Showing papers on "Honing published in 2016"

Life Cycle and Sustainability of Abrasive Tools

Abstract: This monograph focuses on abrasive tools for grinding, polishing, honing, and lapping operations. The book describes the life cycle of abrasive tools from raw material processing of abrasive grits and bonding, manufacturing of monolithic or multi-layered tools, tool use to tool end-of-life. Moreover, this work highlights sustainability challenges including economic, environmental, social and technological aspects. The target audience primarily comprises research and industry experts in the field of manufacturing, but the book may also be beneficial for graduate students

Indirect model for roughness in rough honing processes based on artificial neural networks

Abstract: In the present paper an indirect model based on neural networks is presented for modelling the rough honing process. It allows obtaining values to be set for different process variables (linear speed, tangential speed, pressure of abrasive stones, grain size of abrasive and density of abrasive) as a function of required average roughness Ra. A multilayer perceptron (feedforward) with a backpropagation (BP) training system was used for defining neural networks. Several configurations were tested with different number of layers, number of neurons and type of transfer function. Best configuration for the network was searched by means of two different methods, trial and error and Taguchi design of experiments (DOE). Once best configuration was found, a network was defined by means of trial and error method for roughness parameters related to Abbott–Firestone curve, Rk, Rpk and Rvk.

Application of MCDM-Based TOPSIS Method for the Optimization of Multi Quality Characteristics of Modern Manufacturing Processes

Abstract: Optimization of non-conventional machining (NCM) processes viz. AJM, AWJM, EDM, WEDM, ECM, ECMM, LBM, PAC, etc. has always been an open research area for researchers. In recent manufacturing environment, almost all the NCM processes consist of a number of input and output to be considered together. The purpose of the present article is to highlight the application of a multi-criteria decision making (MCDM) based method called Technique of Order Preference by Similarity of Ideal Solution (TOPSIS) in optimization of some modern manufacturing processes (MMPs). In the present paper, seven different MMPs namely Electro Chemical Honing (ECH), Abrasive Water Jet Machining (AWJM), Abrasive Jet Machining (AJM), Laser Beam Machining (LBM), Plasma Arc Cutting (PAC), Laser Cutting (LC) and Electric Discharge Machining (EDM) were exemplified. The multiple outcomes of all the illustrated MMPs have been optimized simultaneously by using TOPSIS method. It is a simple, systematic, and logical technique which can be employed to obtain the best parametric combination of cutting parameters. It was observed that the results attained by using TOPSIS method were almost tie with those derived by past researchers. This proves the applicability and adaptability of the TOPSIS method while solving different MCDM-based problems in a real manufacturing system.

Effect of modified drill point geometry on drilling quality characteristics of metal matrix composite (MMCs)

Abstract: The abrasive reinforcement present in ‘Metal matrix composites’ (MMCs) is responsible for numerous machining challenges for the research fraternity. The increase in tool wear, burr formation, surface roughness, and increase in cutting forces are few of such machining challenges during the drilling of MMCs. The present research investigation explores the effect of change in drill point geometry on the drilling Quality characteristics (QCs) of the drilled hole wall. The drilling QCs under investigation are, Specific cutting pressure (SCP) and Surface roughness (SR) of the drilled hole wall. The levels of the input process parameters for optimum values of the output responses were established by Taguchi’s methodology. SEM images and contour plots of drilled hole wall have been used to qualitatively explain the drilling behavior of MMCs. The chip formation mechanism observed during drilling establishes the cutting behavior of the different cutting edges of the modified drill point geometry. It has been observed that the single conical chips were produced by primary cutting edge and single ring type chips were produced by secondary cutting edge. The step diameter is the main factor which influences the SCP followed by the feed and point angle. The surface roughness of the drilled hole wall has been governed by the cutting speed, feed and step diameter. Burnishing and honing effect were observed on the drilled hole wall surface because of entrapped free SiC particles using SEM.

