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Research Papers

Optimization of Planar Honing Process for Surface Finish of Machine Tool Sliding Guideways

[+] Author and Article Information
Kory Chang

Advanced Research for Manufacturing Systems
(ARMS) Laboratory,
Department of Mechanical and
Aerospace Engineering,
University of California, Davis,
One Shields Avenue,
Davis, CA 95616
e-mail: kccchang@ucdavis.edu

Masakazu Soshi

Advanced Research for Manufacturing Systems
(ARMS) Laboratory,
Department of Mechanical and
Aerospace Engineering,
University of California, Davis,
One Shields Avenue,
Davis, CA 95616
e-mail: msoshi@ucdavis.edu

Manuscript received July 17, 2016; final manuscript received February 25, 2017; published online April 18, 2017. Assoc. Editor: Radu Pavel.

J. Manuf. Sci. Eng 139(7), 071015 (Apr 18, 2017) (10 pages) Paper No: MANU-16-1389; doi: 10.1115/1.4036224 History: Received July 17, 2016; Revised February 25, 2017

Sliding guideways are often used as the foundation for linear motion in computer numerical control (CNC) machine tools due to their high damping capabilities especially for heavy duty machining applications. However, the traditional manufacturing process with grinding is time-consuming, and the product’s sliding performance has not been optimized nor clearly understood. In order to increase productivity, a machining center based manufacturing method with cubic boron nitride (CBN) milling tools was introduced and tested by researchers. While greatly reducing manufacturing time and cost, a rougher milled surface, in comparison to traditional grinding, is a possible concern for the performance as well as the life of sliding guideways. In this study, a novel planar honing process was proposed as a postprocess of CBN milling to create a finish surface on hardened cast iron sliding guideways used for CNC machine tools. A design of experiment (DOE) was conducted to statistically understand significant factors in the machining process and their relationship with surface topography. Effective planar honing conditions were discovered and analyzed with three-dimensional (3D) and two-dimensional surface parameters.

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References

Figures

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Fig. 1

Traditional method of manufacturing sliding guideways compared to the proposed new method of manufacturing sliding guideways

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Fig. 2

The approach taken to evaluate CBN milling and planar honing on a machining center

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Fig. 3

Flex-Hone for rotors by Brushed Research Manufacturing

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Fig. 4

DMG Mori NV 7000 three-axis vertical milling center with six cast iron samples clamped onto workspace and lowered CBN face end mill

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Fig. 5

Experimental setup with dynamometer and honing tool

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Fig. 6

Average roughness, Sa, of cast iron samples in the design of experiment compared to milled and ground surfaces

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Fig. 7

Peak height, Sp, of cast iron samples in the design of experiment compared to milled and ground surfaces

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Fig. 8

Core roughness, Sk, of cast iron samples in the design of experiment compared to milled and ground surfaces

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Fig. 9

Areal material ratio of cast iron samples in the design of experiment compared to milled and ground surfaces

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Fig. 10

Abbott–Firestone curve for all the experimental runs in the optimization of planar honing design of experiment and a milled surface

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Fig. 11

Abbott–Firestone curve of run 7 in the optimization of planar honing design of experiment and a milled surface

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Fig. 12

Main effects plot for Sk depicting the differences between levels within each factor

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Fig. 13

SEM image of cast iron surface under run 7 conditions of the optimization of planar honing design of experiment

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Fig. 14

SEM image of cast iron surface after CBN face milling with 0.10 mm/tooth feed

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Fig. 15

Three-dimensional view of surface topography of run 7 sample

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Fig. 16

Profile view of surface topography of run 7 sample

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Fig. 17

Three-dimensional view of surface topography of CBN milled sample

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Fig. 18

Profile view of surface topography of CBN milled sample

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