Honing tool and method for manufacturing same

A method for manufacturing a honing tool, the honing tool comprising an integrally formed metal holder having a cavity with an open side of known cross-section formed in one side thereof, the holder having a bottom surface in the cavity opposite the open side and a sidewall extending around the cavity between the open side and the bottom surface, the sidewall including at least one recessed portion at a location spaced from the open side of the cavity defining a cavity portion of larger cross-section than the cross-section of the open side, each recessed sidewall portion including a portion in communication with the larger cross-section cavity portion facing at least partially away from the open side of the cavity, and at least one filament of a polymeric material that melts at a known temperature having particles of an abrasive dispersed throughout, the at least one filament having first and second opposite ends and an overall cross-section corresponding generally to the cross-section of the open side of the cavity, said method comprising the steps of:

• a) heating the holder by induction to at least said known temperature;
• b) holding the first end of the at least one filament and inserting the second end thereof into the cavity of the heated holder such that just said second end is melted by the heated holder into a unitary mass;
• c) pressing the at least one filament deeper into the cavity such that the unitary mass substantially fills the cavity including the larger cross-section cavity portion and intimately engages the portion of the at least one recessed sidewall portion facing away from the open side of the cavity;
• and
• d) allowing the holder to cool such that the unitary mass is hardened and retained in the cavity by the engagement thereof with the portion of the at least one recessed sidewall portion facing away from the open side of the cavity.

A method for manufacturing a honing tool for mounting on a honing machine, the honing tool including a unitary metal holder having an open sided cavity formed in one side thereof, a bottom surface in the cavity opposite the open side, and a sidewall extending around the cavity between the open side and the bottom surface, the sidewall having at least one recessed portion spaced from the open side of the cavity forming a recessed cavity portion, each recessed sidewall portion including a portion adjacent the recessed cavity portion formed thereby facing at least partially away from the open side of the cavity, and a plurality of filaments of a polymeric material that melts at a known temperature having particles of an abrasive dispersed throughout, said filaments having first and second opposite ends, said method comprising the steps of:

• a) heating the holder by induction to at least said known temperature;
• b) holding the first ends of the filaments and inserting the second ends of the filaments into the cavity of the heated holder such that just the second ends of the filaments are melted together into a solitary mass in the cavity by the heated holder;
• c) pressing the filaments farther into the cavity to force the solitary mass against the bottom wall such that the mass spreads sidewardly into the at least one recessed cavity portion and substantially fills the cavity and intimately engages the portion of the at least one recessed sidewall portion facing away from the open side of the cavity;
• and
• d) allowing the holder and the solitary mass to cool such that the solitary mass is hardened and retained in the cavity by the engagement thereof with the portion of the at least one recessed sidewall portion facing away from the open side of the cavity.