Showing papers on "Honing published in 2013"

A Review on Ball Burnishing Process

Abstract: Burnishing is a very simple and effective method for improvement in surface finish and can be carried out using existing machines, such as lathe. On account of its high productivity, it also saves more on production costs than other conventional processes such as super finishing, honing and grinding. Moreover, the burnished surface has a high wear resistance and better fatigue life. A literature survey being specifically focused on Ball burnishing process is done .It gives a thorough idea about various workpiece materials, various cutting tools and machine tools, process parameters ,lubricants, variable measured and methodology used as well as the prominent levels of each, being observed in the researches till today.

Precision Finishing of Bevel Gears by Electrochemical Honing

Abstract: This article presents some studies on precision finishing of straight bevel gears using electro-chemical honing (ECH) process. Surface roughness and form errors in terms of pitch and runout error have been studied as process performance measures. An innovative experimental setup has been designed and developed for ECH of bevel gears using a novel concept of twin complementary cathode gears. It ensures finishing of the entire face width of the workpiece gear and the inter-electrode gap required for the ECM action to take place. In this concept, one of the cathode gears has an undercut conducting layer sandwiched between two insulating layers while, in the other cathode gear, an insulating layer is sandwiched between two undercut conducting layers. The results have shown noticeable improvement in the surface finish and form accuracy in an optimized finishing time of 2 minutes. The scanning electron microscope (SEM) images and bearing area curves have also shown improvement in the surface integrity and mater...

Method and apparatus for hard finishing modified gears

Abstract: The present disclosure relates to a method for the manufacture of a workpiece having a corrected gear geometry and/or a modified surface structure, in particular by a hard finishing process, in particular generation grinding or honing. Provision is made in this respect that it is achieved by a direct generation of a wobble movement and/or of an eccentricity of the tool that a modification, in particular a profile modification or profile waviness, and/or a defined periodic flank waviness is generated on the active surface of the workpiece machined therewith.

Performance impact of honing dynamics on surface finish of precoated cylinder bores

Abstract: The surface modification of engine cylinder bores with improved sliding properties is often produced by the honing process. This multi-stage process is performed using abrasive stones loaded against the bore with simultaneous rotation and oscillation. To guarantee this process robustness with acceptable dimensional accuracy and surface quality, the stone dynamic effects in continuous balanced contact with the workpiece have to be studied deeply. This paper highlights these effects on honed surface textures. The stone dynamic behavior was studied at conventional regime ranged from 0.5 g to 1.5 g as often used in mass production. In this range, the dimensional accuracy is ensured by opposition to the surface appearance. However, higher accelerations up to 2.5 g improve simultaneously the form quality (especially straightness) and reduce the cycle time. This work shows, at least, that the bore surface finish can be dynamically controlled while honing. This technology is enabled by a micro scale regeneration mechanism of abrasive stones.

Effect of Burnishing Process on Behavior of Engineering Materials- A Review

Abstract: Quality of Surface is an important factor to decide the performance of a manufactured product. Surface quality affect product performance like assembly fit, aesthetic appeal that a customer might have for product. The nominal surfaces of the object are represented by perfect straight line, perfect circles, round holes, straightness and absolute perpendicularity A variety of processes are used to make the designed parts. The characteristics of surfaces includes surface texture, surface integrity which is always related with manufacturing processes for maintain quality of surfaces. For better quality surface finish the main factor is surface roughness. The lower value of roughness gives higher surface finish for the manufactured product. Now in present scenario different processes like grinding, honing, super finishing, polishing, burnishing etc are used to reduce the value of surface roughness. Burnishing is one of the processes which majorly affect the surface roughness. In conventional machining processes the tensile residual stresses are induced on the surface of material, which reduces the fatigue strength of material, this can be prevented by inducing residual compressive stresses on the surface of material. Burnishing is a cold working process in which initial asperities are compressed beyond yield strength against load. The surface of the material is progressively compressed, then plasticized as resultant stresses reach a steady maximum value and finally wiped a superfine finish. The highly finished processes find the application in aerospace and aircraft industry.

Flexible right sized honing technology for fast engine finishing

Abstract: The paper discusses a flexible honing technology by describing the new prototype machine with its specificity. Three original methods produced by the flexible honing prototype have been studied. A path combines the two contemporary methods of industrial honing: the helical slide honing at 135° at the bottom of the cylinder and the conventional honing at 45° on the upper part. This method of honing shows the effectiveness of specific motion tracking to remove traces of inversions. Circular trajectories with large radii can be traveled quickly without consuming too much energy. The high cutting speed promotes the removal of material thus saving time. Finally, the multi-circle paths can get original textures thus proving the feasibility of all patterns.

