 - 2.00

0.70 - 1.00

1.10 - 1.60

0.70 - 0.95

1.00 - 1.50

0.80 - 1.00

1.10 - 1.40

0.70 - 0.80

1.20 - 2.25

0.70 - 1.00

1.10 - 1.60

0.70 - 0.80

49 - 59

30 - 37

43 - 59

24 - 31

51 - 69

28 - 37

49 - 79

28 - 39

43 - 63

28 - 37

39 - 59

31 - 39

43 - 55

28 - 31

47 - 89

28 - 39

43 - 63

28 - 31

Peaky Saw Tooth

Plateau

Peaky Saw Tooth

Semi - Plateau

Peaky Saw Tooth

Semi - Plateau

Peaky Saw Tooth

Semi - Plateau

Peaky Saw Tooth

Semi - Plateau

Peaky Saw Tooth

Semi - Plateau

Peaky Saw Tooth

Plateau

Peaky Saw Tooth

Plateau

Peaky Saw Tooth

Plateau

Cylinder Condition Grit & Type Honing Timein Seconds

Finish m RA Finish AA or CLA Profile Characteristics


16/26

Cylinder (). The above SEM photographs show the surace in the fnished honed, As Received condition. Note the degree o smeared, torn and oldedmetal. The intersection o the cross hatch clearly shows a highly stressed condition. The profle o this cylinder shows a peaky saw tooth fnish.

Cylinder (). The above photographs show the surace o this cylinder ater FLEX-HONING. Note that the surace is now largely ree o smeared, torn andolded metal. Especially note that the intersections o the cross hatching have been stress relieved. The surace has also been opened up in that the

graphite grains on or close to the surace have been revealed rather than smeared over. The profle o the surace shows quite clearly that FLEX-HONING hasprovided an excellent plateau.


17/26

Cylinder (6). The above SEM photographs show the surace in the rough honed, As Received condition. Note the high degree o smeared, torn and oldedmetal. Note also the high stress areas at the cross hatch intersections. The profle o the surace is peaky raw tooth.

Cylinder (6). The above SEM photographs show the surace ater FLEX-HONING. Note that the surace is now largely ree o smeared, torn, and olded metal

Slightly less so than Cylinder () ater FLEX-HONING. Cylinder (6) was FLEX-HONED with l 0 grit silicone carbide as opposed to 80 grit on Cylinder ().Again note that the surace has been opened up to expose the graphite grains. The profle ater FLEX-HONING shows a good semi-plateau.


18/26

BEFORE AND AFTER PROFILES OF CYLINDER LINERS , 3, 4, 5, 7, & 8 OF TEST PART ONE:


19/26

Please note the result o the Flex-Honing on the profles o the above cylinders. In every case, Flex-Honing has resulted in a plateau or semi-plateau

profle. Note also how consistent the surace fnishes are ater Flex-Honing.


20/26

TEST PART TWO:

We received just two liners rom this manuacturer o large diesel engines. Both were in the Rough honed condition. That is to say they had been honedor size but not or fnal fnish. The manuacturers fnal fnish specifcation is 0.63 - .00 Am RA (5-40 pH ins. CLA). We cut a section out o cylinder oneor the purpose o an SEM photograph. Both cylinders were checked or surace fnish and profle. As can be seen rom the ollowing table, the results werevery rough indeed and very peaky.

We Flex-Honed both cylinders in a two stage operation. We used a GBD 4-/ 0 grit silicon carbide Flex-Hone or one minute and ollowed with GBD4-/ 80 grit silicon carbide Flex- Hone or a urther minute. In so doing, we achieved an excellent surace fnish within the manuacturers specifcationswith a very good plateaued profle indeed.

A close look at the ollowing table and SEM photographs will show the results in detail. A look at the SEM photographs will reveal that there was an excesso torn, olded and smeared metal on the suraces o the cylinders in the as received condition. Compare the SEM photographs o the cylinders ater Flex-Honing with those in the as received state and you will see that the surace have been opened up, stress relieved and are largely ree o debris.

The Cylinder Liners in Part Two were supplied to us as Hardened & Tempered and rough honed to size.

The beore and ater surace fnishes are shown hereunder:

CONCLUSION:

There can be no doubt whatsoever that the results o Flex-Honing these liners are excellent. The fnish is according to the manuacturers specifcation, has an

excellent plateau profle and the photographs indicate that the surace has been opened up, stress relieved, and cleared very largely o any torn, olded andsmeared metal. The Flex-Hone has produced a clearly defned cross hatch and the fnish is very consistent right through the bores. In act, Flex-Honing hasprovided a fnish which would be very sympathetic to piston rings during the initial running-in period.

(1)

(1)

(2)

(2)

As Received

Flex- Honed

As Received

Flex- Honed

-----

120

180

-----

120

180

-----

60

60

-----

60

60

1.80 - 2.50 71 - 98 Peaky Saw Tooth

Cylinder Condition Grit & Type Honing Timein Seconds

Finish m RA Finish AA or CLA Profile Characteristics

0.80 - 1.10 31 - 43 Plateau

1.80 - 2.20

0.80- 1.00 Plateau

71 - 87

31 - 39

Peaky Saw Tooth


21/26

Cylinder (). The above SEM photographs show the surace in the As Received condition, i.e. Rough Honed to size by standard production rigid hones. Notethat the surace is o smeared, torn and olded metal and that the graphite grains are substantially smeared over. The profle o the surace, as is to beexpected at this stage o production, is very peaky saw tooth.

Cylinder (). The above SEM photographs show the surace ater FLEX-HONING. Note that most o the smeared, torn and olded metal has been removedand that the surace has been opened up to reveal the graphite grains on or close to the surace. The profle shows quite clearly how the FLEX-HONE has

refned the rough honed surace to an excellent Plateaued fnish.


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LAST MINUTE ADDITION:

As this booklet was being typeset we were fnishing up an evaluation study or Waukesha Engine Division o Dresser Industries, Inc. The results are so typicaland graphic that we decided to include them.

Upon receipt o the cylinders rom Waukesha we made Suranalyzer profles o all bores. We decided to use a GBD - 4 80 grit Flex-Hone with Flex-Hone Oil as a lubricant. We used a 500 RPM hand drill and stroked the Flex-Hone in the bore to produce a 5 to 30 cross-hatch angle. We cut o the top

o cylinders # and or SEM photos in the As Received condition. We Flex- Honed, or 30 seconds, the lower portion o # and and then cut a square piece out or SEM photos. Ater examining the SEM photographs and profles we decided to Flex-Hone the remaining 0 cylinders or 45 secondseach. Profles were then taken o all bores or fnal comparison. We eel you will agree with us that the Flex-Hone Process has improved both fnal conditiono the surace and the surace profle.

The As Received condition was typically a peaky saw truth profle. Ater being Flex-Honed the surace fnish was refned to a consistent plateaued or semi-plateaued profle. The SEM photographs show that the smeared, olded and torn metal have been removed leaving an open clean surace or rapid ringseating and the elimination o scufng problems.

Our decision to Flex-Hone the above cylinders or 5 additional seconds was based on the SEM photos o the frst two cylinders. The two cylinders Flex-Honed or 30 seconds still had traces o smeared metal on the surace, which we eel was removed with the additional 5 seconds.


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Documents

BRM - A Study of Cylinder Wall Micro Structure