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Article
Publication date: 2 March 2012

Damir S. Vrac, Leposava P. Sidjanin, Pavel P. Kovac and Sebastian S. Balos

The purpose of this paper is to explore the influence of tool kinematics parameters on surface roughness, productivity and cutting angle for grey cast iron cylinder liners…

Abstract

Purpose

The purpose of this paper is to explore the influence of tool kinematics parameters on surface roughness, productivity and cutting angle for grey cast iron cylinder liners machined by normal honing.

Design/methodology/approach

For experimental investigation, a long stroke honing system was used. Diamond and SiC tools were used, for pre‐ and finishing, respectively. The values of cutting parameters were varied within the following limits: cutting speed vs=0.931‐1.11 m/s; specific pressure of pre‐honing process pd=1.0‐1.4 N/mm2 and specific pressure of finishing honing process pz=0.2‐0.5 N/mm2. The analysis of dispersion was conducted for determining the mathematical model for cutting parameter influence on surface roughness and productivity.

Findings

Dispersion analysis proved that the most influential parameters on maximum roughness depth are cutting speed for D181 tool and specific pressure of finishing honing for D151 tool. The most influential parameter on productivity in the honing process with D181 and D151 tool is cutting speed.

Originality/value

The paper gives new information related to the normal honing optimization process. Normal honing offers the highest surface quality which is achieved by a low speed machining. However, that means also a relatively low productivity, demanding a thorough process optimization. Furthermore, normal honing is usually done by ECH pre‐honing and mechanical finishing honing, but in this paper, all‐mechanical honing was used for the same result, at a lower lost.

Details

Industrial Lubrication and Tribology, vol. 64 no. 2
Type: Research Article
ISSN: 0036-8792

Keywords

Article
Publication date: 27 September 2011

Damir S. Vrac, Leposava P. Sidjanin and Sebastian S. Balos

The aim of this paper was to confirm the hypothesis that it is possible to conduct normal honing by mechanical method, providing the prescribed quality of cylinder liners…

Abstract

Purpose

The aim of this paper was to confirm the hypothesis that it is possible to conduct normal honing by mechanical method, providing the prescribed quality of cylinder liners. For this, cutting parameter optimization is needed.

Design/methodology/approach

Normal honing was performed on grey cast iron with lamellar graphite and mostly pearlitic microstructure of metal matrix. Cutting speed, feed rate and specific pressure during metalworking were varied and accordingly, a mathematical model for processing of results by the least squares method was proposed. Surface texture was controlled by scanning electron microscope.

Findings

A mathematical model describing the influence of cutting speed, feed rate and specific pressure during metalworking was devised. At the same time, surface texture was adequate, with geometrically appropriate crosshatch pattern, without standing‐out material and mashed graphite lamellas.

Originality/value

It was found that normal honing may be done by mechanical means, providing exceptional quality of lubrication. The most influential metalworking parameter was shown to be specific pressure.

Details

Industrial Lubrication and Tribology, vol. 63 no. 6
Type: Research Article
ISSN: 0036-8792

Keywords

Article
Publication date: 4 March 2014

Damir Vrac, Leposava Sidjanin, Sebastian Balos and Pavel Kovac

In this paper, the influence of cutting regimes on surface texture and productivity of cylinder liner is shown, obtained by normal honing. Furthermore, normal honing power…

Abstract

Purpose

In this paper, the influence of cutting regimes on surface texture and productivity of cylinder liner is shown, obtained by normal honing. Furthermore, normal honing power and torque is discussed. The paper aims to discuss these issues.

Design/methodology/approach

Normal honing was done on grey cast iron cylinder liners. Both pre- and finishing honing were done by mechanical means, to achieve the required level of surface texture quality, traditionally achieved by a combination of electrochemical pre-honing and mechanical finishing honing. To determine the most influential parameter on normal honing, statistical mathematical model was devised. Surface texture was controlled by light microscope and scanning electron microscope.

Findings

Mathematical model describing the influence of cutting speed, feed rate and depth of cut has shown that the most influential parameter on maximum peak height, productivity and specific volume productivity was shown. The most influential parameter has shown to be cutting speed.

Practical implications

There are two practical implications of this work: this work is a further contribution of understanding normal honing and the influence of various parameters on the quality of normal honing, both in view of surface texture and productivity, as the main drawback of this method. This work offers useful information for honing system designers, as torque and power of normal honing are given.

Originality/value

Two main achievements are given in this paper: as the main drawback of normal honing is lower productivity, the optimization of honing parameters may to some extent resolve this problem. Lower productivity is the result of lower cutting speeds and pressures, which in turn, give normal honed surface a higher quality compared to plateau honing. Lower power and torque demand a lower energy demands, as well as a less complex honing machine which may lead to further savings.

Details

Industrial Lubrication and Tribology, vol. 66 no. 2
Type: Research Article
ISSN: 0036-8792

Keywords

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