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Research Papers

Methodology to Improve the Cylindricity of Engine Cylinder Bore by Honing

[+] Author and Article Information
Xueping Zhang

School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: zhangxp@sjtu.edu.cn

Xiaoqing Wang, Zhenqiang Yao, Lifeng Xi

School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China

Daming Wang, Xiaojuan Wang

SAIC GM Wuling Automobile Co. Ltd,
Liuzhou 545007, Guangxi, China

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received August 17, 2016; final manuscript received September 1, 2016; published online October 3, 2016. Editor: Y. Lawrence Yao.

J. Manuf. Sci. Eng 139(3), 031008 (Oct 03, 2016) (10 pages) Paper No: MANU-16-1440; doi: 10.1115/1.4034622 History: Received August 17, 2016; Revised September 01, 2016

Cylindricity of engine cylinder bore is identified as one of the crucial factors to exert great influence on engine performance including piston friction and wear, energy consumption, and gas emission. Cylindricity at macroscopic level as well as surface roughness at microscopic level such as peak roughness, core roughness, and valley roughness of engine cylinder bore is typically generated by honing operations. However, the selection of the process parameters of honing is currently based on empirical methods since honing is mechanically complex process. It thus makes a significance to analytically investigate honing operation to effectively improve the cylindricity of engine cylinder bore based on its functional 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 cylinder bore honing with its previous boring operation, and optimizing honing parameters such as honing velocity, stroke speed, and overrunning distance. The research presents a systematical thinking to achieve macrogeometrical features in the honing of engine cylinder bore and a theoretical approach for the successful selection and optimization of honing process parameters.

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Figures

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Fig. 1

Honing principle and crosshatch pattern illustration

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Fig. 2

The principle of cylindricity generation in honing: (a) honing trajectory, (b) 2D model of honing trajectory, (c) fuzzy processing model, (d) model of the number of honing trajectory, (e) material removal model, and (f) cylindricity of honed cylinder bore

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Fig. 3

Trajectory of honing stone center point along cylinder bore during one complete upstroke and down stroke

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Fig. 4

Modeling trajectory of honing stone center point along cylinder bore

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Fig. 5

Modeling the superimposition of trajectory of honing stone

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Fig. 6

Modeling the trajectories of four honing stones during bore honing operation

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Fig. 7

Description of honing stone trajectory: (a) two honing stones movement, (b) overlapped area of two honing stones, and (c) material removed area

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Fig. 8

Discretization of cylinder bore and its 2D deployment

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Fig. 9

Contact area variation as honing stone against cylinder bore

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Fig. 10

Indentation depth model for one single abrasive in honing

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Fig. 11

Estimation of average distance between abrasives

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Fig. 12

Simulation procedure of bore honing operation

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Fig. 13

Predicting the MRR and the cylindricity of cylinder bore by honing operation

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Fig. 14

Bore honing experimental system: (a) testing configuration and (b) cylinder bore and tested locations

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Fig. 15

Cylindricity measurement system and testing principle: (a) measurement system and (b) measurement locations

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Fig. 16

The principle of drum shape generation of cylindricity: (a) honing trajectory simulation and (b) drum shape cylindricity

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Fig. 17

Improvement principle of drum type cylindricity by changing honing stone structure: (a) traditional honing head, (b) improved honing head structure, (c) the trajectories of initial and improved honing head structure, (d) improved honing trajectory simulation, and (e) improved drum type cylindricity

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Fig. 18

Improvement mechanism of macroscopic cylindricity by coordinating boring and honing operations sequentially

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Fig. 19

Cylinder bore honing parameters illustration

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Fig. 20

Typical macroscopic cylindricity: (a) drum type, (b) cone type, (c) tube type, and (d) waist type

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Fig. 21

The effects of velocity of honing head, stroke speed, and overrunning distance on the trajectory of bore honing operation: (a,b) honing velocity, (c,d) stroke speed, and (e,f) overrunning distances: (a) w = 219 r/min, (b) w = 274 r/min, (c) v = 47 m/min, (d) v = 25 m/min, (e) (l1 + l2)=53 mm, and (f) (l1 + l2) = 110 mm

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