Honing

About: Honing is a research topic. Over the lifetime, 3530 publications have been published within this topic receiving 17491 citations.

Analyzing the Effects of Three-Dimensional Cylinder Liner Surface Texture on Ring-Pack Performance With a Focus on Honing Groove Cross-Hatch Angle

Abstract: Frictional losses in the piston ring-pack of an engine account for approximately 20% of the total frictional losses within an engine. Although many non-conventional cylinder liner finishes are now being developed to reduce friction and oil consumption, the effects of the surface finish on ring-pack performance is not well understood. The current study focuses on modeling the effects of three-dimensional cylinder liner surface anisotropy on piston ring-pack performance. A rough surface flow simulation program was developed to generate flow factors and shear stress factors for three-dimensional cylinder liner surface textures. Rough surface contact between the ring and liner was modeled using a previously published methodology for asperity contact pressure estimation between actual rough surfaces. The surface specific flow factors, shear stress factors, and asperity contact model were used in conjunction with MIT’s previously developed ring-pack simulation program to predict the effects of different surface textures on ring-pack behavior. Specific attention was given to the effect of honing groove cross-hatch angle on piston ring-pack friction in a stationary natural gas engine application, and adverse effects on engine oil consumption and durability were also briefly considered. The modeling results suggest that ring-pack friction reduction is possible if the liner honing cross hatch angle is decreased by reducing the feed-to-speed ratio of the honing tool. Reducing the cross-hatch angle increased oil flow blockage and increased the lubricant’s effective viscosity during mixed lubrication. This allowed more load to be supported by hydrodynamic pressure, reducing ring-pack friction. However, there appeared to be a potential for increased oil consumption and scuffing tendency corresponding to a decrease in honing cross-hatch angle.Copyright © 2005 by ASME

Macroscopic simulation of the liner honing process

Abstract: The form quality, the roughness and the surface appearance produced by honing minimizes the friction of the piston in the liner. The process is however mechanically complex and the selection of the process parameters is currently based on empirical methods. The aim of this paper is thus to develop a macroscopic simulation environment of complete real honing cycles, which will help end-users during the setting-up. This virtual tool is based on a space–time discretization and a macroscopic cutting model taking into account local contacts between the workpiece and the abrasive tool. The space–time discretization allows representing the machine environment with the tool, the workpiece and the kinematics. Simulation results are finally validated by comparison with industrial experiments.

Identification of significant parameters and appropriate levels in honing of cylinder liners

Abstract: Surface topography of cylinder liners influences the functional behaviour of internal combustion engines. The cylinder liners after boring operation are subjected to rough, finish and plateau honing operations in which parameters such as rotary speed, reciprocating speed, pressure and honing time are selected on the basis of operator's experience. The present work is a comprehensive investigation carried out to identify the significant honing parameters and their values for different honing operations. The honing trials are carried out according to design of experiments. Before each operation, all cylinder liners are processed identically under conditions identified from the previous operation. Parameters considered for characterising the surface topography are roughness average (Ra) and all five bearing area parameters (Rpk, Rk, Rvk, Mr1 and Mr2). It is established in the present work that Ra can be replaced effectively by Rk in finish and plateau honing operations to control the final surface topography and these parameters (Ra, Rk) are influenced by honing pressure. For the most important bearing area parameter Mr2, the significant process parameters are medium honing time in finish honing and high reciprocating speed in plateau honing. These results are useful for controlling the honing operations during the manufacture of the cylinder liners.