Showing papers on "Honing published in 2003"

Optimisation of the cutting edge roundness and its manufacturing procedures of cemented carbide inserts, to improve their milling performance after a PVD coating deposition

Abstract: The fatigue and wear behaviour of PVD coatings on cemented carbide inserts with various cutting edge radii are investigated experimentally and analytically in milling. The inserts with cutting edge radii from 8 up to 35 μm were manufactured by honing and micro-blasting. The tool wear progress was depicted through Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray (EDX) microspectral analysis. The Finite Elements Method (FEM) simulation of the contact between the tool and the workpiece highlights the effect of the cutting edge radius on the first coating fracture and the further wear development. The wear behaviour of the cutting edge radii manufactured by honing, in comparison to the corresponding ones by means of micro-blasting, is significantly enhanced, whereas the cutting edge radius increasing can lead to a higher tool life.

Two-cavities cutting matrix

Abstract: The invention relates to a cutting matrix (10) to be tighten in a cutting tool (14) used for cutting cast materials. The inventive cutting matrix comprises a top surface (13), a first cavity for tightening (11) in the cutting tool (14) and a cutting edge for cutting by stock removal. The aim of the invention is do not modify the tightening characteristics of the cutting matrix (10) by honing or grinding the top surface (13) thereof. For these purposes, a second tightening cavity (12) is arranged coaxially with respect to the first cavity (11). Said first cavity (11) is embodied such that it is deeper than the second tightening cavity (12), both cavities being arranged more deeply with respect to the upper surface (13) of said cutting matrix.

Wafer polishing method and wafer polishing apparatus in semiconductor fabrication equipment

Abstract: When honing an abrasive pad for polishing a wafer by rotating while closely contacting the wafer by bringing a conditioner into contact with the abrasive pad, forces applied from the abrasive pad to the conditioner are detected by a plurality of pressure detectors through a conditioner driving unit for holding the conditioner. The pressure detectors are respectively able to detect forces in two directions such as rotational direction and radial direction. A memory stores correlations between detection values and wafer polishing quantities under various conditioning terms. Therefore, it is determined whether the detection values are kept within acceptable limits stored in the memory. When the values are out of the acceptable limits, a controller controls the values so that they fall within the acceptable limits by properly changing conditioning terms.

Deposit Formation on Cylinder Liner Surface in medium-speed Engines

Abstract: The presence of deposits in the honing grooves in diesel engine cylinder liners can cause a severe increase in the consumption of lubricating oil. These deposits may appear amber in which case they ...

Machine for superfinishing by honing

Abstract: The invention relates to a honing machine for superfinishing workpieces e.g. by honing using a tool spindle (7) which can be rotatably driven and can receive a tool, and a motor which rotates the tool spindle, said tool spindle (12) being arranged on a carriage (12) which can be displaced on a machine frame (16), by means of a drive device, in the direction of the rotational axis of the tool spindle. Said drive device consists of a plane primary part (13) and a secondary part (17) of an electric linear motor (18), said secondary part being linearly displaceable on the primary part. One (13) of the components primary part/secondary part (13, 17) of the linear motor (18) is arranged on the machine frame (16), and the other (17) on the carriage (12).

Micro-welded gun barrel coatings

Abstract: A micro-welding process is used to apply erosion and wear resistant coatings to the internal diameter of gun barrels. The applied coatings are then treated by methods such as honing and/or rotary forging. The protective micro-welded coatings may comprise ceramic, cermet and/or refractory metal materials, and may be used with rifled or smooth gun barrels of various sizes.

