Machining Performance Research Articles

Powder mixed micro-electric discharge milling of Ni-rich NiTi SMA: an investigation on machining performance and biocompatibility

ABSTRACT Nickel and titanium (NiTi) based shape memory alloys (SMAs) are novel materials endowed with exceptional super-elasticity, corrosion resistance, and shape memory capabilities, making them well-suited for biomedical and industrial applications. The current study explores the impact of process parameters in powder mixed micro-electrical discharge milling (µ-EDM) on NiTi SMA, focusing on pulse on time (TON), voltage, pulse off time (TOFF), and RPM individually, employing a one factor at a time (OFAT) methodology to analyze surface characteristics, surface roughness (Ra), and material removal rate (MRR). The impact of black phosphorus powder combined with sesame oil (dielectric) on the surface of fabricated channels in commonly used biomaterials was investigated. The cytotoxicity test for biocompatibility was carried out to enhance the cell viability up to 79.89% after machining, which showed enhanced cell viability. The highest MRR the lowest Ra were obtained at the best input factors combination of 24 µs (TON), 6 µs (TOFF), 240 V, and 50 RPM tool rotation. Improved micro-channel quality was observed with lower TON, voltage, and RPM.

Pre-Compensation Strategy for Tracking Error and Contour Error by Using Friction and Cross-Coupled Control

This paper focuses on improving the tracking accuracy for servo systems and increasing the contouring performance of precision machining. The dynamic friction during precision machining is analyzed using the LuGre model. The dynamic and static parameters in the friction model are efficiently and accurately identified using the improved Drosophila swarm algorithm based on cross-mutation. The friction tracking error can be deduced from the friction state space and an expression is derived. To compensate for the tracking error caused by friction, a feedforward compensation control is designed to avoid signal lag in traditional friction controllers. Furthermore, the factors of multi-axis parameter mismatching that impact the machining profile accuracy are analyzed for multi-axis control. An adaptive cross-coupled control-based pre-compensation strategy of contour error is designed to reduce both the tracking error and the contour error. The effectiveness of the proposed method is validated through several experiments, which demonstrate a remarkable improvement in tracking performance and contour accuracy.

Exploring Electrochemical Direct Writing Machining of Patterned Microstructures on Zr702 with Polyacrylamide Polymer Electrolyte.

Zirconium alloys possess excellent wear resistance, which ensures the durability and longevity of the components, making them widely used in medical and other fields. To enhance the functionality of these materials, it is often necessary to fabricate functional microstructures on their surfaces. Electrochemical machining (ECM) techniques demonstrate excellent machining performance for these metals, particularly in the processing of microstructures on complex curved surfaces. However, ECM often faces challenges due to the fluid nature of the electrolyte, resulting in low machining accuracy and localization. This paper proposes a novel method for fabricating complex patterned microstructures using a maskless electrochemical direct writing technique with a polyacrylamide (PAM) polymer electrolyte. By leveraging the non-Newtonian properties of PAM, this method effectively confines the electrolyte to specific areas, thus addressing the issue of poor localization in traditional ECM and reducing stray corrosion. To elucidate the electrochemical removal mechanism of Zr702 in the presence of PAM, polarization curves, viscosity characteristics, and current efficiency parameters were analyzed. Additionally, an experimental study was conducted using a custom-designed nozzle structure. The results showed that the PAM electrolyte could effectively reduce the EF, positively impacting machining accuracy and localization. By controlling the nozzle's motion trajectory, complex microstructures were successfully fabricated through direct writing, demonstrating promising application prospects.

FABRICATION AND CHARACTERIZATION OF AA6082-T6 PRODUCED BY FRICTION STIR ADDITIVE MANUFACTURING

The machinability of aluminum alloy (Al-6082) has the scope of enhancement by integrating Friction Stir Processing (FSP) with tool geometry, tool shape and different tool materials. In this research, the role of tool pin shape has been studied by experimenting on various tool shapes (square, hexagonal and octagonal) with the aim of machinability improvement. In FSP, the tool rotation speed is 930[Formula: see text]rpm and tool travel speed is 26[Formula: see text]mm/min. The specimens have undergone tensile, microhardness and microstructure testing using optical microscope and scanning electron microscopy. The percentage elongation has been increased from 15% to 29% in the case of the octagonal-shaped tool pin; similarly, the (Vickers’) microhardness value is 14.6% higher than the square- and hexagonal-shaped tool pins. Among these tool pin shapes, the octagonal-shaped tool pin succeeded in providing the best-in-class machinability performance on Al-6082 T6 alloy with FSP. It may unveil the newer scopes of FSP on Al-6082 for automotive components assembly and other similar applications.

