Kinematic Simulation of Material Removal at Single-pass Honing with Additional Oscillation

Abstract

The manufacturing process single-pass honing is mostly used when very high demands on the quality of bore holes must be met, especially in terms of shape and dimensional accuracy. Process features that contribute to these improvements in comparison to other manufacturing processes are very high tool rigidity and the bore hole filling tool. Unlike conventional honing tools, which require a honing machine or a special plug-in to expand the abrasive stones by an integrated mechanism, single-pass honing tools can be used with conventional tool holders. This is due to the fact that the abrasive stones are adjusted to the desired diameter before machining [1]. In single-pass honing most of the material is removed during the first plunge of the tool into the bore hole. This results in significant disadvantages in comparison to the conventional long-stroke honing, such as very high machining forces and torques, lower axial velocities and clogging of the chip space of abrasive stones. Previous investigations had shown that a significant reduction in machining forces and torques can be generated by overlaying the axial movement with an oscillation [2]. To analyse the effects of axial oscillations during single-pass honing a kinematic simulation of the material removal was developed. In this publication the basic geometrical and kinematical conditions of the manufacturing process as well as the composition of the developed simulation are depicted. A variety of plausibility checks were conducted to evaluate the quality of the simulation results. Finally the model is used to test several process parameters and their influence on the simulated work results.