Cylinder liner with its inner peripheral surface formed with surface treatment layer, and method for machining to the surface treatment layer

Abstract: A cylinder liner for use in an internal combustion engine has an inner peripheral surface at which a surface treatment layer is formed upon water vapor treatment The surface treatment layer has a surface configuration capable of providing excellent lubrication oil retaining function and initial break-in property as well as capable of being machined easily The treatment surface of the cylinder liner has a plateau configuration providing a surface roughness Rz of 08 to 59 μm, and the plateau configuration is defined under DIN4776 by a reduced peak height Rpk of not more than 064 μm, a core roughness depth Rk of 005 to 18 μm, and a reduced valley depth Rvk of 015 to 33 μm For grinding to the surface, a honing machine employs a grindstone containing metal bonded diamond grains at high density Diamond grain size is not less than 4000

Numerical control (NC) processor with onboard grinding unit

Abstract: A numerical control (NC) processor with an onboard grinding unit is disclosed in which a workpiece is first cut in a preselected contour with a Y-axis cutting tool, and then subjected to honing operation intact whereby both the cutting and honing operations can be performed with just a single processor with high-speed, high-acceleration. With the NC processor, the Y-axis cutting tool is mounted on a sliding base above an X-axis table in a way allowed to move back and forth in a Y-axis direction, while a grinding unit is installed in close proximity to the sliding base. A slider moves back and forth in synchronized relation with rotation of a work spindle to first let the Y-axis cutting tool cut the workpiece into a preselected contour, and then cause a buffing material of the grinding unit to grind a work surface of the workpiece into a high-quality surface finish in conformity with a programmed contour while the workpiece remains held intact in a chucking device.

Advances in Abrasive Technology V

Abstract: Abrasive technologies are central to modern manufacturing as applied to a wide variety of products covering many disciplines: from nanoscale components to large-scale equipment, and from biomedical devices to aerospace structures.This special issue brings together the latest advances in, and applications of, abrasive technologies. It comprises 122 selected peer-reviewed technical and review articles, and covers a broad range of research topics including: design, fabrication, truing and dressing of grinding wheels, precision grinding, abrasive-jet processing, lapping, honing, polishing and non-conventional finishing, semiconductor processing, micro/nano- machining, fabrication and forming, advanced machining and rock-cutting technologies, tribology in manufacturing, process monitoring and measurement, and other novel techniques and advanced studies related to abrasive technologies.

The interaction of wear rate and friction with surface roughness for a lubricated sliding contact

Abstract: This study considers a spheroidal grey cast-iron pin on a hardened and polished spring steel disc, with an automotive SAE 10W40 lubricant in unidirectional sliding. This material pair is comparable to a piston ring and cylinder from an engine, a system that has long been associated with complex surface texture honing and running-in phenomena. Changes in friction, wear rate and surface roughness were monitored. The aim was to understand the relationships between operating conditions such as contact friction and sliding distance on the one hand, and wear rate and the evolution of surface texture and roughness on the other. Non-dimensional surface parameters σ/β and ηβσ (σ=r.m.s. roughness, β=mean asperity tip radius and η=asperity surface density) have been calculated for measured surface topographies from a gasoline engine cylinder liner and top piston ring during 120 hours of use as well as for data from the bench test described above. These parameters are utilised in the model of Greenwood and Tripp for asperity contact when two rough surfaces are in close proximity. They are thus relevant to the wear response in a sliding contact.

Rough honing process for boring surface involves offsetting longitudinal axis of boring before honing from that of finished boring

Abstract: The rough honing process is for the surface (3) of a boring (2), using a honing tool (5) with honing bar (7) on a spindle (6). The longitudinal axis (MA) of the tool is offset from the longitudinal axis (MB) of the initial boring. During honing, material is honed off till the difference is eliminated and the two axes are co-axial.

Cylinder for internal combustion engine and method of treating inner surface of the cylinder

Abstract: A cylinder for an internal combustion engine and a method for treating the inner surface of the cylinder, which enables the inner surface constituting a piston-sliding surface of the cylinder to have a high quality plated layer which is uniform in thickness and smooth in surface at low cost without necessitating grinding work such as honing work. The cylinder and the method of the present invention are characterized in that the inner surface of the cylinder is provided with a plated layer which is deposited thereon by a PR (Periodical Reverse) method employing a high-speed polarity reversal power source.