Honing machine with a plurality of work stations and a rotary table

Abstract: A honing machine (100) for performing honing operations on at least one bore in a workpiece (102), in particular for hone machining cylindrical bores in a cylinder crankcase, has a machine base (110), a plurality of vertical stands (112A-112D) arranged in the peripheral area of the machine base, an upper machine part (120) that is arranged at a distance above the machine base and is supported by the stands, and a rotary table (130), arranged on the machine base, that can be rotated about a vertical rotary table axis (134) and has a plurality of workpiece holders (135) which are radially spaced from the rotary table axis and offset from one another circumferentially in such a manner that a workpiece received in a workpiece holder can be transported successively to different work stations (140, 150, 160) of the honing machine by rotating the rotary table. At least one of the work stations is a honing station having at least one honing unit (180) supported by the upper machine part (120), said honing station having a honing spindle that can be rotated about a vertical spindle axis and moved back and forth parallel to the spindle axis.

Improvement of the manufacturing process of abrasive stones for honing

Abstract: In the present work, the mixing process of different components of abrasive stones of cubic boron nitride used for rough honing was studied. Stones are made by the sintering process of abrasive grains, a metallic bond, and a humectant that favors covering of each abrasive grain by the bond. Incorrect mixing of abrasive grains with the bond and humectant can result in stones with nonuniform abrasive grain distribution. As the abrasive stone wears out, grain distribution will vary and modify efficiency of the honing operation. Tin is the metal having the lowest melting point among metals in the bond. By means of a scanning electron microscope and energy-dispersive X-ray microanalysis, tin segregation was discarded, which could have led to abrasive grain segregation. Later, mixing tests of the different components of the stones were performed at different mixing times. Both homogeneity degree of the abrasive content of different samples in a mix and covering degree of abrasive grains by bond were determined through two new parameters introduced in the present study. It was noted that use of a chain to accelerate the mixing process excessively reduces covering degree of abrasive grains even at initial mixing times. The highest quantity of humectant is recommended in order to get better covering degree. Mixing time should be high enough to assure homogeneity degree of the mix but low enough to avoid excessive reduction of covering degree.

Study on the relevance of some of the description methods for plateau-honed surfaces

Abstract: Much work has been undertaken in recent years into the determination of a complete parametric description of plateau-honed surfaces with the intention of making a link between the process conditions, the surface topography and the required functional performances. Different advanced techniques (plateau/valleys decomposition using the normalized Abbott–Firestone curve or morphological operators, multiscale decomposition using continuous wavelets transform, etc) were proposed and applied in different studies. This paper re-examines the current state of developments and addresses a discussion on the relevance of the different proposed parameters and characterization methods for plateau-honed surfaces by considering the control loop manufacturing-characterization-function. The relevance of appropriate characterization is demonstrated through two experimental studies. They consider the effect of the most plateau honing process variables (the abrasive grit size and abrasive indentation velocity in finish-honing and the plateau-honing stage duration and pressure) on cylinder liner surface textures and hydrodynamic friction of the ring-pack system.

A High Resolution Surface Model for the Simulation of Honing Processes

Abstract: The demand for highly resistant surfaces is driven by the requirement for resource efficiency and rising environmental concerns. Finishing processes like long-stroke honing for the machining of boreholes of chuck components make it possible to create surfaces with favourable tribological properties. Since variations of process parameter values have complex effects on the resulting workpiece topography and its characteristic values, many experiments might be necessary to achieve certain properties. To avoid this, a simulation-based approach has been developed that relies on a high resolution model of the tool and the workpiece. For its calibration and validation, systematic investigations of a honing process and the machining parameter values have been conducted, and the measured surfaces are compared to the computed workpiece topographies.

Investigation of Variance of Roller Burnishing Parameters on Surface Quality by Taguchi Approach

Abstract: Surface roughness of engineering parts is very significant property that effectively influences on the wear and fatigue strength. There are many methods for improving surface quality of engineering parts such as grinding, lapping and honing. One of the methods for improving surface quality is Roller Burnishing. Roller Burnishing improves surface quality of engineering parts by means of Cold working. Roller Burnishing depends on many factors such as RPM of work piece, feed rate of Burnishing tool and the penetration depth of Roller burnishing tool into the work piece. At the present paper, we have tried to investigate the effective factors of Roller Burnishing and optimize them by means of Taguchi approach.

Comparison of Different Approaches to Force Controlled Precision Honing of Bores

Abstract: Honing is a machining process which can economically produce exact bores regarding form, geometry and surface quality. During the honing process, the tool, equipped with one or several abrasive honing stones, combines three movement components: rotation, oscillation in axial direction and radial feed movement of the honing stone. The feed movement is a decisive factor for the results of the honing process and can be controlled either by a gradual lining in fixed time intervals or by the regulation of the occurring forces. The presented studies show different approaches for the regulation of force controlled honing and their effects on the measured forces, the torque and the quality parameters of the process.

A Review On Internal Gear Honing

Abstract: In recent years a new method for hard gear finishing that produces a favorable surface texture and possibly allows gear correction was introduced. Among the techniques used in surface finish machining of gears, the internal gear honing process has been highlighted due to high efficiency in the finishing of hardened gears and ease of adjusting the involutes profile and incident angle in the counter-part. Material removal by the shavegrinding or gear honing process is the result of a rolling and sliding movement between the geared workpiece surface and the abrasive grits bonded in a resin, vitrified or metal tool matrix, shaped similar to an internal gear wheel. The internal gear honing process is used to eliminate errors that appear after the heat treatment on the tooth surface. Although the material and cutting speed of the tool are similar to the grinding process, honing the process simulates true cinematic movement of the mesh gear, which provides a better surface roughness compared to the hobbing, green-shaving and grinding. The present study is aimed at a deeper understanding of internal gear honing process, mechanism and advantages over other gear finishing processes. Results of the investigation shows that among all gear finishing processes internal gear honing is most efficient process of gear finishing provides an excellent surface finish of the sprockets compared to the other processes like green-shaving and grinding.

