SAFARI

4 DLT ENGINE

No. of strokes/min. - 50

Coolant to be used - Honilo 480 / Kerosene

Spark Out or Idle stroke after honing - One to two.

Hydraulic pressure for stick expansion - max. 5 bar.

Stick - D181 Diamond or (Sic 39C68 Jk 8VK)

Size : 8 X 8 X 70 mm

2.2 Base Honing :

The function of this honing stage is to generate number

of equal pitch vallies to give a good lubrication effect

for the engine. Here the pressure for stick expansion

must be less (2.5 to 3.5 bar max.) Operation must be

gentle. Max. 15 micron material to be removed.

Shape or geometry of the B/Bore must be 8 micron

max. Size at bottom bore must be more by 2 to 5 um

than the top size. Surface finish generated after "Base"

honing must be below 1 um Ra or 0.8 to 1.0 um Ra

max.

Machining data :

RPM - 120

No. of Stroke/min - 55/60

Coolant - Honilo 480/Kerosene

Spark out/Idle stroke - One or two

Hydraulic Expansion Pressure - 2.5 to 3.5 bar max.

Stick - 39C 120 J8 VK P TR 22 Size 8X8X70 mm.

or 39C 100 J8 VK P TR 22 Size - same

or SG 100 - 20 J VK Size 8X8X70 mm

Stock - Material to be left for plateau operation -

5 um.

2.3 Plateau Honing :

The function of this honing stage is to eliminate the

run in time of the block. This operation is removing

the crest surface peaks to generate a plateau effect

on running in surface. This plateau band must have

very find surface to generate a gliding effect of

lubrication film for piston rings.

Material removal expected is 3 to 5 microns only.

Machining data :

RPM - 120

No. of strokes/min. - 60

Coolant - Honilo 480

Operation to be carried out for 5 to 8machining strokes

only (as suitable to get good plateau).

2.4 Brush Honing

1 mm dia. Size bristles nylon make to be used just to

get a cleaning effect of honed surface. 10 to 15 strokes/

bore the operation to bemade.Honilo 480 / Kerosene to

be used with a heavy jet. RPMmust/may be more than

200. This operation can be carried out on a radial drill

machine holding the brush holder in the normal adapter.

Operator can make 10 to 15 strokes by hand only.

This operation does not remove any material.

3.Washing and Cleaning of Job :

Washing of the job after honing operation is a must.

This is preferably hot bath.

Clean the job by air at a closed area to remove dirt

and dust.

4. Oil & Grease :

After washing and air cleaning the barrel bore must

be lubricated or greased, if the block is to be

assembled later.