Role of spark energy and frequency on wire-EDM performances of Al-2Mg alloy and Al-2Mg/20 Al3Fe composite: a comparative study

ABSTRACT The performance of wire-electric discharge machining (WEDM) method is inevitably affected by the electric spark. A comparative study is presented related to the influences of spark energy (SE, 1.68–8.40 mJ) and spark frequency (SF, 12.82–15.15 kHz) on machining responses of Al-2Mg/20 vol.% in-situ Al3Fe composite with respect to Al-2Mg alloy. Such comparison is scanty in the literature. Machining performances were measured concerning material removal rate (MRR), cutting speed (CS), and surface roughness (SR) apart from the morphological evolution of machined surfaces. Irrespective of machining condition (for instance, at SE of 5.04 mJ), composite exhibited lower CS (1.27 mm/min), MRR (4.20 mm3/min), and SR (4.42 µm) due to the insulating effect of reinforcement than alloy (i.e. 1.70 mm/min, 5.81 mm3/min, and 4.82 µm, respectively). For both alloy and composite, all three machining performances increased linearly with rising the SE and SF, although the influence of SE was more pronounced over SF. With increasing SE, the difference in the magnitudes of CS and MRR between alloy and composite widened, while the same for SR narrowed. Formations of micro-cracks, lumps of debris, craters, and re-solidified layers were observed more on alloy machining surface than composite; these features enlarged with increasing SE and SF.

Investigating micro-EDM machinability of Ti-35Nb-7Zr-5Ta (TNZT) alloy

ABSTRACT Titanium and its new-generation alloys are widely employed in high-end applications due to their special properties. Modern industries frequently use micro – Electro Discharge Machining (μ-EDM), a non-conventional machining technique that is especially useful for processing hard to machine materials like titanium alloys. μ-EDM can produce intricate shapes with excellent dimensional precision. The main emphasis of this work is an experimental analysis of the μ-EDM of TNZT alloy (Ti-35Nb-7Zr-5Ta) employing a tungsten carbide (WC) electrode. The results showed that with the increase in capacitance (C) 10nF to 100nF at Voltage (V) 80 V, the machining performance parameters such as material removal rate (MRR), overcut (OC), crater area, surface microhardness, and surface roughness increase by 6.38, 1.52, 4.66, 1.07, and 3.29 times, respectively. However, the circularity error of the µ-hole increases by 1.81 times. This study intends to show how the two key machining factors (C & V) influence significant machining performance parameters.

Development of a Fast Positioning Platform with a Large Stroke Based on a Piezoelectric Actuator for Precision Machining.

In this paper, a fast positioning platform (FPP) is proposed, able to meet simultaneously the requirements of large stroke and high frequency response, developed based on a PZT (piezoelectric actuator) and a quad-parallel flexible mechanism, for application in precision machining. The FPP is driven by a high-stiffness PZT and guided by a flexible hinge-based mechanism with a quad-parallel flexible hinge. The proposed quad-parallel flexible hinge mechanism can provide excellent planar motion capability with high stiffness and good guiding performance, thus guaranteeing outstanding dynamics characteristics. The mechanical model was established, the input and output characteristics of the FPP were analyzed, and the working range (output displacement and frequency) of the FPP was determined. Based on the mechanical model and the input and output characteristics of the FPP, the design method is described for of the proposed FPP, which is capable of achieving a large stroke while responding at a high frequency. The characteristics of the FPP were investigated using finite element analysis (FEA). Experiments were conducted to examine the performance of the FPP; the natural frequency of the FPP was 1315.6 Hz, while the maximum output displacement and the motion resolution of the FPP in a static state were 53.13 μm and 5 nm, respectively. Step response testing showed that under a step magnitude of 50 μm, the stabilization times for the falling and rising edges of the moving platform were 37 ms and 26 ms, respectively. The tracking errors were about ±1.96 μm and ±0.59 μm when the amplitude and frequency of the signal were 50 μm, 50 Hz and 10 μm, 200 Hz, respectively. The FPP showed excellent performance in terms of fast response and output displacement. The cutting test results indicated that compared with the uncontrolled condition, the values of surface roughness under controlled conditions decreased by 23.9% and 12.7% when the cutting depths were 5 μm and 10 μm, respectively. The developed FPP device has excellent precision machining performance.

