Characterization and life prediction of single-pass honing tool for fuel injection nozzle

Single-pass honing is an important machining method for finish machining of holes,which can meet the requirement for high efficiency and consistency of holes.Characterization and life prediction of single-pass honing tool are necessary to improve the machining accuracy of holes honed,especially dimension accuracy.Single-pass honing tool is a single layer abrasive tool with fixed dimension,which still remains problematic for characterization and life prediction.For fuel injection nozzles with bore diameter under 1 mm,the stiffness of the single-pass honing tool is poor.This article presents a novel analytical model that predicts life of the tool with poor stiffness.Firstly,according to the bore diameter and dimension tolerance,the single-pass honing tool is designed and manufactured.Based on the prepared single-pass honing tool,the measurement and characterization methods are established.Furthermore,the tool wear tests are carried out,and the tool contour evolution model is established to predict the tool life.