Method of operating honing feed system having full control of feed force, rate, and position

A method of honing a surface of a bore of a workpiece, comprising steps of:

• providing a honing tool supported on a spindle for rotation about an axis through the tool and for axial stroking movement, the honing tool having at least one radially expandable honing element;
• providing a feed system in connection with the honing tool, including a movable feed element automatically controllably operable for applying a feed force against the honing tool for radially expanding the at least one honing element;
• providing a control operable for automatically controlling operation of the feed system;
• providing a stroking system operable for axially stroking the honing tool along the axis;
• providing a drive for rotating the honing tool about the axis;
• providing a device for determining information representative of a feed force applied against the honing tool by the feed element and outputting a signal representative thereof to the control;
• providing a device for determining information representative of a position of the feed element and outputting a signal representative thereof to the control;
• automatically operating the feed system to move the feed element to radially expand the at least one honing element unrestrained by a surface of a bore, and determining information representative of a baseline feed force required for the expansion;
• automatically operating the feed system to move the feed element at a first feed rate to radially expand the at least one honing element within the bore of the workpiece without rotating or stroking the honing tool, so as to initially contact the surface of the bore to cause a responsive increase in the feed force to a level greater than the baseline feed force serving as an indicator of the contact;
• then
• automatically radially retracting the at least one honing element to reduce the feed force;
• and then
• commencing rotation and stroking of the honing tool while operating the feed system at a second feed rate slower than the first feed rate to radially expand the at least one honing element for contacting and honing the surface of the bore.