Problems on this page:
Bore size out of tolerance
Hits OEE: Quality
Symptoms: Honed bores measure oversize or undersize.
Size control gauge not calibrated
Calibrate the in-process or post-process gauge with a master ring.
Stone wear not compensated
Check the feed compensation for stone wear.
Part temperature different from gauging
Let parts reach a stable temperature before final gauging.
Stock removal from the previous operation varying
Check the bore size coming from boring or turning.
Prevention: Bore size charted on samples each shift.
Bore not round or straight
Hits OEE: Quality
Symptoms: Roundness, taper or barrel shape on the honed bore is out of tolerance.
Stroke length or position wrong
Set the stroke so the stones overrun both ends of the bore by the right amount.
Tool float or guides worn
Check the float of the tool and the guide strips, and replace worn parts.
Part clamped too tightly and distorted
Reduce the clamping force and check the fixture faces for dirt.
Stones worn to an uneven shape
True the stones or fit a new set so they contact the full bore length.
Prevention: Bore geometry measured on samples from each batch.
Surface finish or cross-hatch wrong
Hits OEE: Quality
Symptoms: The cross-hatch angle or the roughness of the bore does not match the specification.
Rotation and stroke speed ratio wrong
Set the rotation and stroke speeds for the cross-hatch angle the drawing asks for.
Wrong stone grit for the finish
Check the stone specification against the finish required.
Honing oil dirty
Filter or change the honing oil, and check the filter fineness.
Plateau finishing step missing or shortened
Check the finishing step of the program against the approved version.
Prevention: Roughness and cross-hatch angle measured on samples.
Stones glazing or breaking
Hits OEE: Availability
Symptoms: Stones stop cutting and glaze over, or break up during the cycle.
Feed pressure too low or too high
Set the feed pressure for the stone and the material; too low glazes, too high breaks.
Wrong stone for the material
Check the stone specification with the supplier for that material.
Honing oil not flushing the bore
Check the oil flow at the tool and clear blocked passages.
Stones not dressed on schedule
Dress the stones at the interval set for the part.
Prevention: Stone life recorded per material.
Cycle time increasing
Hits OEE: Performance
Symptoms: Each part takes longer to reach size than the standard cycle.
Stones glazed and cutting slowly
Dress the stones, and fit a new set if dressing does not restore the cut.
More stock left from the previous operation
Measure the incoming bores and agree the stock allowance with the boring step.
Feed settings changed in the program
Compare the program with the proven version and restore it.
Oil filter blocked so swarf stays in the bore
Change the oil filter and check the flow to the tool.
Prevention: Cycle time trended per part number.
Honing oil contaminated
Hits OEE: Quality
Symptoms: The oil turns dark, smells or carries swarf, and the bore finish suffers.
Filter elements overdue
Change the filter elements at the interval set for the swarf load.
Heavy stock removal making more swarf than planned
Reduce the stock left from the previous step so honing removes only what it should.
Water or coolant leaking into the oil
Trace the leak, for example a part washer or coolant line nearby.
Tank sludge never cleaned out
Drain and clean the tank, then refill with fresh oil.
Prevention: Oil condition checked weekly.
Gauge readings unstable
Hits OEE: Quality
Symptoms: In-process size readings jump, so the machine stops early or late.
Air gauge jets dirty
Clean the air gauge jets and check them for damage.
Air supply pressure varying
Check the air supply and the regulator feeding the gauge.
Gauge not set on the master ring
Set the gauge on the master ring at the start of each shift.
Gauge electronics or transducer faulty
Have the gauge unit checked by the maker if readings stay unstable after cleaning.
Prevention: Gauge set on the master at each shift start.
Parts marked or scratched
Hits OEE: Quality
Symptoms: Honed bores show scratches or deep marks that fail inspection.
Loose grit carried in the honing oil
Filter the honing oil and check the filter is the right fineness for the finish.
Stone breaking up during the cycle
Replace damaged stones and check the feed pressure that broke them.
Tool guides worn and rubbing the bore
Replace worn guide strips on the tool.
Parts knocked during loading
Check the loading device and part handling between machines.
Prevention: Bores inspected under good light on samples each shift.
Guidance only. Always follow lockout/tagout and your site's safe-work procedures, and verify against OEM manuals before acting.
Related equipment guides: cylindrical grinder · surface grinder · CNC machine · lathe · deburring machine
Stop the same fault coming back
Recurring honing machine stops usually trace to a cause you cannot see by hand. The partner we recommend is Fabrico: it tracks OEE and downtime live from PLCs, IoT sensors or AI cameras; where cameras are fitted, the video of a stop sits next to its machine data so the cause can be reviewed; and a technician opens the work order from the stop in the same system. Data is hosted in the AWS EU region, and Fabrico and the company behind it hold ISO/IEC 27001, ISO/IEC 20000-1 and ISO 9001.
Book a Fabrico demo
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Related tools: full troubleshooting directory · OEE calculator · downtime cost · MTBF / MTTR · glossary
Methods that cut recurring stops: the six big losses · root cause analysis · preventive vs predictive maintenance · TPM · SMED & changeover