The removal mechanism is of importance to the grinding of hard and brittle ceramic materials. It is more suitable to analyze
the
material removal during ceramics honing processes by means of indention fracture approach. There are two honing characteristics different from grinding, the honing
incidental tensile stresses and the crosshatch pattern. The stresses may influence material removal of brittle ceramics with lower tensile strength. In addition, the criss-cross cutting pattern on a bore known as crosshatch may also have its effect on the material removal of ceramics. The material removal of alumina is analyzed on the basis of honing characteristics, honing incidental tensile stresses and crosshatch pattern. By means of indentation fracture mechanics of brittle solids, the theoretical analysis of stress intensity factor and the crack response prove that honing incidental tensile stresses can increase the stress intensity factor of honing cracks and decrease the grinding stresses. So, the fracture criterion for crack propagation can be met easily. Therfore, it is possible to machine ceramic materials with small grinding forces in honing processes. The alumina honing experiments show that material at crosshatch intersecting point is removed by way of chipping which is similar to the edge-crumbled of ceramics. For brittle ceramics with lower tensile strength, such as Al 2O 3, SiO 2, the influences of the honing incidental tensile stresses and the crosshatch pattern on material removal are bigger than that of ceramics with relative higher toughness, such as ZrO 2 and Si 3N 4. Hence, the honing of Al 2O 3, SiO 2, is superior in cutting ability to the grinding. The large stock removal of brittle ceramic materials can be obtained through higher honing pressures. The increase in honing pressures can increase intensity factor of honing cracks, decrease the grinding stresses, and remarkably improve material removal rate. The researches show that honing is an efficient bore machining operation for brittle ceramics.