Method of the Environmentally Friendly Dry Single-Pass Honing with Use of the Superimposed Low Frequency Oscillations
1
Institute for Machine Tools and Factory Management (IWF), Technische Universität Berlin, Germany
2
Fraunhofer Institute for Production Systems and Design Technology (IPK), Fraunhofer, Germany
Submission date: 2023-04-18
Final revision date: 2023-08-08
Acceptance date: 2023-08-19
Online publication date: 2023-08-24
Publication date: 2023-09-30
Corresponding author
Rozek André
Institute for Machine Tools and Factory Management, Technische Universität Berlin, Pascalstraße 8-9, 10587, Berlin, Germany
Institute for Machine Tools and Factory Management, Technische Universität Berlin, Pascalstraße 8-9, 10587, Berlin, Germany
Journal of Machine Engineering 2023;23(3):116-129
KEYWORDS
TOPICS
ABSTRACT
Single-pass honing is used as a finishing process to meet high demands regarding form and dimensional accuracy of drilled holes. The disadvantages of single-pass honing compared to the conventional long-stroke honing are high process forces and torques as well as an increased risk of chip space clogging of the abrasive stones. Following this, the oscillation-superimposed single-pass honing without cutting fluid has been conducted in this work, which is promising when it comes to the environmentally friendly improvement of machining processes. It was shown that the omitted lubrication and flushing effect of the contact zone between the tool and the workpiece could be compensated with the aid of the superimposed oscillations. The process forces of the dry honing process are up to 37 % lower compared to the conventional process, the height of the surface profile Rz decreases by 33 % and the form deviations decrease up to 47 %. Hence, the new method allows the saving of resources, while improving the work results.
REFERENCES (20)
1.
KLOCKE F., 2009, Manufacturing Processes 2 – Grinding, Honing, Lapping, 1st ed. Heidelberg, Springer.
2.
DAVIM J.P., 2008, Machining – Fundamentals and Recent Advances, 1st ed. London, Springer.
3.
SARIKAYA M., GUPTA M.K., TOMAZ I., DANISH M., MIA M., RUBAIEE S., JAMIL M., PIMENOV D.Y., NAVNEET K., 2021, Cooling Techniques to Improve the Machinability and Sustainability F Light-Weight Alloys: A State-of-the-Art Review, J. Manuf. Process., 62, 179–201.
4.
KROLCZYK G.M., MARUDA R.W., KROLCZYK J.B., WOJCIECHOWSKI S., MIA M., NIESLONY P., BUDZIK G., 2019, Ecological Trends in Machining as a Key Factor in Sustainable Production: A Review, J. Clean. Prod., 218, 601–615.
5.
SINGH G., AGGARWAK V., SINGH S., 2020, Critical Review on Ecological, Economical and Technological aspects of Minimum Quantity Lubrication towards Sustainable Machining, J. Clean. Prod., 271.
6.
WEINERT K., INASAKI I., SUTHERLAND J.W., WAKABAYASHI W., 2004, Dry Machining and Minimum Quantity Lubrication, CIRP Annals, 53/2, 511–537.
7.
CHINCHANIKAR S., KORE S.S., TOMAZ I., HUJARE P., 2021, A Review on Nanofluids in Minimum Quantity Lubrication Machining, J. Manuf. Process., 68, 56–70.
8.
KAPPMEYER G., 1997, Dornhonen mit Ultraschallunterstützung, Jahrbuch Schleifen, Honen, Läppen und Polieren, Essen, Vulkan, 475–489.
9.
FLORES G., 1992, Qualitätsverbesserung von Bohrungen durch Hochfrequenzhonen, VDI-Z, 134, 94–102.
10.
MA K., ZHU X., CUI X., WANG J., YU R., XIAO L., ALAMIR M., YE L., LI X., 2020, Experimental Investigation on Surface Quality in Ultrasonic-Assisted Honing of 304 Stainless Steel, Precis. Eng., 63, 148–158.
11.
MANSORI M.E., GOELDEL B., SABRI L., 2013, Performance Impact of Honing Dynamics on Surface Finish of Precoated Cylinder Bores, Surface & Coatings Technology, 215, 334–339.
12.
BABY A.K., RAJENDRAKUMAR P.K., DEEPAK LAWRENCE K., 2022, Influence of Honing Angle on Tribological Behaviour of Cylinder Liner-Piston Ring Pair: Experimental Investigation, Tribology International, 167, https://doi.org/10.1016/j.trib....
13.
BO Z., CHUANSHAO L., GUOFU G., FENG J., 2002, Surface Characteristics in the Ultrasonic Ductile Honing of ZrO2 Ceramics Using Coarse Grids, Journal of Materials Processing Technology, 123/1, 54–60.
14.
ZHU X.S., XU K.W., ZHAO B., MA D.Z., 2002, Experimental an Theoretical Research on ‘Local Resonance’ in an Ultrasonic Honing System, Journal of Materials Processing Technology, 129/1–3, 207–2011.
15.
UHLMANN E., ZIMMERMANN S., THALAU J., 2020, Dornhonen mit induzierten Schwingungen, wt Werkstatts technik online, 110, 471–477.
16.
UHLMANN E., ROZEK A., 2022, Influence of Superimposed Low Frequency Oscillations on Single-Pass Honing of Long-Chipping Steel, Proc.. CIRP, 108, 607–612.
17.
ZIMMERMANN S., UHLMANN E.. 2018, Kinematic Simulation of Material Removal at Single-pass Honing with Additional Oscillation, Schmitt R, Schuh G, editors, Advances in Production Research, WGP, 19–20, Aachen, Germany, 381 390.
18.
GIWERZEW A., 2003, Spanbildungsmechanismen und tribologisches Prozessverhalten beim Schleifen mit niedrigen Schnittgeschwindigkeiten, Forschungsberichte aus der Stiftung Institut für Werkstofftechnik Bremen, Dissertation, Universität Bremen, Aachen, Shaker.
19.
ZAPP M., 1998, Ultraschallunterstütztes Schleifen von Hochleistungskeramik – Ein Beitrag zur gezielten Beeinflussung der Eigenschaften von Bauteilen durch eine ganzheitliche Prozeßkettenbetrachtung, FBK Produktionstechnische Berichte, Dissertation, Universität Kaiserslautern, Kaiserslautern, ZBT-Foto-Repro-Druck.
20.
LYPOVKA P., 2018, Werkzeug- und prozessseitige Grundlagen des Schienenschleifens unter Berücksichtigung der Schienentemperatur und der Wechselwirkung mit dem Einsatzverhalten der Schiene, Berichte aus dem Produktionstechnischen Zentrum Berlin. Dissertation, Technische Universität Berlin, Stuttgart, Fraunhofer IRB.
| eISSN: | 2391-8071 |
| ISSN: | 1895-7595 |
