Standard Flex-Hone Sizes & Grits
The standard Flex-Hone range is made from Silicon Carbide abrasive and comes in diameters ranging from very small 4mm to very large 475mm (18"). Aluminium Oxide abrasive is also generally available in Flex-Hones in a range of diameters to suit small tube up to 100mm for engine cylinders. The main abrasive grit sizes are 180 grit (medium) and 240 grit (medium fine). Specified grit sizes in Flex-Hones are not at all similar to grit sizes in other grinding media such as grinding wheels or abrasive cloth or paper. For instance a surface finished with a 180 grit Flex-Hone would produce very much finer surface patterns than a 180 grit sheet of cloth abrasive. Flex-Hone finish can also be varied by using different weights of lubricant during honing. For instance grease smeared in a cylinder bore before Flex-Honing will produce a finer cut than oil. Other grit sizes generally available in Flex-Hones are 120 grit (coarse), 320 grit (fine) and 400 grit (extra fine).
Factory Special Flex-Hones
Flex-Hones can be made to order for special applications. Possibilities include grit sizes from 20 grit to 800 grit and very large diameters up to 900mm (36"). Factory specials are also available in non standard abrasives such as Boron Carbide, Tungsten Carbide, Alumina Zirconia, Levigated Alumina, Diamond and CBN.
Selecting Correct Grit Size for a Flex-Hone
The grit size required for a particular job will be determined by a number of factors. These factors include such things as the type of material being honed, the type of engine rings or hydraulic seals used and the grade of lubricant used in service in the engine or machine. As explained above choice of cutting lubricant used during the honing process also affects finish and grit selection. If finish is critical, the only conclusive way to establish the best grit size for an application is by conducting tests on the actual job. Probably 99% of general applications produce a very satisfactory finish using either 180 grit or 240 grit coupled with variations of cutting lubricant. Coarser and finer grits can increase the cost of the tool substantially so they are generally reserved for special and critical applications.
How to Select the Correct Size Flex-Hone
The Flex-Hone tool is flexible and each size of tool can be used over a range of bore sizes. The nominal diameters shown in the table below give the maximum diameter that each tool will hone. A Flex-Hone will compress by up to 10% to suit a minimum bore size of 90% of its nominal diameter. It should be noted that a new Flex-Hone is approximately 10% larger than the nominal diameters shown to ensure spring tension on the bore and to compensate for wear.
200mm overall length
GB Series - Normal Duty
340mm overall length
GBD Series - Heavy Duty
Overall length to suit size
GBD Large Cored Series
Separate long hex shaft
Rejuvenate Large Engines
Recondition Large Machinery
Finish Hydraulic Cylinders
How does Flex-Hone offer these gains?
Comparison - Rigid Hones or Cutting Tools
Descale Heat Exchangers & Boilers
Diagram #1 Microscopic schematic & roughness readout
Microscopic schematic & roughness readout
< ------------------ From 480mm Large to 4mm Miniature ------------------ >
and up to 900mm special orders
Gun Cleaning Flex-Hones
Honing with Flexhone (ball hone) - Australian importer of cylinder hone tools for honing cylinders - deburring - boiler cleaning & heat exchanger cleaning . Used in hydraulics & engines - diesel, petrol & large marine engines down to small 4mm valve guide & tube sizes. Flex-Hones give you increased service life in many types of equipment - hydraulic and engine cylinders show dramatically decreased wear on mating parts and seals after Flex-Hone finishing. Boiler heat exchanger tubes stay clean & descaled much longer if cleaned with Flex-Hone. This is because Flex-Hone removes "plateaus" i.e. flattens and smooths the tops of the minute sharp hills which are invariably left by any other machining or ordinary fixed stone honing. Flex-Hone is a great remedy for oil burning and hydraulic fluid leakage. So whether you need to remove scale in boiler heat exchanger tubes or repair everyday engine and hydraulic cylinders, a Flex-Hone treatment is the superior way to finish your work.
How to Deburr Quicker & Better
INDEX to Flex-Hone Information
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Flex-Hones are low RPM tools. The RPM you will use depends mainly on the diameter of the Flex-Hone and also on what your application is. The table [left] is only a guide. You will need to work out what suites your requirements by experiment.
The number of times you plunge in and out per second or "stroke rate" is only important if you need to create a cross hatch pattern. As a guide with Flex-Hones 125mm diameter or less start at 1 stroke per second then speed up or slow down the rate to get your selected cross hatch angle. The video [link below] demonstrates general use including stroke rates etc.
You will need to assess grit selection by considering the time budgeted to do your job and the degree of surface finish improvement you want. If your starting surface has a coarse finish you may need to use a range of Flex-Hones with progressively finer grits before you get to the finish you require. The chart [at right] is only intended to offer a starting point in selecting grits. Because type of material and original finish can differ widely from job to job, the only real way to determine what works for you on a particular job is by actual trial and measurement.
3a Small - 6.4mm; 7mm; 8mm; 9mm; 10mm; 11mm; 12mm; 1/2”; 5/8”; 3/4”; 7/8”; 1”;
3a Small (Extended) - 6.4mm; 7mm; 8mm; 9mm; 10mm; 11mm; 12mm; 1/2”; 5/8”; 3/4”; 7/8”; 1”; 1-1/4"; 1-1/2" & 1-3/4"
3b General Range - 2”; 2-1/8”; 2-1/4”; 2-1/2”; 2-3/4” & 3”
3c Medium - 3-1/4”; 3-1/2”; 3-3/4”; 4-1/8”
3d Large - 4-1/2”; 5”; 5-1/2”; 6”; 6-1/2” & 7”
4a Small & 2 Stroke - 2-1/8”; 2-1/4”; 2-1/2”; 2-3/4”; 3”; 3-1/4” & 3-1/2”
4b Domestic Mower - 2-1/8”; 2-1/4”; 2-1/2”; 2-3/4” & 3”
4c Cars & Light Truck - 3-1/4”; 3-3/4”; 4-1/8” & 4-5/8”
4d Large & Diesel - 4-1/2”; 5"; 5-1/2”; 6”; 6-1/2”; 7”
4m Motorcycle - 2-1/8”; 2-1/4”; 2-3/8”; 2-1/2”; 2-5/8”; 2-3/4”; 2-7/8”; 3-1/4” & 3-1/2”
Valve Guide & Small Hole Kits
2V - 6.4mm; 7mm; 8mm; 9mm; 10mm; 11mm; 12mm; 1/2”
Brake Cylinder & Small Engine Kits
2a Small - 18mm; 20mm; 7/8”; 1” & 1-1/8”
2b Extended - 1-1/2”; 1-5/8”; 1-3/4”; 1-7/8” ; 2”; 2-1/8”; 2-1/4”; 2-1/2”; 2-3/4” & 3”
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