Showing papers on "Honing published in 2020"

Theoretical and experimental investigations on nano-finishing of internal cylindrical surfaces with a newly developed rotational magnetorheological honing process:

Abstract: In the current scenario, the advanced industries are using highly sophisticated types of machinery. These types of machinery use numerous cylindrical components made with superior materials and tec...

Multi-responses optimization of finishing honing process for surface quality and production rate

Abstract: The finishing honing process is an effective machining to enhance surface properties. The objective of this work is to optimize the machining parameters, including the tangential speed (H), linear speed (L), and grit size (G) for minimizing the average roughness (Ra), maximum height roughness (Ry), and machining time (TM). The honing experiments were performed with the aids of an industrial machine and the Box–Behnken experimental matrix. The nonlinear relationships between machining parameters and honing responses were developed using response surface method models. Subsequently, two optimization techniques, including the desirability approach and non-dominated sorting genetic algorithm II (NSGA II), were used to solve the trade-off analysis among three technological responses and find the optimal factors. Finally, the machining time reductions were assessed in consideration of constrained roughness properties. The obtained results showed that surface roughness and machining time were strongly influenced by abrasive grit size, followed by the tangential speed and linear speed. The optimal values of the H, L, and G were 36.0 m/min, 9.5 m/min, and 220 FEPA, respectively. The reductions in the average roughness, maximum height roughness, and machining time are 53.13%, 8.93%, and 13.95%, respectively, as compared to common values used. Moreover, the genetic algorithm-based approach could be employed to produce reliable values in comparison with the desirability approach. The outcome is expected as a technical solution to enhance the surface properties and productivity of the finishing honing process.

Recent advances in ultraprecision abrasive machining processes

Abstract: Traditional approaches to understanding ultraprecision machining processes such as grinding, polishing, lapping, micromachining, machining, etc., have focused on developing analytical, semi-empirical and empirical models that seek to explain the output of processes based on many input variables. However, those models are not very well suited to providing inputs to develop improved abrasive products such as grinding wheels, lapping wheels, honing laps, coated abrasives, loose abrasives and their associated bonding systems and lubricants. In order to develop new products to improve ultraprecision processing of materials, it is necessary to focus on the mechanisms of microscopic interactions between abrasive products and the workpiece material. This paper reviews the current grinding theories and the methods employed to understand microscopic interactions due to cutting, plowing and sliding motions and how they can be used to develop new products using materials science principles that enhance and uniquely describe the removal of material in ultraprecision machining processes.

Experimental investigations and optimization of machining parameters for Magneto-rheological Abrasive Honing process

Abstract: Being an advancement of conventional honing method, Magneto-rheological Abrasive Honing (MRAH) process is one of the unconventional nano-finishing processes which has the capability of finishing th

Performance of laser surface textured cemented carbide tools during abrasive machining: Coating effects, surface integrity assessment and wear characterization

Abstract: Laser surface texturing (LST) and coating deposition are implemented on cemented carbide (WC-CoNi) tools to extent their application in abrasive-like machining processes. The topographic features of a conventional cubic boron nitride based honing stone are achieved by LST, whereas wear resistance is enhanced by deposition of a ceramic layer. Three tool types are considered here: uncoated and coated LST WC-CoNi tools, besides a honing stone used as reference. They are tested under abrasive-like cutting conditions using an in-house workbench and a workpiece made of 20MnCr5 steel. Wear resistance and mechanisms as well as surface integrity of the tools after cutting tests are evaluated. It is found that LST cemented carbide tools achieve similar material removal effectiveness to the honing stone. Furthermore, coated LST tool exhibits a better cutting capacity, in terms of machined workpieces with smoother surfaces and enhanced wear resistance. However, the cutting process using cemented carbide tools is not as stable as the one developed employing the honing stone. The different response is related to the tribological conditions of the cutting edges of the laser-shaped pyramids. Damage within constitutive microstructural phases is clearly reduced for the coated condition, although it is still directly related to geometrical complexity of the pyramids.

