Modelling and Analysis of The Effect of Plateau Honing Operation on Cylinder Liners

Abstract

Honing is an abrasive procedure that removes material and creates grooves by employing three simultaneous motions of abrasive stones. Because honing is an abrasive operation, predicting the process outcome analytically is challenging. The steep peaks of a surface are eliminated during the plateau honing process, producing a reasonably plateau finish along with cross hatch pattern for retaining oil and increased bearing area. A cylinder liner is installed in an engine block to provide a cylindrical chamber where the piston may move extremely smooth. To obtain a honing pattern and good surface roughness, the machine setting plays an important role which includes many machine parameters like honing force, number of stokes, feed rate, processing time etc. So, in order to obtain an optimal machine set up, multiple trails on cylinder liners are done, which takes more time, and for each trail, one cylinder liner specimen is utilised, which results in the consumption of more cylinder liner solely for trail purposes. In this work, the key parameters effecting the surface roughness of cylinder liner are identified and optimal honing parameters (machine setup) are selected. FEA analysis is carried out to find the effect of pressure on the walls of cylinder liners. Based on the results of experiment, the optimal setting for honing machine is obtained for the selected surface roughness with less ovality and taper and also has less effect on cylinder liners.