Investigations on surface quality improvement of straight bevel gears by electrochemical honing process

Abstract: Electrochemical honing is a hybrid finishing process combining advantages and simultaneously overcoming the individual limitations of electrochemical machining and mechanical honing. Finishing of c...

Effect of honing gear hardness on microgeometry and surface quality improvement of straight bevel gears in PECH process

Abstract: The present research is directed to investigate pulsed electrochemical honing (PECH) of bevel gears. Honing gears made of 20MnCr5 alloy steel were case hardened (found to have Vicker’s hardness value as 900 HV) using glow discharge plasma nitriding process. The hardened honing gear was used to finish workpiece gear made of same material. Unhardened honing gear having Vicker’s hardness value as 630 HV was also used to finish workpiece gears for comparison. The microgeometry of the workpiece bevel gear was evaluated using deviations in pitch, run-out and topology, while surface quality was evaluated in terms of surface finish, microstructure and microhardness. This research proves that the honing gear hardness is an important aspect for improving the surface quality and microgeometry of the gears. These improvements will enhance service life and operating performance of the PECH-finished gears and will reduce their noise level and chances of their premature failures.

Investigations on surface quality, surface integrity and specific energy consumption in finishing of straight bevel gears by PECH process

Abstract: Applications of electrochemical finishing (ECF) and its hybridization with the other mechanical processes are attracting the interest for finishing various engineering components due to their flexible behavior. Pulse electrochemical honing (PECH) is a hybrid finishing process which provides benefits of pulsed ECF and mechanical honing processes simultaneously to improve the surface quality and surface integrity of the workpiece components. The present study is aimed at studying the effects of the three most important PECH parameters namely applied voltage, electrolyte composition, and electrolyte concentration on the aspects of surface quality (i.e., surface roughness, waviness, material ratio curve), of surface integrity (i.e., wear indicators, microhardness, microstructure, and residual stresses), and of finishing productivity (i.e., material removal rate) of the straight bevel gears made of alloy steel (20MnCr5) by the PECH process. An aqueous mixture of non-passivating electrolyte (i.e., NaCl) and passivating electrolyte NaNO3 was used as electrolyte. The three input parameters were varied at three levels to identify their optimum combination using preidentified optimum values of other process parameters. The identified optimum values are 75 % NaCl + 25 % NaNO3 as electrolyte composition, 7.5 % as electrolyte concentration, and 8 V as applied voltage while finishing the bevel gears for an optimum duration of 6 min. Results have shown significant improvement in surface roughness (i.e., the average surface roughness value reduced from 2.84 to 1.03 μm; the maximum surface roughness value decreased from 24.59 to 6.06 μm; depth of roughness reduced from 13.51 to 5.42 μm) and surface waviness (i.e., average waviness reduced from 5.04 to 1.58 μm; maximum waviness reduced from 30.17 to 5.52 μm). Analysis of microstructure, residual stresses, material ratio curve, wear indicators, and microhardness of the PECH-finished gears also showed significant improvement in them compared to an unfinished gear. Comparative analysis of energy consumption in PECH and ECH processes found that PECH consumes 25 % less energy than the ECH process does for achieving the same level of finishing. The present work proves that PECH is a superior, productive, and more energy-efficient process compared to the conventional gear finishing processes and ECH process.

Preparation method and use of self-sharpening sintered abrasive material

Abstract: The invention discloses a preparation method and a use of a self-sharpening sintered abrasive material. The preparation method is characterized in that the excellent sintered abrasive material is prepared by processes such as metering needed raw materials in percentage by weight, mixing the raw materials, cementing the raw materials, crushing the raw materials, grading the raw materials, sintering the raw materials and post-processing the raw materials. The sintered abrasive material has proper self-sharpening property, so that large sintered particles does not drop entirely in a grinding process; a binding agent among small raw material particles inside the sintered abrasive material has fatigue rupture, loses efficiency and is further crushed, so that the original small abrasive particles constituting the sintered abrasive material drop one by one. The sintered abrasive material provided by the invention has good self-sharpening property, is beneficial for stabilizing the processing efficiency and increasing an abrasive material usage rate, can be used in processing processes such as grinding, grinding and polishing, honing and saw-cutting, also can be used for preparing finished product tools such as a grinding wheel, a grinding mat, a honing head and a saw blade. The method provided by the invention has the advantages of being simple in process, high in yield, low in cost and the like.

