Bore Cylindricity in Finish Cylinder Boring

[+] Author and Article Information
Lei Chen

Department of Mechanical Engineering University of Michigan, Ann Arbor, MI 48109

Juhchin A. Yang

Virtual Manufacturing Section Ford Motor Company, Livonia, MI 48150

Albert J. Shih

Department of Mechanical Engineering, and Department of Biomedical Engineering University of Michigan, Ann Arbor, MI, 48109

1Corresponding author.

ASME doi:10.1115/1.4039442 History: Received October 26, 2017; Revised January 24, 2018


Finish boring is a machining process to achieve the cylinder bore dimensional and geometrical accuracy. The bore cylindricity error sources, including the workpiece thermal expansion and deformation due to cutting and clamping forces, and spindle radial error motion, in finish boring were identified using combined experimental and finite element method (FEM) analysis. Experiments were conducted to measure the workpiece temperature, cutting and clamping forces, spindle error, and bore shape. FEM analysis of the workpiece temperature, thermal expansion, and deformation due to cutting and clamping forces was performed. The coordinate measurement machine (CMM) measurements of the bore after finish boring showed the 5.6 µm cylindricity and a broad spectrum from the 2nd to 10th harmonics. The FEM revealed effects of workpiece thermal expansion (1.7 µm cylindricity), deformation due to cutting force (0.8 µm cylindricity), and clamping force (1.9 µm cylindricity) on the finished bore and the dominance by the 1st to 3rd harmonics using the three-jaw fixture. The spindle synchronous radial error motion (3.2 µm cylindricity) was dominated by the 4th and higher order harmonics and matched well with the high (above the 4th) harmonics in CMM measurements (2.9 µm cylindricity). The spindle error was the dominant error source for bore cylindricity in this finish boring study, contributing to about half of the total cylindricity error.

Copyright (c) 2018 by ASME
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