Machining and Sustainability Performance Comparison for the Milling Process of Al6082 Alloy Under Various Minimum Quantity Lubrication Conditions

Machining and Sustainability Performance Comparison for the Milling Process of Al6082 Alloy Under Various Minimum Quantity Lubrication Conditions

Proposal of trapezoidal vibration-assisted diamond cutting for ductile-regime machining of brittle crystals: A case study on KDP crystal

Despite various vibration-assisted cutting techniques have been utilized to increase the machining performances of brittle materials, the highly dynamic variations of cutting process quantities lead to the complicated brittle-ductile transition (BDT) mechanism and the formation of undesired vibration marks on the machined surfaces. In this paper, a novel ultra-precision vibration-assisted cutting process, named trapezoidal modulation diamond cutting (TMDC), is firstly proposed for ductile-regime machining of brittle materials with significantly increased BDT cutting depth. By imposing a dedicate trapezoidal locus to the diamond tool, the unique invariable uncut chip thickness and cutting states were achieved for realizing stable vibration-assisted cutting without the formations of vibration marks. Systematic cutting experiments of KDP crystals were carried out to comprehensively investigate the influences of different process parameters on the machining performances of TMDC process. In addition, the underlying mechanisms of machining performance improvements have been discussed under the different combinations of process parameters, based on which the guidelines for optimal process parameter selection are given for increasing the BDT cutting depths. The outcomes of this study contribute to not only improving the ductile machining efficiency and machining quality of KDP crystals, but also help to deepen the understandings of BDT mechanism during vibration-assisted diamond cutting of common brittle materials.

Parametric Investigation of Die-Sinking EDM of Ti6Al4V Using the Hybrid Taguchi-RAMS-RATMI Method

Ti6Al4V is a widely used alloy due to its excellent mechanical qualities and resistance to corrosion, which make it fit for automotive, aerospace, defense, and biomedical sectors. Due to its high strength and limited heat conductivity, it is difficult to machine. Both the workpiece’s and the electrode’s conductivity are important factors that impact the electro-discharge machining (EDM) process. In this case, the machining efficiency is also influenced by the electrode selection. As a result, choosing the right electrode and machining parameters is essential to improving EDM performance on the Ti6Al4V alloy. Research on EDM for Ti6Al4V is limited, with little focus on electrode material selection and shape. The impact of EDM settings on MRR, TWR, and surface roughness is complex, and a comprehensive optimization strategy is needed. Copper electrodes are widely used, but further investigation is needed on EDM’s effects on Ti6Al4V’s surface properties and surface integrity. Addressing these research gaps will improve the understanding and application of EDM for Ti6Al4V, focusing on parameter optimization, surface integrity, and thermal and mechanical effects. By employing copper tools to optimize four crucial EDM process parameters—peak current, duty cycle, discharge current, and pulse-on time—this research aims to increase surface integrity and machining performance. A comprehensive Taguchi experimental design is used to systematically alter the EDM settings. By optimizing parameters using tolerance intervals and response modelling, the recently developed RAMS-RATMI approach improves the dependability of the EDM process and increases machining efficiency. With the optimized EDM settings, there were notable gains in depth of cut enhancement, surface roughness minimization, tool wear rate (TWR) reduction, and material removal rate (MRR). The results of the surface integrity examination showed fewer heat-affected zones, fewer microcracks, and a thinner recast layer. Analysis of variance was used to verify the impact and resilience of the optimized parameters. Superior machining performance, higher surface quality, and increased operational dependability were attained with the Ti6Al4V-optimized EDM process, providing industry practitioners with insightful information and useful recommendations.

Electro discharge machining performance of cryogenic heat treated copper electrode

Abstract In this study, the EDM machining performance of a cryogenic heat treated copper electrode was investigated. Within the scope of the study, electrodes selected from copper material were subjected to cryogenic heat treatment with a cycle between [room temperature/ − 184 °C/room temperature]. In the experimental design, the electrode material was changed at two levels: copper electrode (Cu) and cryogenic copper electrode (CCu). Controllable machine parameters, peak current (Ip), active pulse duration (Ton), pulse gap duration (Toff) and gap voltage (Vg) were changed at three levels. The effects of these parameters on outputs such as recast layer thickness (RLT), material removal rate (MRR), electrode wear rate (EWR) and taper angle (TA), which are taken into consideration in determining the processing quality after EDM machining experiments, were taken into account. A total of 18 experiments were carried out on Ti–6Al–4V (Titanium alloy) workpiece with copper electrode. Lower YKTK with combinations of EDM process parameters such as cryogenic copper electrode (CCu), 4 A peak current (Ip), 110 µs active pulse duration (Ton), 72 µs pulse gap time (Toff) and 6 V gap voltage (Vg), It was observed that EWR and TA and higher MRR were obtained.