Surface Topography Quantification of Super Hard Abrasive Tools by Laser Scanning Microscopy

Abstract: Non-conventional super hard abrasive tools are made of composite materials containing super hard grains, eg, diamond or cubic boron nitride (CBN) grains, bound by a metallic constitutive phase These tools are usually produced by means of sintering, and are widely applied in the abrasive machining processes of modern manufacturing, especially in precision machining The abrasive grains, which induce the material removal processes, are embedded in the metallic binder They emerge as a consequence of self-dressing, resulting in a self-sharping effect Therefore, the cutting surface of the tool displays an irregular topography Quantification of surface topography scenario may supply valuable information to evaluate and understand its correlation to wear mechanisms In this study, an experimental protocol consisting of five steps: specimen preparation, surface scanning, image assembly, image digital processing and surface quantification, was proposed and validated by characterizing two CBN honing tools used for precision machining: B151/L2/2010/50 (B151) and B91/128/x44/35 (B91) CBN honing stones It involved the use of laser scanning microscopy and digital imaging processing for assessing significant dimensional, geometrical, and positional properties of CBN grains at the surface of super hard abrasive tools It was shown that surface topography quantification is an effective method to evaluate and obtain the defined parameters However, smaller grains may require images with higher resolution; thus, scanning must be refined Finally, a critical comparative analysis of the experimental results attained for the studied tools pointed out honing stone B91 as more appropriated than B151 one for achieving a higher machining quality of the workpiece

Taguchi Design of Experiment for the Optimization of Electrochemical Polishing of Metal Additive Manufacturing Components

Abstract: 3D Printing (Additive Manufacturing, AM) offers benefits such as lower costs, easier customization and creating complex functional products. However, utilization of AM components in the engineering applications may be severely limited by the high surface roughness. For most industrial uses the high surface roughness can cause stress concentrations, premature failure, and corrosion susceptibility. Unfortunately, conventional surface reduction processes like machining, extrude honing, and sandblasting, may not be feasible for the complex AM components. This research focused on exploring electropolishing as a viable surface smoothing approach for the AM components. However, electropolishing is a multivariable process and requires extensive parameter optimization. We have employed Taguchi’s design of experiment to find the suitable combination of electropolishing parameters. Our Taguchi analysis yielded a set of optimum experimental parameters for the electropolishing of steel AM components. This experimental process reduced the roughness of AM component surfaces as much as ∼63%.Copyright © 2016 by ASME

Manufacturing and sustainability of bonding systems for grinding tools

Abstract: Grinding and honing processes are quality-defining operations in the production of many modern products. Process performance and product quality are contingent on selecting the correct abrasive tool for a specific application. Thus, tools with different bonding systems are used, namely resin bonded tools, vitrified bonded tools, and metallic bonded tools. Tool manufacturers have great knowledge in the choice and intricate production of these bond types and their countless variants. Most bond systems pass through mixing, forming, pressing, heat treatment, and post-processing steps. Single-layer metallic bonds can be generated by electroplating or brazing processes. This article reviews the manufacturing of tools with different bonding systems and discusses their ingredients. Furthermore, the economic, environmental and social dimension of tool production and tool use are considered to understand sustainability issues of different bond types. The review of tool manufacturing is necessary to enable informed life cycle assessments or other sustainability analyses for grinding or honing.