Influence of Honing Dynamics on Surface Formation

Abstract: The dynamics of the rotating tool commonly employed in deep hole honing is considered. The mathematical model of the process including the dynamic model of the tool and the interaction of the workpiece surface and honing sticks is analyzed. The honing tool is modeled as a continuous slender beam with a honing mandrel attached at the intermediate cross section. A single row of stones on the tool rotates and has reciprocational motion in the axial direction. The honing stones are expanded to the machined surface by a special rigid mechanism that provides cutting of workpiece cylindrical surface and which vibrates in the transverse and axial directions. The removal of chip and the tool vibrations cause the variation of expansion pressure and depend on the surface state formed by previous honing stone. The equations of new surface formation are separated as a specific set of the dynamic model. These equations inherently consider the regenerative effect of oscillations during cutting. The expansion pressure, tool stiffness, and technology conditions are considered as varying parameters since their influence on the process are different. The process productivity and precision can be improved by choosing rational conditions evaluated by simulation. The corresponding models and results of numerical simulation are presented. All the results are given in dimensionless form and therefore they are applicable to a wide range of real manufacturing process conditions. The model of new surface formation presented allows the simulation of the machined surface variation in time and to predict workpiece accuracy and possible correction of surface errors.Copyright © 2003 by ASME

Honing method and honing apparatus

Abstract: In a coarse honing step in a section (101), a honing head (15) provided with coarse honing hones (17) is inserted into a cylinder bore (13) of a cylinder block (11), the honing head 15 is rotated while axially moving it, and the inner peripheral surface of the cylinder bore (13) is thereby ground. In the next idling step in a section (102), the cylinder block (11) is left as it is for (60) seconds to generate a springback (S). In a subsequent finishing honing step in a section (103), a honing head (21) provided with finishing honing hones (19) is inserted into the cylinder bore (13), the honing head (21) is rotated in a reverse direction to a rotational direction in the coarse honing step while axially moving it, and the inner peripheral surface of the cylinder bore (13) is thereby ground. Further, a coolant is supplied to the sections of the coarse honing step, the idling step, and the finishing honing step from coolant nozzles (23), (25), and (27), respectively, using a common coolant supply source (29).

Gear wheel honing method and working machine

Abstract: PROBLEM TO BE SOLVED: To provide a method for gear-wheel honing in which tooth doubling is carried out so that a working allowance becomes equal by simple formation, and by synchronously spinning a grinding stone gear-wheel and a worked gear-wheel with high accuracy, by a synchronous rotation by which a highly accurate gear-wheel is manufactured with efficiency and at a low cost. SOLUTION: In this gear-wheel working method, a driving spinning phase is fixed by performing the engagement spinning of both spindles by synchronous control by driving the worked gear-wheel 2 and the grinding stone gear-wheel 1 together, by performing the mounting of the worked gear-wheel to the supporting shaft of the worked gear-wheel, by clamping the worked gear-wheel to the above supporting shaft of the worked gear-wheel, by measuring a spinning phase difference between the worked gear-wheel and the supporting shaft of the worked gear-wheel with a device for positioning the worked gear-wheel, by synchronizing the worked gear-wheel and the grinding stone gear-wheel by the controlling of each control motor and by doubling and spinning a spinning phase so as to cancel the spinning phase difference, in a condition in which the driving torque of the worked gear-wheel or the grinding stone gear-wheel is lowered to a degree not to receive cutting due to the grinding stone gear-wheel, by approaching the worked gear-wheel and the grinding stone gear-wheel up to the vicinity of a backlash zero position, by reading the spinning phase difference between the worked gear-wheel and the grinding stone gear-wheel at the vicinity of the backlash zero position and by making adjustment so as to cancel the spinning phase difference of each control motor between the worked gear-wheel and the grinding stone gear-wheel. COPYRIGHT: (C)2005,JPO&NCIPI

11 – Characterisation of Automotive Engine Bore Performance using 3D Surface Metrology

Abstract: This chapter investigates the engine performance as a function of 3-D surface topography. A series of engine bench tests undertaken by Volkswagen as part of the overall SURFSTAND project is presented. During these bench tests the functional performance and the wear of the cylinder bores of engines with different surface finishes were examined. For monitoring the functional performance, power, torque, and oil consumption were recorded. Additionally, geometrical changes such as the cylindricity of the bore and the geometrical change of the counterparts, piston and piston ring were measured. The change of surface topography throughout the engine life was examined using 3D surface metrology. A significant change to the surface occurs during the first hours of running of the engine. A mathematical model describing the wear-time-relationship was developed for the test engines. The chapter concludes that engine bench tests have proved a relationship of functional performance of engine cylinder bores and 3-D surface topography exists. The flatter laser textured engine surface, with pockets retaining lubricant, shows less wear then the surface manufactured by conventional honing.