Process Parameter Effects on Powder Mixed EDM Machining Characteristics Using Biocompatible Ti-6Al-4V Alloy

This study examines how various process parameters affect the machining properties of a bio-compatible Ti-6Al-4V alloy using PMEDM with silicon carbide (SiC) powder. The parameters investigated include peak current, pulse on/off time, powder concentration, and voltage gap. The study analyzed their effects on material removal rate (MRR), tool wear rate (TWR), surface roughness (SR), and surface morphology. A central composite design was used in the tests to make empirical models that use response surface methods to link the process parameters to the machining results. It is found that the Pulse current and Ton influence the material removal rate and the surface roughness significantly. The powder concentration also impacts PMEDM's machining performance. The Scanning electron microscopic images reveal the effect of powder seen in the machined components. The crater, micro cracks and machining marks can be seen in the SEM images. The surface integrity is correlated with the output parameters of surface roughness. The developed mathematical models effectively predict and optimize the machining properties of Ti-6Al-4V alloy using PMEDM with SiC powder. This research offers valuable insights for applying PMEDM in the fabrication of biomedical implants and devices made from Ti-6Al-4V alloy.

Bubble behavior of single-pulse discharge in EDM

The removal of machining debris in the narrow discharge gap primarily relies on high pressure bubble expansion and fluid agitation induced by the bubble pulsation in electrical discharge machining (EDM). Observing bubble behavior and elucidating the mechanism of bubble behavior is an increasing concern in EDM. The purpose of this study is to investigate the bubble behavior of single pulse discharge in EDM. Using a high-speed camera, this study observed the bubble evolution and measured the discharge duration dependent bubble characteristics. The results show that the bubble experiences rapid expansion, contraction, primary pulsation, intense pulsation in the post-discharge process, and subsequent bubble energy dissipation behavior. Furthermore, the arc plasma persists for a duration even after the discharge ends in positive polarity machining. The findings suggest that bubble behavior in single-pulse discharges is primarily dominated by the discharge energy, with the bubble behavior during the discharge significantly influenced by the jumping and oscillation of the arc plasma. Our research may introduce new ideas for improving the depth-to-diameter ratio of deep micro-holes in EDM and provide fresh perspectives on the mechanism analysis of how machining parameters affect machining performance. For instance, by synchronizing the pulse intervals with the bubble stabilization time, bubble coalescence can be reduced, thus increasing bubble removal in the small machining gap. The stability of deep micro-hole EDM may depend on bubble behavior, which is determined by the electrical parameters.

An Investigation of the Effect of Novel Mono/Bi-Layered PVD-Coated WC Tools on the Machinability of Ti-5Al-5V-5Mo-3Cr.

The Ti-5Al-5V-5Mo-3Cr (Ti-5553) alloy is a relatively novel difficult-to-cut material with limited machinability and tool life analysis available in the literature, and hence requires further investigation. This study focuses on the machining and tribological performance of Ti-5553 under high-speed finish turning (150 m/min, 175 m/min, and 200 m/min) via novel mono/bi-layered PVD-coated WC tools. A base AlTiN coating is used as the reference monolayer coating, with AlCrN, diamond-like ta-C, and TiAlSiN coatings each deposited on top of a base AlTiN coating, totaling four separate coated tools (one monolayer and three bi-layer). Tool life, cutting forces, workpiece surface quality, and tribological chip analysis are among the subjects of investigation in this study. Overall, the AlTiN/AlCrN coated tool outperformed all the other combinations: an improvement of ~19% in terms of tool life in reference to the base AlTiN coating when averaging across the three speeds; lowest surface roughness values: ~0.30, 0.33, and 0.64 µm; as well as the lowest chip back surface roughness values: ~0.80, 0.68, and 0.81 µm at 150, 175, and 200 m/min, respectively. These results indicate that the AlTiN/AlCrN coating is an excellent candidate for industrial applications involving high-speed machining of Ti-5553.

