Spaulding particularly appreciates how the flexible hone’s abrasive globules each have independent suspension that is self-centring, self-aligning to the bore, and self-compensating for wear, all of which facilitate close-tolerance finishing work.

Prototypes of the US Air Force's sixth generation fighter jet, which is meant to be deployed in 2030, have already flown in secret.

I’ve experienced the difference a good tool vs a bottom of the barrel tool can make in a finishing cut. Does this also apply to roughers or are they all pretty similar in operation? I’d imagine the “nicer” roughers are just sharper and better balanced leading to lower cutting pressures/higher material removal rate than the cheap ones?

Prototypes of the US Air Force's sixth generation fighter jet, which is meant to be deployed in 2030, have already flown in secret.

The Boeing X-37B spaceplane is to begin executing a series of novel manoeuvres, called aerobraking, to change its orbit around Earth, the US Space Force has announced.

According to Scott, flexible hones are ideal because it is a cost-effective solution to smooth edges and produce a blended radius for crosshole deburring.

The forward and reverse rotation creates a symmetrical deburring pattern. Coolant should be used to keep metal cuttings and deburred metal in suspension.

“The hone conforms to whatever you are working with, even if it’s irregular,” he says. “For example, if the back side of the part is not flat or not on consistent level plane in Z, the tool is flexible enough to still remove any burrs.”

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Characterised by the small, abrasive globules that are permanently mounted to flexible filaments, the product is a flexible, low cost tool utilised for sophisticated surfacing, deburring and edge-blending.

I recently had to remove a good bit of material (subjective i know, I’m working my way up to vince and the like ) This probably took an hour or so with a very aggressive adaptive clearing strategy from fusion 360. If I could reduce my cutting time 20% just by using a rougher that would be well worth the tool change. Not to mention the saved life on the fancy single flute datrons I’ve been eyeing

For best results, the deburring tool is typically rotated into the main bore into which the crossholes break. After a few clockwise strokes, the tool is removed and the spindle reversed to rotate and stroke the flexible hone in a counter-clockwise direction for a few more strokes.

These options, which include thermal, abrasive flow, electrochemical, and high-pressure water, effectively remove excess material but they also build time into the manufacturing process and add to costs.

The more ideal option, however, for many aerospace operations is to integrate deburring into the automated process with a simple, effective crosshole deburring tool such as the Flex-Hone from Brush Research Manufacturing (BRM). By doing so, operators can speed up the manufacturing process and ensure uniform quality for precision parts.

“Getting rid of burrs is really important because if there is any loose material that gets dislodged when the product is in use, it can cause major problems,” says Anthony Scott, lead machinist at Orange Vise Company, a manufacturer of machine vices and quick change fixturing components used throughout aerospace.

“The tool can be used in CNC machines and also with a cordless drill,” says Scott. “So, if you manage to deburr 90% of the holes in a machine, but have a few left you can’t access easily, you can use it with a handheld drill and maintain the uniformity in surface finish and process.”

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According to Orange Vise’s Scott, although the Flex-Hone is often used with automated production equipment it can also be used for secondary deburring options offline as needed.

Available in sizes ranging from very small diameter hones (4mm) to those up to 36 inches or more in diameter (a size appropriate for large engine cylinder bores), these deburring tools can be custom designed to the size, shape and abrasive grit to fit any application’s needs.

Although there are many techniques for deburring internal passages at cross-holes, the majority require sending out parts or investing in equipment to complete the work in-house that can cost tens of thousands of dollars.

Despite the challenges, the removal of burrs from the production process is an absolute must for the high quality, precision parts required in aerospace. In many applications, cross-drilled holes act as conduits for fluids, lubricants and gases. Failing to remove burrs can cause blockage of these critical passages or create turbulence in the flow. Burrs can also lead to part misalignments, affect dimensional tolerances, and limit the overall efficiency of machined components.

Additional customisation from BRM in a variety of shapes is also possible to meet the requirements of non-traditional applications. This includes spherical-end configurations, stepped or multi-diameter configurations for double diameters and counter-bores, tapered or cone shapes, segmented shapes, or combining Flex-Hone globules with other filament materials.

For engineers in aerospace manufacturing, the ball-style hone is a highly specialised abrasive tool that is instantly recognisable by its appearance.

Babcock International Group (Babcock), the defence company, has been awarded a two-year contract extension by the UK Ministry of Defence (MOD) to continue to provide technical support services across the UK armed forces.

“It is really about accessibility, because there aren’t many tools that can do this,” he says. “Whether it is internal grooves or multiple cross-holes, there is really no way to reach those areas with any other tool we have found.”