UV-Laserbelichtung von Grauguss-Zylinderlaufbahnen von Verbrennungskraftmaschinen

Abstract: The developement of combustion engines is put in motion by the desire of the customers to have more power and economy of operation, as well as the legislative authority by introducing a higher fuel tax and new environmental laws. From this three objectives of developement can be derived: reducing fuel and oil consumption and increasing working life. The first two items are connected with higher combustion pressure which acts in a higher tribological stress to the piston rings and the cylinder surface. The result is increasing wear. The wear effects to the oil consumption and the closeness to the combustion gas of the system cylinder surface and pisten rings. Both issues highly influence the exhaust gas and its composition as well as the efficiency of the engine. Conventional honing creates a structure of crossing groves in the cylinder surface and limits the reduction of wear and oil consumption. If a cylinder surface is pretreated by honing in three stages prior to exposure with the UV-laser, two effects are obtained: first the uncovering of graphite lamellae at the surface due to the vaporisation of material during ablation of grey cast iron, and second, the formation of a molten surface layer. The uncovered graphite acts as a microhydrodynamic surface structure. The physical properties of the UV-irradiation-process result in the incorporation of about 16% to 18% nitrogen in the surface, producing a layer with a non-metallic character. The open graphite lamellae and nitrogen-hardened layer improves the tribological properties of the cylinder surface, piston and piston rings system. In comparison to conventionally honed cylinders, for UV-exposed cylinder surfaces the wear is reduced by 23% to 89%. Actual motor tests demonstrate that the oil consumption decreases up to 75%. The principle design of the equipment for exposing cylinder surfaces with the UV-laser is described and schown in figure 15.

Tool for polishing the edge of a knife

Abstract: A tool for polishing knife's edges, the tool ( 1 ) comprising two oppositely positioned and co-rotating rings of elongate honing studs ( 10 ), extended at intersecting directions forming an angle (α) wherein the knife's edge is inserted to be straightened by the rotating polishing tool.

Front face milling cutter

Abstract: PROBLEM TO BE SOLVED: To perform machining with little vibration and chatter and to improve the surface roughness and accuracy of a machined surface and the life of a cutting blade in a face milling machining for a thin work material made of an aluminum alloy or others. SOLUTION: In this front face milling cutter, a plurality of chips having a main cutting edge projected from the outer peripheral surface of a tool body and a front face cutting edge projected from one end face of the tool body are disposed along the outer peripheral surface of the tool body. In at least one or more chips, the main cutting edge is run off in the radial direction of the front face milling cutter to the chip disposed either right before or right behind in the rotating direction of the front face milling cutter, the front face cutting edge is projected in the axial direction, the main cutting edge and the front face cutting edge are formed of sintered diamond or cemented carbide as base metal coated with diamond, and the ridge line of the main cutting edge and/or the front face cutting edge is subjected to honing. COPYRIGHT: (C)2004,JPO&NCIPI

Boring and honing equipment for cylinder repairing

Abstract: The utility model is a special equipment for repairing cylinder boring and honing of motorcycles, cars, tractors, comprising a cutter head, a transmission device and dynamic power, wherein, the dynamitic power comprising a motor of a main shaft and a motor of a gear pump; an oil cylinder is connected with the main shaft through a tightening bolt to achieve the function of cylinder boring; when the tightening bolt is loosened, the motor of a gear pump will be started up to drive the oil cylinder to move so as to achieve the function of honing hole. Such two different mechanisms are used to control the speed of the working stroke of the same oil cylinder to control the different movement ways of the cutter head, so that the application of one equipment can achieve both the boring and the honing functions, thereby saving money and occupied area of the equipment.

