Influence of superpositioned velocity components on process parameters and work results at single-pass-honing

• Applicant: Professor Dr.-Ing. Eckart Uhlmann
• Subject Area: Metal-Cutting and Abrasive Manufacturing Engineering
• Term: from 2018 to 2023
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 392314670

The manufacturing process Single-Pass-Honing is mostly used when, among other things very high demands are placed on the holes to be processed in terms of form and dimensional accuracy. Process features that contribute to these improvements in comparison to other manufacturing processes are on the one hand very high tool rigidity, and secondly, that the tool is filling the whole bore hole. Unlike conventional honing tools that require the presence of a honing machine or special plug-ins to expand the honing stones by an integrated mechanism the tools of Single-Pass-Honing can be used in commercially available machine tools, because the honing stones are fixed to the diameter to be manufactured before machining.During Single-Pass-Honing almost the entire workpiece material is cut during the first plunge of the tool into the cylinder, the so-called Intensivzerspanung. This process results in significant disadvantages in comparison to the long-stroke-honing, like very high machining forces and torques, lower axial velocities and in particular the addition of the chip space of honing stones. Significant disadvantages that results in comparison to the long-stroke-honing, are very high machining forces and torques, lower axial velocities, the loading of the chip space of honing stones with loose workpiece material and a flattening of the abrasive grains caused by the uniaxial load. Within the described research project it is planned to overcome these disadvantages by adequate methods.At previous investigations it was found that a significant reduction in machining forces and torques could be generated by a temporarily reversal movement of the honing tool. It can be assumed that the chip space of the honing stones was released by this reversal movement. Within the proposed research project it should be determined whether the systematic influencing of the tool movement has an effect to improve the process of Single-Pass-Honing during the Intensivzerspanung. By overlaying the axial and tangential velocities with particular oscillating components the loading direction can be influenced at the individual abrasive grains similar to the preliminary investigations. The main objective of the proposed research project is therefore to identify the effect of overlaying dynamic velocities on process parameters and work results in Single-Pass-Honing.

• DFG Programme: Research Grants