Analysis of the Possibility of Using Wavelet Transform to Assess the Condition of the Surface Layer of Elements with Flat-Top Structures

Abstract: The paper focused on a topic related to the possibilities of using wavelet analysis to evaluate the changes in the geometrical structures of the surfaces arising during the honing process with whetstones with variable granularity. The cylinder liners of the combustion engine are machined elements. The basics of the wavelet analysis and the differences between filtering with standardized filters (e.g., Gauss filter), Fourier analysis, and the analysis of the results obtained when measuring the surface roughness with other wavelets were described. Trials of honing four cylinder liners were carried out. Roughness measurements of 3D spatial structures of the prepared liners were made. The principle of selecting wavelets for roughness assessment of structures with cross-hatch pattern was described. Roughness structures generated on the honed surfaces of cylinder liners were assessed using Gaussian filtration and Morlet, Daubechies Db6, and Mexican hat wavelets. In order to demonstrate the differences generated when the Gaussian filtration and selected wavelets were used on surface structures, the surfaces obtained with the use of these filtering tools were subtracted from each other, which allowed obtaining information about the changes occurring on the assessed surfaces, which were generated after the use of various filtering tools. For the assessed surfaces, during the subtraction operation, the mean square error was calculated, informing about the degree of similarity of both compared surfaces. The result of the work carried out is the creation of basic recommendations for the selection of wavelets when assessing honed surfaces with different degrees of regularity of the traces generated on them.

Experimental investigation on surface quality in ultrasonic-assisted honing of 304 stainless steel

Abstract: Honing is a surface finishing technology, which plays an important role in improving the surface quality and working performance of workpieces. However, with the extensive application of hard-to-machine materials and the increasing requirement for the surface properties of workpieces, the performance of conventional honing (CH) is becoming more and more difficult to meet the production needs. The ultrasonic vibration provides a way to overcome the technological constraints of CH and improve the machined surface properties. To realise the ultrasonic vibration of honing stone, a slotted block horn was used as a vibration transmission component and a supporting component of honing stone in this study. Finite element method was used to analyse and optimise the block horn to improve the uniformity of the amplitude on the output surface, to provide stable and efficient vibration for the honing stone. In this study, the effects of processing parameters on surface roughness in CH and ultrasonic-assisted honing (UAH) of stainless steel SUS304 were studied. The results indicated that the application of ultrasonic vibration in honing made a significant contribution to the formation of a dense punctiform morphology and reduction of the defects of the workpiece surface. Moreover, interactions between ultrasonic vibration, speed of revolution, and honing time in UAH make the changes of surface roughness much different from the CH. On the whole, for UAH, it is a feasible approach to improve the surface roughness by using a smaller amplitude, increasing the speed of revolution appropriately, and extending honing time.

Investigation on the effect of honing parameters on cylindricity of engine cylinder liner

Abstract: The real challenge is to establish a calculation model to predict the cylindricity of the honed cylinder liner before honing. In this paper, the relationship between honing parameters and the cylindricity of the cylinder liner is investigated; then a novel prediction model of the cylindricity of honed cylinder liner is proposed by considering the effect of honing parameters such as honing pressure, oilstone particle size, and overrunning distance on the material removal amount. The cylindricity of the honed cylinder liner is determined by the proposed model combining with the spatial trajectory of honing oilstone. The honing processing with different parameters is performed to obtain the cylindricities of honed cylinder liner. The predicted results by the proposed model are in good agreement with the measured cylindricities. The results show that the overrunning distance has a greater effect on the cylindricity of the honed cylinder liner, and a better cylindricity can be obtained when the honing pressure is lower. When the overrunning distance is 20 to 30% of the length of the oilstone, the cylindricity of the honed cylinder liner is better.

Characterization of Lubricated Friction Behavior of Thermal Spray Steel Coatings in Comparison with Grey Cast Iron