A Study on Characteristics of Parameters Influencing Internal Grinding Process with MRR

Abstract: Objective: To generate the information about the process of internal grinding applied to envisage the grinding performance and accomplish the optimal operating procedure characteristics. In recent engineering and technology surface finish and precision are playing a major role in the manufacturing organizations. Method/Analysis: Different methods such as burnishing, honing, lapping and grinding are exercised for accomplishing good quality of surface finish. Grinding is the appropriate method for improving the surface finish and precision concurrently between all of those constraints. Recently lot of researches has been carried out on surface grinding process, but only few articles were elaborately described about the internal grinding procedure. In view of the fact the internal grinding processes was chosen as a main tool to characterize throughout this study. Findings: Similar to surface grinding various process parameters are used to get high surface finish and it could be achieved for the various components. This article relating the possibilities to get greater surface finish in internal grinding process and also it demonstrates the machining parameters involved in this process. Application/ Improvements: The machining parameters involved in these abrasive machining technologies were speed, feed, depth of cut and material removal rate and also these constraints were considered throughout the theoretical investigation.

Preparation method of mixed ultra-hard honing oil stone

Abstract: The invention relates to the technical field of ultra-hard honing, in particular to a preparation method of a mixed ultra-hard honing oil stone. The preparation method of the mixed ultra-hard honing oil stone is characterized in that diamond with the surface being subjected to tungsten-plating metallization and cubic boron nitride (CBN) with the surface being subjected to tungsten-plating metallization are used for preparing the honing oil stone as abrasive materials. The preparation method comprises the steps that firstly, the molten salt process and magnetron sputtering tungsten-plating pretreatment are conducted on diamond abrasive particles and CBN abrasive particles; secondly, the pretreated abrasive particles and metal bonding agent powder are subjected to ball milling after being mixed according to a certain proportion; and thirdly, mixed powder subjected to ball milling is placed in a graphite mold to be hot-pressed and sintered or is placed in a steel mold to be pressed into a blank, and non-pressure compacting sintering is conducted in the reducing atmosphere. The honing oil stone prepared through the preparation method has the advantages of being high in strength and hardness, high in honing efficiency, high in self-sharpness, long in service life and the like.

Manufacturing method for diamond honing oilstone

Abstract: The invention relates to the technical field of superhard honing, in particular to a manufacturing method for tungsten-plated diamond honing oilstone. The manufacturing method is characterized in that diamond subject to surface metallization treatment serves as an abrasive material to prepare the honing oilstone. The manufacturing method includes the steps that diamond particles are subject to tungsten-plated pretreatment, and the pretreated diamond particles and a metallic bond are mixed according to a certain proportion to be subject to ball milling; and ball-milled mixing powder is placed into a graphite die to be subject to hot pressing sintering, or arranged in a steel die to be pressed into a green body, and pressureless sintering is carried out in a reducing atmosphere. The diamond honing oilstone manufactured through the method has the beneficial effects of being high in intensity, hardness, grinding efficiency and self-sharpening performance, long in service life, low in process cost, easy and convenient in process and the like.

A Quality Function Deployment-Based Model for Cutting Fluid Selection

Abstract: Cutting fluid is applied for numerous reasons while machining a workpiece, like increasing tool life, minimizing workpiece thermal deformation, enhancing surface finish, flushing away chips from cutting surface, and so on. Hence, choosing a proper cutting fluid for a specific machining application becomes important for enhanced efficiency and effectiveness of a manufacturing process. Cutting fluid selection is a complex procedure as the decision depends on many complicated interactions, including work material’s machinability, rigorousness of operation, cutting tool material, metallurgical, chemical, and human compatibility, reliability and stability of fluid, and cost. In this paper, a decision making model is developed based on quality function deployment technique with a view to respond to the complex character of cutting fluid selection problem and facilitate judicious selection of cutting fluid from a comprehensive list of available alternatives. In the first example, HD-CUTSOL is recognized as the most suitable cutting fluid for drilling holes in titanium alloy with tungsten carbide tool and in the second example, for performing honing operation on stainless steel alloy with cubic boron nitride tool, CF5 emerges out as the best honing fluid. Implementation of this model would result in cost reduction through decreased manpower requirement, enhanced workforce efficiency, and efficient information exploitation.

