Analysis of Honing Material Removal Rate and Surface Quality Using Electroplated Oilstone

The manufacturing precision of electro-hydraulic servo valve sleeves is critical to the performance and longevity of the valves. To ensure the service life of these valves, the valve sleeve is typically made from high-hardness martensitic stainless steel, which is considered a hard-to-cut material. Current honing methods often suffer from inefficiency and instability. This study compares the honing processes using electroplated and sintered oilstones, emphasizing processing efficiency and surface quality. Initially, the morphology of the oilstones was examined. Equivalent honing depth and material removal rate per unit width were developed to characterized material removal. The influence of various parameters on honing depth and material removal rates was explored, along with the surface morphology and roughness after honing. The results indicated that electroplated oilstones achieved a material removal rate 2.5 times higher than sintered oilstones. In contrast, sintered oilstones produced superior surface quality. To optimize both surface quality and efficiency, we proposed a sequential honing method: using electroplated oilstones for significant material removal followed by sintered oilstones for surface finishing, which enhanced efficiency by 1.6 times. Electroplated oilstone has broad application prospects in the field of precision and efficient machining of hydraulic components.