Abstract: This work examines friction properties of smooth-honed thermal spray (TS) low carbon steel coatings produced on an Al-9.0% Si alloy using a plasma transferred wire arc (PTWA) method and an AISI 1010 wire used as feedstock in comparison with the ASM type D grey cast iron (CI) samples subjected to the same (smooth) honing process. CI samples prepared using a standard honing process were also tested for comparison. Reciprocating sliding tests were performed using a Cameron–Plint tribometer against CrN-coated counterfaces within a speed range of 0.06–1.20 m/s covering the boundary and mixed lubrication conditions. Stribeck curves were constructed to show the coefficient of friction (COF) variations with the ratio (λ) of lubricant film thickness to composite surface roughness of TS and CI samples at the mid-stroke position where sliding speeds and surface roughnesses were measured. Examination of the Stribeck curves showed that the TS coated surfaces provided lower COF values compared to CI surfaces given the same smooth honing treatment, e.g., for λ = 2.7 a COF of 0.029 was observed for TS and 0.035 for CI, whereas conventional honing of CI provided a COF of 0.047 under the same condition. Metallographic evidence was given for the surface features and formation of tribolayers on the contact surfaces. The arithmetic mean heights of the surfaces, Sa measured after the tests remained similar for the smooth-honed TS and CI samples. The low COF values of the TS samples were discussed in terms of the surface pores generated during their manufacturing process, and the high oil retention depth ratio (Svk/Sk) of the TS coated surfaces due to the presence of these pores.

A Novel Method of Obtaining Honing Tool Profile for Machining Gears With Profile Modifications

Abstract: In this study, a mathematical model of the honing process for helical gears with external teeth was developed. The proposed novel method of obtaining the two-parameter envelope of a family of surfaces proved useful in simulated machining by means of a tool with a profile deviation. Based on performed simulations and industrial applications, it was found that this method can be useful in predicting the accuracy of machined gear and therefore can be used in the design process of honing tool for high precision aerospace gears. For the example provided, the average absolute prediction error of machined tooth profile was 0.28 µm.

A Trending Nonconventional Hybrid Finishing/Machining Process

Abstract: In today’s era of hybrid machining, there is a continuous demand of highly precise dimensional products. The hybrid machining processes are gaining interest for the researchers to have more efficient and productive part in the segments of electronics, automotive, and aerospace industries where high accuracy and surface quality are of great concern. Different hybrid machining processes are being used for different purposes to increase finishing till micro- and nano-levels. From the past years, conventional finishing processes such as grinding and honing are generally used to finish the surface of these components. But still more machining efficiency and cost reduction is still under play. These problems can be resolved using magnetorheological (MR) finishing processes. These processes use MR polishing fluids which behave like semisolid fluid under the magnetic field with controlled finishing forces. This chapter emphasizes on the capability of various magnetically assisted finishing processes for various internal and external surfaces with their mechanism of material removal. The MR abrasive flow finishing (MRAFF) process is investigated for the internal cylindrical finishing of non-ferromagnetic specimens. Also, rotational-MRAFF (R-MRAFF) process is slightly modified to increase the process performance and to raise the shearing tendency of the abrasive particles for enhancing the surface roughness. Further, a novel ball-end MR finishing (BEMRF) process is developed for finishing the 3-D surfaces through BEMRF tool. Lastly, magnetorheological honing (MRH) process has been discussed that focused on finishing the internal surface of ferromagnetic specimens. KeywordsHybrid machining; Magnetorheological finishing processes; Ferrous material; Magnetorheological honing process.

The Proposition of an Automated Honing Cell with Advanced Monitoring

Abstract: Honing of holes allows for small shape deviation and a low value of a roughness profile parameter, e.g., Ra parameter. The honing process heats the workpiece and raises its temperature. The increase in temperature causes thermal deformations of the honed holes. The article proposes the construction of a honing cell, containing in addition to CNC honing machine: thermographic camera, sound intensity meter, and software for collecting and analyzing data received during machining. It was proposed that the level of sound intensity obtained during honing could be monitored continuously and that the images from a thermographic camera could be analyzed on-line. These analyses would be aimed at supervising honing along with the on-line correction of machining parameters. In addition to the oil cooler, the machining cell may have an automatic selection of the grain trajectory shape, with specified value of the radii of curvature of the abrasive grain trajectories, according to the wall thickness of the honed workpiece, which will result in reducing the temperature generated during honing. Automated honing cell can mostly increase honing process efficiency. Simulations in FlexSim showed the possibility of increasing the efficiency of the honing process more than 20 times.

An Analysis on the Parametric Optimization of Electrochemical Honing Process

Abstract: Electrochemical honing (ECH) is a nontraditional machining process hybridizing the conjoint benefits of electrochemical machining (ECM) and mechanical honing actions. In this process, maximum amoun...