Improving the performance of cutting fluids by using ZnO and ZrO2 nanoparticles

Sustainability is nowadays a global research priority, especially in machining, where optimizing production processes for increased productivity, profits, and efficiency is key. Addressing this need, the adoption of nanofluids in minimum quantity lubrication machining has surged, aligning with environmental concerns and regulatory demands. In this study, sustainable zinc oxide (ZnO) and zirconium dioxide (ZrO2) nanoparticles fabricated using plant extracts have been incorporated into conventional cutting fluids to enhance their machinability performance under minimum quantity lubrication for turning process. The microstructural analysis confirms the successful synthesis of the targeted nanoparticles with excellent purity and size distribution. The addition of nanoparticles significantly enhanced thermal conductivity from 0.5916 W/(m⋅K) for the base fluid to 0.6286 W/(m⋅K) for ZnO and to 0.6242 W/(m⋅K) for ZrO2. Further, nanofluids exhibited an increased dynamic viscosity, 1.435 mPa.s for ZrO2 and 1.125 mPa.s for ZnO as compare to 0.7644 mPa.s of base fluid, attributed to the nanoparticle confinement effect whereas contact angle measurements indicated an improved wettability for all nanofluids. Machining experiments validate the efficacy of nanofluids, demonstrating reduced cutting temperatures and enhanced surface finish. Notably, ZrO2-based nanofluids exhibit improved tribological response, while ZnO-based nanofluids showcase exceptional heat transfer ability, offering promising solutions to key technical challenges in machining processes. In conclusion, this study underscores the potential of green, sustainable ZnO and ZrO2 nanoparticles as additives in cutting fluids, poised to revolutionize metalworking and manufacturing processes, thereby enhancing product quality and sustainability.

Highly wear resistant metal bond for diamond tool based on two-step reactive sintered Fe3Al

Metal bond diamond tools are regularly used in the machining of various hard and brittle materials. The mechanical properties and wear resistance of the metal bond are very important for the tool's life and machining performance. Herein, a low-cost and highly wear resistant Fe3Al bonded material for diamond tool was proposed. A novel two-step reactive sintering method, integrating short-term high-temperature reactive sintering and long-term low-temperature densification sintering, was proposed to prepare Fe3Al bond diamond tools. The effect of sintering temperature on the microstructure and mechanical properties of the Fe3Al bond was examined during one-step reactive sintering. The mechanical properties and tribological characteristics of the one-step and two-step reactive sintered Fe3Al and commercial Fe alloy bond were compared. The machining performance of the two-step reactive sintered Fe3Al bond diamond tool on sapphire was also examined and compared to that of a commercial Fe alloy bond diamond tool. The results showed that the relative density and mechanical properties of the Fe3Al bonded material were enhanced by increasing the sintering temperature during one-step reactive sintering. Moreover, the sample sintered at 1150-850 °C exhibited better mechanical properties and wear resistance compared to the one-step reactive sintered Fe3Al and commercial bond. The grinding ratio of the two-step reactive sintered Fe3Al bond diamond tool was 157 % higher than that of the commercial Fe alloy bond diamond tool.

Study on the wear characteristics of a 3D printed tool in flat lapping of Al2O3 ceramic materials

Widespread and popular use of ceramic products in various industry sectors necessitates the search for methods of their efficient processing. Lapping technology, which enables obtaining high dimensional and shape accuracy and high surface flatness, is one of the basic methods of finishing hard and brittle technical ceramics with a porous structure. This study analyzed the characteristics and wear value of an SLS-printed abrasive tool intended for single-sided lapping of Al2O3 technical ceramics. As earlier research demonstrated, introduction of a 3D printed lapping plate by selective laser sintering (SLS), leads to a significant development in the field of precision machining technology. This method showed not only efficient machining performance on oxide technical materials, but was also characterized by relatively low abrasive wear. Straightness errors were evaluated with the use of a least-squares method (LSQ) and minimum zone method based on control line rotation scheme (CLRS). The proposed model proved the experimental results by identifying a similar location of a higher contact density on the lapping tool, where this location is expected to be the one for bigger wear. Surface topography of the lapping tool depends on the tool wear intensity and as a consequence on its shape error. An SLS-printed lapping plate, by obtaining good technological effects, revealed its potential ability in machining hard and brittle technical ceramics.

