The investigation of the effect of particle size on wear performance of AA7075/Al2O3 composites using statistical analysis and different machine learning methods

\n Sequential honing process is usually implemented in engine cylinder bore processing to obtain the cross-hatched surface texture with excellent function to balance lubricant storage capacities and supporting performance. Many researches have devoted to correlating honed surface quality of cylinder bore with honing process parameters by means of experiments or simulations. Quite a few efforts have addressed the effect of sequential multiple steps on the surface texture in the honing of engine cylinder bore. However, these researches cannot provide an explicit and analytical methodology to predict honed surface texture efficiently and accurately. This paper presents an analytical and explicit methodology to incorporate a proposed microscale abrasive model into the analytical simulation process of sequential honing. The proposed abrasive model synthetically considers the shape, size, posture, and position of abrasives randomly distributed in honing stone, which is incorporated into honing head motions in terms of rotation, oscillation and feeding. The kinematics of honing head is calculated by space-time discretization to capture the interaction between honing stones and cylinder bore surface. The above procedure acts as each single step for the sequential honing processes. This study investigates the sequential honing of two stages including semi-finish honing and plateau honing at different feeding speeds by applying the abrasive model with different abrasive sizes. The formation of cross-hatched surface texture was successfully achieved sequentially by semi-finish honing and plateaus honing. Then the Abbott-Firestone Curve of the honed surface can be obtained to analyze the influences of abrasive size and honing time of two stages on the surface roughness. Correctness of surface roughness predicted by the model is verified by comparing with a group of experiment measurements in terms of Abbott-Firestone Curve. Most errors of all the predicted Rk roughness family roughness parameters in the two honing stages are less than 15%. Based on the model, simulations are done to analyze the influences of abrasive size and honing duration time of two stages on the surface roughness. The result shows that the larger abrasive used in finish honing leads to the decrease of the material portions Mr1, Mr2 and the increase of the reduced valley depth Rvk. The longer plateau honing duration time is preferred to produce the larger Mr1, Mr2 and the smaller Rvk.

Honed Surface Multiscale Prediction Based on Multi-Stage Honing Process of Engine Cylinder Bore

Estimation of wear performance of AZ91 alloy under dry sliding conditions using machine learning methods

Effect of electroless Ni-B and Ni-W-B coatings on the corrosion-fatigue behaviour of 7075 Al alloy

The surface of cylinder liner is tribologically important. In most cases, it has a two-process cross-hatched structure created by the plateau honing process. Because the surface topography of cylinder liners is complicated, its analysis is challenging. Special methods have been used to analyse the textures. In this article, first, the parameters in the standard are reviewed. Next, the methods for selecting the reference elements are presented. Other comprehensive methods of cylinder surface analysis are described. Finally, methods of cylinder texture modelling are analysed.

Analysis of surface texture of plateau-honed cylinder liner – A review

Predicting Microscale Cross-Hatched Surface Texture in Engine Cylinder Bore

Predicting Multi-Scale Dimensional Accuracy of Engine Cylinder by Honing

\n The dimensional accuracy of engine cylinder bore at multiscale has a tremendous influence on engine performances including friction power loss, vibration, leak tightness between piston and cylinder, and wear resistance. Tremendous researches were devoted to predict the dimensional accuracies of the honed cylinder by means of analytical, experimental, and numerical simulation methods. The dimensional quality of the honed cylinder bore was usually determined by establishing the relationship between honing parameters and dimensional accuracies of the honed cylinder bore. However, most researches predicted dimensional accuracy at macroscale or surface texture at microscale, respectively. Few efforts were devoted to predict the dimensional quality of honed cylinder bore at both macroscale and microscale levels simultaneously. To explore a new understanding of the honing mechanism of the cylinder bore, a multiscale model is proposed to predict the dimensional accuracy and surface texture of cylinder bore generated from the honing process at the macroscale and microscale simultaneously. The model aims to integrate both microscale factors including honing stone abrasives distribution, abrasive wear process, previous cylinder surface topography, and macroscale factors including cylinder geometric features and honing head motion trajectory into a multiscale analytical analysis. A force matching method is adopted in the multiscale predictive model to determine the feed depth in the honing of the cylinder bore. Thus, the proposed multiscale analytical model possesses an excellent capacity to simultaneously predict the roundness and cylindricity of the honed cylinder bore, as well as the surface texture/roughness of the honed cylinder bore in terms of Abbott-Firestone curve. The simulated results also revealed that the material removal process is closely related to the initial shape deviations of the cylinder bore, which cannot be corrected, compensated, or eliminated by the subsequent honing process given the deviations are associated with wavelengths higher than 27 mm under the given honing condition.

Zaoyang Zhou

Papers

Honed Surface Multiscale Prediction Based on Multi-Stage Honing Process of Engine Cylinder Bore

Predicting Microscale Cross-Hatched Surface Texture in Engine Cylinder Bore

Predicting Multi-Scale Dimensional Accuracy of Engine Cylinder by Honing

Analytically Predicating the Multi-Dimensional Accuracy of the Honed Engine Cylinder Bore