Super abrasive grain wheel for flat honing, dressing method thereof, and grinding device using the wheel

Abstract: PROBLEM TO BE SOLVED: To provide a super abrasive grain wheel for flat honing in which the dynamic pressure generated when grinding a work is distributed and reduced, and the grinding of high surface accuracy can be realized. SOLUTION: A plurality of super abrasive grain layers of strip shape of the width of <=10 mm are fixed to a surface of a disk-like base plate, and the super abrasive grain layers 1 are disposed in a radial direction so as to be across in an angular range of ±15 deg. with respect to a predetermined axis passing through the center of the disk-like base plate.

Method for machining surface of cylindrical recess in workpiece uses integrated honing tool and fine lathe to first prime and then hone surface in single work step

Abstract: The surface is in a single work step first primed by a fine lathe (3) and then honed by a honing tool (2). Independent claim describes device with combination tool having an integrated honing tool and fine lathe with a common rotatable drive axis and with the fine lathe set in front of the honing tool in the machining direction.

Fine machining system for inner surface of hollow cylinder made of materials of different hardness with conical or flat honing stones has axially and radially movable holder

Abstract: The cylinder is made off two cylinders of different hardness. A first hard cylinder (4) is butted (14) against a soft cylinder (6) underneath. The inside diameter of the composite cylinder may be machined to a double cone shape (11), with the butt joint in a gently sloping region. The hone may have two stones (8) on a movable holder (7). The alteration in radius (12) may be between 10 and 100 mu and the conical region may be between 20 and 200 mm long.

Method for manufacturing cylinder liner

Abstract: PROBLEM TO BE SOLVED: To suppress deformation of an intermediately processed cylinder liner by steam treatment, in a manufacturing process for a cylinder liner for an internal combustion engine having a steam treated iron oxide coating on its inner peripheral surface. SOLUTION: Annealing is applied to the cylinder liner after cutting, honing and grinding except for grinding of its outside diameter are applied to it, steam treatment and grinding of the outside diameter are then applied to it, and grinding of the outside diameter and honing are applied to it to finish the cylinder liner having excellent roundness.

Numerical control (NC) machine with onboard grinding unit

Abstract: A numerical control (NC) machine with an onboard grinding unit is disclosed in which a workpiece (9) is first cut in a preselected contour with a Y-axis cutting tool (20), and then subjected to honing operation intact whereby both the cutting and honing operations can be performed with just a single processor with high-speed, high-acceleration. With the NC machine, the Y-axis cutting tool (20) is mounted on a sliding base (1) above an X-axis table (4) in a way allowed to move back and forth in a Y-axis direction, while a grinding unit (11) is installed in close proximity to the sliding base (1). A slider (18) moves back and forth in synchronized relation with rotation of a work spindle (10) to first let the Y-axis cutting tool (20) cut the workpiece (9) into a preselected contour, and then cause a buffing material (27) of the grinding unit (11) to grind a work surface of the workpiece (9) into a high-quality surface finish in conformity with a programmed contour while the workpiece (9) remains held intact in chucking means (8).

Method for honing blind bores in workpieces

Abstract: A device for honing blind bores in parts, a blind bore including a cylindrical bore open at one end and closed adjacent to the opposite end including a honing mandrel for mounting on a honing machine that produces rotation thereof, the mandrel having a cylindrical honing portion adjacent one end which portion and the adjacent portion of the mandrel have spaced axially extending slot therethrough to enable the honing portion of the mandrel to expand and contract in size, the honing portion having a portion adjacent to the end thereof which is somewhat larger than the rest of the honing portion when the honing portion is expanded for honing in the blind hole, the end portions of the mandrel between the spaced slots being elastically expandable from a retracted position which is less than the diameter of the surface to be honed to enable insertion therein to a more expanded condition wherein the diameter of the honing portion at the largest point is the diameter at which the mandrel will hone the blind hole. The present invention also includes a method for programming the operation of the device to produce the desired honing operations when honing blind holes.