Experimental investigations on redefining the surface quality of bevel gears by pulsed electrochemical honing

Abstract: This paper reports on the influence of electrolyte flow rate and rotary speed of workpiece on the quality of straight bevel gears finished by a pulsed electrochemical honing process. Electrolyte flow rate was varied at four levels and rotary speed at three levels. The quality of bevel gear was studied in terms of the percentage variations in three surface roughness parameters (i.e. centre line roughness, maximum height of roughness and average maximum height of roughness), microgeometry parameters (i.e. variation in pitch and runout) and surface topography (i.e. vertical deviation from the ideal flank surface of gear tooth). Pre-identified values of electrolyte composition, pulse-on time, pulse-off time and finishing time were used. Microstructure and microhardness of the best finished gear were also studied. The optimised values of electrolyte flow rate (20 Lpm) and rotary speed of workpiece gear (40 rpm) yielded significant percentage enhancements in surface roughness parameters i.e. 62.45% in Ra, 60.58...

Machining technology for small deep step hole of high-precision medical apparatus and instrument

Abstract: The invention relates to a machining technology for a small deep step hole of a high-precision medical apparatus and instrument, and belongs to the technical field of product machining of the medical apparatus and instrument. The technology mainly comprises center through hole drilling, outer circle turning, boring through a grinding head assembly, honing, step milling, electropolishing and the like. The defects that when a traditional boring cutter carries out boring, the boring cutter is likely to be broken, the boring roughness is large, the machining efficiency is low, and the machining cost is high are mainly overcome.

Grinding force model for worm-shaped grinding wheel gear grinding

Abstract: The invention relates to a grinding force model for worm-shaped grinding wheel gear grinding, and belongs to the field of gear machine manufacturing. On the basis of a G.Wener grinding force model, the invention provides a new grinding force model for the worm-shaped grinding wheel gear grinding. Firstly, an approximate model is established according to the relationship of the geometrical shape and the speed of a honing wheel and a workpiece on a contact point in a worm-shaped grinding wheel gear grinding process; secondly, establishing a cuttings model on the basis of the approximate model, and calculating speed, grinding thickness and equivalent diameter in a grinding process; and finally, on the basis of the approximate model, establishing an intermedian-gear gear honing grinding force model. The grinding force model is suitable for the worm gear grinding and intermedian-gear gear honing processing method. The method is suitable for calculating grinding force in the gear grinding processing which adopts a worm-shaped grinding wheel and comprises a worm grinding wheel gear grinding method and an intermedian-gear gear honing processing method. The method makes a gear grinding process be approximate into an excircle grinding process so as to simplify a calculation process and fill up the blank in the grinding force model for the worm-shaped grinding wheel gear grinding.

Methodology to Improve the Cylindricity of Engine Cylinder Bore by Honing

Abstract: Cylindricity of engine cylinder bore is identified as one of crucial factors to exert great influence on engine performance such as piston friction and wear, energy consumption and emission. Cylindricity at macroscopic level as well as surface roughness at micro-level such as peak roughness, core roughness and valley roughness for engine cylinder bore is typically generated by honing operation. However, the selection of the process parameters of honing is currently based on empirical methods since honing is mechanically complex. It thus makes a significance to analytically investigate honing operation to significantly improve the cylindricity of engine cylinder bore based on its function requirements. This research aims to explore the methodology on achieving the desired cylindricity for engine cylinder bore through several approaches including simulating honing motion trajectory, improving honing head structure, coordinating honing with its previous boring operation, and optimizing honing parameters including honing speed, feed rate, overrunning distance. This research aims to provide a systematical thinking to achieve macro-geometrical features in honing engine cylinder bore and a theoretical approach for the selection and optimization of honing process parameters.Copyright © 2016 by ASME