And just to add real quick: I’ve done most of what i can think of in terms of general performance increases. Smw mod vise keeps things nice and rigid. Fogbuster with iso keeps chips cool and clear. Advanced tool paths in fusion.

However, with the serrated flutes, that means each flute is removing less material at the same stepover. So you may get some advantage, just nothing like an industrial machine that can handle larger stepovers / MMR.

In celebration of World Space Week, Space-Comm Expo has announced visitor registration is now officially live and open for the London ExCeL, event, running 11-12 March 2025.

“I use the Flex-Hone quite a bit working in aerospace,” explains Ken Spaulding of Zodiac Engineering, a contract manufacturer in California. “We do a lot of parts that involve tubes with multiple crossholes and slots. Getting inside there to reach the burrs, particularly if the walls are thick, is extremely difficult.”

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Despite the challenges, the removal of burrs from the production process is an absolute must for the high quality, precision parts required in aerospace. In many applications, cross-drilled holes act as conduits for fluids, lubricants and gases. Failing to remove burrs can cause blockage of these critical passages or create turbulence in the flow. Burrs can also lead to part misalignments, affect dimensional tolerances, and limit the overall efficiency of machined components. “Getting rid of burrs is really important because if there is any loose material that gets dislodged when the product is in use, it can cause major problems,” says Anthony Scott, lead machinist at Orange Vise Company, a manufacturer of machine vices and quick change fixturing components used throughout aerospace. Although there are many techniques for deburring internal passages at cross-holes, the majority require sending out parts or investing in equipment to complete the work in-house that can cost tens of thousands of dollars. These options, which include thermal, abrasive flow, electrochemical, and high-pressure water, effectively remove excess material but they also build time into the manufacturing process and add to costs. Before and after deburring The more ideal option, however, for many aerospace operations is to integrate deburring into the automated process with a simple, effective crosshole deburring tool such as the Flex-Hone from Brush Research Manufacturing (BRM). By doing so, operators can speed up the manufacturing process and ensure uniform quality for precision parts. According to Scott, flexible hones are ideal because it is a cost-effective solution to smooth edges and produce a blended radius for crosshole deburring. “It is really about accessibility, because there aren’t many tools that can do this,” he says. “Whether it is internal grooves or multiple cross-holes, there is really no way to reach those areas with any other tool we have found.” For engineers in aerospace manufacturing, the ball-style hone is a highly specialised abrasive tool that is instantly recognisable by its appearance. Characterised by the small, abrasive globules that are permanently mounted to flexible filaments, the product is a flexible, low cost tool utilised for sophisticated surfacing, deburring and edge-blending. Available in sizes ranging from very small diameter hones (4mm) to those up to 36 inches or more in diameter (a size appropriate for large engine cylinder bores), these deburring tools can be custom designed to the size, shape and abrasive grit to fit any application’s needs. “I use the Flex-Hone quite a bit working in aerospace,” explains Ken Spaulding of Zodiac Engineering, a contract manufacturer in California. “We do a lot of parts that involve tubes with multiple crossholes and slots. Getting inside there to reach the burrs, particularly if the walls are thick, is extremely difficult.” Spaulding particularly appreciates how the flexible hone’s abrasive globules each have independent suspension that is self-centring, self-aligning to the bore, and self-compensating for wear, all of which facilitate close-tolerance finishing work. “The hone conforms to whatever you are working with, even if it’s irregular,” he says. “For example, if the back side of the part is not flat or not on consistent level plane in Z, the tool is flexible enough to still remove any burrs.” For best results, the deburring tool is typically rotated into the main bore into which the crossholes break. After a few clockwise strokes, the tool is removed and the spindle reversed to rotate and stroke the flexible hone in a counter-clockwise direction for a few more strokes. The forward and reverse rotation creates a symmetrical deburring pattern. Coolant should be used to keep metal cuttings and deburred metal in suspension. According to Orange Vise’s Scott, although the Flex-Hone is often used with automated production equipment it can also be used for secondary deburring options offline as needed. “The tool can be used in CNC machines and also with a cordless drill,” says Scott. “So, if you manage to deburr 90% of the holes in a machine, but have a few left you can’t access easily, you can use it with a handheld drill and maintain the uniformity in surface finish and process.” Additional customisation from BRM in a variety of shapes is also possible to meet the requirements of non-traditional applications. This includes spherical-end configurations, stepped or multi-diameter configurations for double diameters and counter-bores, tapered or cone shapes, segmented shapes, or combining Flex-Hone globules with other filament materials. www.brushresearch.com

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