Specifications

TABLE 5-1, Operational Troubleshooting Index (cont’d)

PROBLEM PROBABLE CAUSE SOLUTIONS SEC. SCREEN

Taper in Open 1. Improper overstroke A. Lengthen overstroke on 3 Run / Diagnostic

Hole tight end

2. Workpiece and Spindle A. Align Workpiece and 3 Run / Diagnostic

not aligned Spindle

3. Part/tool geometry A. Readjust stroke position 3

Taper in Blind 1. Improper stroke length A. Increase stroke length 3

Hole 2. Inadequate relief in blind end A. Provide sufficient relief

B. Short stroke tight end 3 Run / Diagnostic

C. Replace tool 2 Setup

3. Inadequate oil flow A. Adjust Oil Nozzle

Out-Of-Round 1. Undersize honing tool A. Replace tool 2 Setup

2. Workpiece flexing (thinwall) A. Decrease feed rate 3 Run / Diagnostic

B. Change method of fixturing 2

C. Decrease spindle speed 3 Run / Diagnostic

D. Reduce stock removal

3. Improper tool A. Replace tool 2 Setup

4. Excessive float in tool(s) A. Decrease tool float 2 Setup

5. Fixture not properly Aligned A. Adjust Fixture 2 Setup

Waviness 1. Improper tool length A. Use tool with sufficient 2 Setup

stone length to bridge

waviness in bore

Rainbow 1. Improper tool length A. Replace tool 2 Setup

(tool length should be

1-1/2 times bore length)

2. Improper overstroke A. Shorten overstroke 3 Run / Diagnostic

3. Improper tool A. Replace tool 2 Setup

Rough Finish 1. Improper feed rate A. Decrease feed rate 3 Run / Diagnostic

2. Improper tool A. Replace tool 2 Setup

3. Material loading tool A. Inspect & clean

4. Improper or diluted coolant* A. Check coolant* 4

Scratches in Bore 1. Improper feed rate A. Decrease feed rate 3 Run / Diagnostic

(Random) 2. Improper tool A. Replace tool 2 Setup

3. Improper or diluted coolant* A. Check coolant* 4

*NOTE: Many honing problems, such as poor tool life and rough finish, are caused by the following: the wrong

coolant, insufficient coolant, dirty coolant, or contaminated coolant. Use ONLY clean, full-strength Sunnen

Industrial Honing Oils or Water-Based Coolants. DO NOT dilute or “cut” the oil or coolant in your Machine with

other oils or coolants. Keep solvents and cleaning fluids away from your Machine.