Card for printing, substrate and method for making card

Abstract: PROBLEM TO BE SOLVED: To provide a card for printing having a receptive layer having appropriate adhesive strength even when an inexpensive adhesive material having weak adhesive power is used. SOLUTION: As the substrate 100 of a card for printing, PET is used. On the surface of the substrate 100, a honing treated surface 101 is formed. With the honing treated surface 101, the surface treatment having an arithmetic mean roughness Ra of 0.3-0.7 μm and a maximum height Rmax of 2.0-4.8 μm is provided by jetting a fluid containing abrasive grains from a nozzle in the form of a curtain. On the honing treated surface 101, a receptive layer 103 or a mixed layer 104 is (A) directly or (B) indirectly is formed. Due to jetting of the fluid, the deformation of the substrate 100 of PET by abrasive heat is rendered small, and the adhesive force of the receptive layer 103 or the mixed layer 104 is secured by the specified range of Ra and Rmax. COPYRIGHT: (C)2004,JPO

Honing method and method for manufacturing of electrophotographic photoreceptor

Abstract: PROBLEM TO BE SOLVED: To provide a honing method for a cylindrical substrate in which the outer surface of a wet-honed cylindrical substrate after washing is free from a polishing agent (abrasive particles), and to provide a method for manufacturing an electrophotographic photoreceptor using such a cylindrical substrate as a conductive substrate and free of occurrence of image defects such as voids, black spots, and density unevenness in an image when used in an electrophotographic apparatus. SOLUTION: The honing method includes at least a surface roughening step in which a honing liquid containing a polishing agent is blown on the cylindrical substrate to roughen the outer surface of the cylindrical substrate, and a washing step in which the polishing agent remaining on the outer surface of the cylindrical substrate is washed off, wherein particles of the polishing agent having a particle diameter of ≥10 μm do not adhere to the inner surface of the cylindrical substrate after the surface roughening step. COPYRIGHT: (C)2004,JPO&NCIPI

Inner surface polishing method of tubular brittle material and tubular brittle material obtained by the polishing method

Abstract: PROBLEM TO BE SOLVED: To provide a polishing method for manufacturing a high profile irregularity tubular brittle material with the maximum roughness Rmax of the inner surface of 0.1 μm or less, the center line average roughness of 0.1 μm or less in a comparatively short time, and a high profile irregularity tubular brittle material obtained by the polishing method. SOLUTION: According to this polishing method for polishing the inner surface of the tubular brittle material with good profile irregularity, the inner surface of brittle material previously ground to be tubular by a honing machine is polished with paper to which diamond abrasive grains adhere. COPYRIGHT: (C)2004,JPO&NCIPI

Coroning: High Performance Gear Honing Without Dressing

Abstract: Gear honing with internally toothed tools was first used as a gear finishing process for improving unfavorable surface conditions of external cylindrical gears after grinding. Stock removal was minimal (less than 0.01 mm) and only dressable tools were used. From the beginning, the multi-directional surface structure created by gear honing was considered beneficial for gear noise performance. But limitations of the early machine and tool technology did not allow for more stock removal. For a long time gear honing represented an additional finishing process, performed after pre-finishing by shaving or grinding. In the early 1990’s, significant research and development efforts aimed at higher stock removal capacity as well as improved ability to eliminate pre-machining errors. The requirement of combining advantageous functional work piece characteristics after gear honing and the economic benefits of a single hard finishing process has led to the development of Coroning. Using similar process kinematics as in conventional gear honing, Coroning distinguishes itself by the application of highly aggressive electroplated diamond tools. Because of the increased stock removal capability of Coroning, it is a true single-finishing process for mass production. Coroning is applied after gear hobbing or shaping and heat treatment. It does not require prior shaving or grinding. This paper will explain the unique tool concept used for Coroning and discuss related process kinematics in comparison with conventional gear honing. Tool design aspects will be considered and suitable process strategies will also be presented. Application examples will be used to describe typical stock conditions, process parameters and the geometric quality that can be achieved with Coroning.Copyright © 2003 by ASME