Vertical ultrasonic cylindrical honing device

Abstract: The invention discloses a honing device and particularly discloses a vertical ultrasonic cylindrical honing device. The vertical ultrasonic cylindrical honing device comprises a floating mechanism, a collecting device and a honing head. The floating mechanism comprises a fixing ring disposed on the outer side of an ejector rod. A sliding bush is disposed in the floating mechanism and is located outside the fixing ring. A linear bearing is disposed between the sliding bush and the fixing ring. A pull-up spring is disposed outside the sliding bush. The honing head comprises an inner part and an outer part. A circular wedging sleeve is arranged between the inner bottom of the outer part and the outer bottom of the inner part. A piezoelectric chip set is embedded in the circular wedging sleeve. A plurality of oilstone holders are evenly fixed on the lower inner wall of the inner part. An oilstone bar is fixed to each oilstone holder. The vertical ultrasonic cylindrical honing device allows the oilstones to vibrate radially (transversely), so that ultrasonic energy transmission chains are shortened and the oilstone bars are fast to replace. The vertical ultrasonic cylindrical honing device is especially applicable to processing of cylinders with small diameter and is available in forming overlapping curves on the surfaces of the cylinders.

Large Engine Cylinder Honing as a Contribution to Emissions Reduction

Abstract: As well as new combustion processes and aftertreatment, increasingly rigorous environmental protection regulations are also promoting advances in engine manufacturing techniques. These measures include optimised surfaces made possible using the most modern honing technologies, such as those already in widespread use in the manufacture of automotive engines. The transfer of these honing technologies to large high and medium speed engines is best achieved using new machining concepts.

Modular honing guide system

Abstract: A modular honing guide system comprised of interchangeable parts, having a multitude of configurations (FIGS. 1 A, 4 C, 8 A, 9 A, 10 P, 11 D, 12 H, 13 A, 14 A, 16 A, 17 A) for manually sharpening or honing a multitude of tool types used for but not limited to wood carving, wood working, fine art printmaking, jewelry making and metal work. Tools are honed on a planar abrasive surface, while a honing guide base is moved across a supporting work surface. A plurality of edge tool clamps can be mounted to a unified honing guide base system. With manual random motion or combined random motion and uniform rotational or rocking motion, a combined cutting edge and honing guide is moved across abrading and work surfaces respectively. A multitude of bevel, skew and cutting edge profiles are attained. System is an improvement over honing guides which are designed for specific or limited types of edge tools.

Design and Modeling of Fixture for Cylinder Liner Honing Operation

Abstract: Model of new fixture design is presented for cylinder liners honing operation to improve productivity and reduce the rejection rate on honing machine. In mass production of cylinder liners, the industrial honing involves abrasive finishing process, during that liners need to be fixed on honing machine, For that a new model of fixture setup relative to honing operation of cylinder liner is proposed, planned and modeled such that the liners can be held in form closure and totally immobilized. This paper uses newer and innovative design of present day manufacturing industries for locating, positioning, clamping, for uniforce clamping hydraulic clampings are used. Fixture design is one of the important factor that play a role in providing manufacturing processes with more productivity and have brought many benefits like reduced rejection. Fixtures are used in many manufacturing processes to locate, hold and support the work securely. While designing this paper, a good number of literature written on the subject by renowned authors are referred. The paper includes finished parts model and 3D assembled view of fixture using Pro/Engineer Wildfire.

Elastic suspension honing device

Abstract: The utility model belongs to the field of the honing technology and specifically relates to an elastic suspension honing device for clamping work pieces in hone machining The elastic suspension honing device comprises a base plate fixedly connected with honing equipment, a line rail fixedly connected with the base plate, a sliding block matched with the line rail in a sliding manner, an installing plate integrated with the sliding block, a limiting baffle installed on the base plate, a drive rod fixedly connected with the installing plate, a baffle configured on the installing plate, an O-shaped ring installed on the baffle, and an elastic suspension mechanism configured on the installing plate, the elastic suspension honing device is characterized in that the two baffles are distributed at the two ends of a work piece hole and fixedly connected to the installing hole; active gap is left between the baffles and the two ends of the hole of the work piece; the work piece is arranged on the elastic suspension mechanism and the middle of the baffle; under the elastic support of the elastic suspension mechanism, the work piece is balance to the gravity of the work piece; the axis of the work piece hole is coincided with that of a honing head; and the work piece can realize reciprocating reversion under the dragging of the two baffles and is linearly fed along the axis of the honing head The elastic suspension honing device has the characteristics of simple structure, convenient operation and capacities of reducing the influence caused by the work piece gravity and improving the honing machining precision of the hole