Brush Research Manufacturing: Ordering Information

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Tool diameter is determined by the nominal bore size in which the tool is to operate. The Flex-Hone tool is always produced and used in an oversize condition. The degree of oversize creates a soft cutting action. For example, a 1" Flex-Hone size is ordered if a 1" bore is to be finished and the tool is provided oversized. If the bore size is between standard Flex-Hone sizes, the next larger standard Flex-Hone should be selected.

Abrasive selection is largely dependent on the base material being finished and whether the application is for surface finishing or deburring. Silicon carbide is by far the most popular abrasive type. It is used to finish mild steel, stainless steel and cast iron. Aluminum Oxide is the next most popular abrasive and it is used to finish non ferrous materials like aluminum, brass, bronze and softer metals. Zirconia Alumina (Z-Grain) has very similar cutting properties to silicon carbide and can generally offer longer tool life. It is available in two grades: #1525 (25% Zirconia, 75% Alumina) and #1549 (40% Zirconia and 60% alumina). It is used to finish low carbon to medium carbon steels, stainless steel and cast iron. Boron Carbide is used to finish medium to high carbon steels and heat-treated steels to 50 Rc. It is also useful in titanium, Inconel and Monel. Tungsten Carbide is used for the high carbon steel alloys and more exotic space age alloys. Levigated Alumina is a super fine abrasive used for a final polish on many materials. This abrasive should be used where Ra requirements are very low. CBN and Diamond are experimental and are not commercially available at this time.

The amount of work to be performed and the degree of surface finish improvement required govern grit selection. Coarse finishes may require progressively finer Flex-Hones to meet final surface finish requirements. In very general terms, final finish will be in the following ranges. This chart is intended to offer a starting point in selecting a grit but the final selection must be verified by actual trial.

Grit	Finish Range
800-LA	Ra 3-10 (.05 - .2 Micrometer)
600	Ra 8-12 (.2 - .3 Micrometer)
400	Ra 10-20 (.3 - .6 Micrometer)
320	Ra 18-30 (.5 - .7 Micrometer)
240	Ra 24-32 (.6 - .8 Micrometer)
180	Ra 30-40 (.7 - . 1 Micrometer)
120	Ra 35-50 (.9 -1.4 Micrometer)
80	Ra 45-64 (1.2 - 1.6 Micrometer)
60	Ra 60-80 (1.5 - 2 Micrometer)
40	Ra 70-125 (1.7 to 3.2 Micrometers)
20	Ra 125-250 (3.2 to 6.3 Micrometers)

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