Nozzle Wear in Abrasive Water Jet Based on Numerical Simulation.

Particle diameters and jet pressure in abrasive water jet (AWJ) are significant jet properties which deserve a better understanding for improving AWJ machining performance. Some influence factors have been verified regarding nozzle wear in abrasive water jet polishing application. A three-dimensional model of a nozzle is established to analyze the influence of internal multi-phase flow field distribution, which is based on Euler-Lagrange methodology. With the increase of jet pressure, the erosion rate decreases; with the increase of the diameter and mass flow rate of the erosion particles, the erosion speed increases as well. When the diameter of the outlet is worn to 1.6 mm, the pressure on the work piece caused by the abrasive water jet increases by more than double compared to the non-worn nozzle; when the diameter of the nozzle outlet is worn to 1.6 mm, the shear force is 2.5 times higher than the shear force when the diameter is 1.0, which means that the jet force is divergent when the diameter is 1.6 mm, and the damage of the work piece is very serious. The obtained results could improve polishing efficiency on the work piece, extend nozzle lifetimes, and guide the future design of AWJ nozzles.

Experimental investigations and sustainability analysis on the performance of vegetable oil-based MQL drilling of SS316L

ABSTRACT Recently, efforts have been made to reduce the use of conventional cutting fluids. Minimum Quantity Lubrication (MQL) has become a favourable approach to enhance machining performance and sustainability. This study investigated the impact of various cutting conditions on the drilling performance of SS316L, considering surface roughness, tool wear, and chip forms. The drilling tests are performed under dry, flood, and vegetable oil-based MQL (VMQL) conditions. The drilling under the VMQL condition resulted in a desirable surface finish, as indicated by a lower Ra value of 1.81 µm for 20 holes drilled compared to the other conditions. The results highlighted the efficacy of VMQL in reducing tool wear during drilling. Furthermore, the analysis of chip quality demonstrated that VMQL produced favourable chip forms compared to flood cooling and dry machining. The enhanced lubricating and cooling mechanism enabled the creation of desired chip forms under VMQL. In summary, the study clarified the specific benefits of different machining conditions, highlighting the crucial importance of lubrication in achieving desired surface finish, chip quality, and tool wear in various machining environments. The sustainability assessment is conducted using the Pugh matrix approach, and the superiority of VMQL over other drilling conditions is found.

Дослідження впливу параметрів процесу хонінгування силікатними брусками на якість обробленої поверхні

Numerous studies have shown that the kinematics of the honing process, which determines the trajectory of the cutting grain during machining, has a major impact on the parameters of macro- and microrelief. The complex working movement during honing of holes creates favourable conditions for the fuller use of the cutting capacity of the bars and uniform wear of the tool, which positively affects the machining performance and accuracy of the geometric shape of the surface. It is shown that, in this regard, there is a need to investigate the influence of the parameters of the honing process with silicate bars on the quality of the machined surface. The paper presents the results of a study of the effect of the contact pressure of the bars and the axial and circumferential speeds on the quality of the treated surface. The study was performed on a vertical single-spindle honing machine. The samples used were cylinder liners of car engines made of grey alloy cast iron. The evaluation was based on the roughness of the machined surface and the mass removal of metal during machining. The best performance was achieved by those bars that resulted in the lowest roughness of the samples. It was found that with an increase in the circumferential speed, the surface quality improves, and with an increase in the axial speed, it deteriorates after processing with diamond, abrasive and silicate stones. With an increase in the contact pressure of the bars, the surface quality deteriorates after machining with diamond bars and improves after machining with abrasive and silicate bars. It has been proven that the high surface quality after treatment with silicate blocks is due to the formation of amorphous silica during honing, which, under the influence of abrasive grains, falls into the cavities of the treated surface and adheres to the surface, thus saturating the treated surface with silicon oxide. It has been established that with an increase in the axial speed of the bars, metal removal increases, and with an increase in the circumferential speed, it decreases after machining with diamond, abrasive and silicate bars. With an increase in the contact pressure of the stones, metal removal increases after machining with diamond stones and gradually decreases after honing with abrasive and silicate stones. It was found that the metal removal after machining with silicate stones is 2 times less than after honing with diamond stones. It is proposed to set the allowance for finishing honing with silicate stones for cylinder liners made of alloy cast iron (HB 240) within 0.01-0.02 mm.