Contact Pressure in Honing

Abstract: Contact in the honing of cylindrical holes is simulated. Nonlinear behavior of the mean contact pressure and the transfer coefficient is observed. These factors depend on the applied force and the surface relief, as well as the materials used in the tool and workpiece.

Influence of the Density of the Track Grid on the Surface Roughness in Raster Honing

Abstract: The influence of the density of the tool’s track grid (the raster cycloid) on the surface roughness of a cylindrical surface is studied experimentally. The resulting mathematical formulas permit calculation of the height of the surface irregularities with variation in the density of the track grid in the course of honing by abrasive bars of different grain size.

Honing machine discharging device for cylinder sleeve production

Abstract: The utility model relates to the technical field of cylinder sleeve production. The utility model discloses a honing machine discharging device for cylinder sleeve production. The honing device comprises a supporting base, a hydraulic rod, a rotating motor, a cylinder sleeve body and a honing piece. The top side of the support seat is welded with the bottom of the support frame; the bottom of thehydraulic rod penetrates through the top of the supporting frame and is fixedly connected with the supporting frame. The bottom of the hydraulic rod is fixedly connected with the rotating motor, an output shaft of the rotating motor is welded to the top of the fixing rod, the bottom of the fixing rod is welded to the top of the positioning mechanism, the air cylinder sleeve body is connected to the bottom of the positioning mechanism, the bottom of the air cylinder sleeve body is clamped in the honing piece, and the honing piece is fixedly connected to the top of the supporting base. The air cylinder sleeve body is conveniently and quickly positioned and disassembled through the positioning mechanism, fixation is firm, the air cylinder sleeve body is prevented from falling off when honingis conducted on the air cylinder sleeve body, and the air cylinder sleeve has the advantages that honing, disassembling and assembling are conducted on the air cylinder sleeve body conveniently, and labor intensity is low.

Capacity of globoidal gear-honing

Abstract: A capacity is characterized by a value of material removal per time unit. A globoidal gear-honing capacity was defined by general normal changing before and after processing. In the course of an experimental part fulfillment the removals were defined depending on the properties of material worked, the abrasive layer characteristics of a globoidal hone and working modes. The experimental results are presented in a graphical form.

High-precision honing device for inner wall of pipeline

Abstract: The invention discloses a high-precision honing device for the inner wall of a pipeline The high-precision honing device for the inner wall of the pipeline comprises a movable plate, wherein the center of the lower surface of the movable plate is connected with a power motor through a power motor welding plate, the output end of the power motor is fixedly connected with a transmission shaft, theend, far away from the power motor, of the transmission shaft is connected with a honing head body, a lead screw is inserted in each of the two ends of the movable plate and is in threaded connected with a lead screw nut, the lead screw nuts are fixed to the lower surface of the movable plate through lead screw nut fixing plates, and the lower ends of the lead screws are rotatably connected to a base frame through first bearings The high-precision honing device for the inner wall of the pipeline is simple in structure, convenient to use, capable of quite conveniently and accurately positioning the circle center axis of the pipeline, low in operation difficulty, novel and practical

Shaping tool for improving quality of cycloid hydraulic motor stator

Abstract: The utility model discloses a shaping tool for improving the quality of a cycloid hydraulic motor stator. The tool comprises a workpiece fixing structure, a workpiece and a tool body. The workpiece fixing structure comprises a press workbench. A tool base is installed on the press workbench. A tool base plate is mounted at the upper end of the tool base; workpieces are fixedly placed at the upperends of the working base plates; a cutting through hole is pre-formed in the middle of the workpiece; a cutting through hole is formed in advance, so that the cutter main body is conveniently insertedfor turning; conveniently positioning cutter main body, the numerical control honing cutter has the beneficial effects that the machining precision of parts is obviously improved, the honing of the original machining path is changed into the sectional cutting and extrusion treatment of a new process, the equipment investment is much less, the size consistency of the machined parts is high, the surface compactness of an extruded area is better, and the service life is longer. The machining efficiency is about minute/piece, and the machining time is not much different from honing time.