Abstract
This study focuses on obtaining regression models for material removal rate and tool wear in rough honing processes. For this purpose, experimental tests were carried out according to a central composite design of experiments. Five different parameters were varied: grain size or particle size of abrasive, density of abrasive or abrasive concentration, pressure of the stones against the cylinder internal surface, tangential speed (in this case, corresponding to the rotation speed of the cylinder), and linear speed of the honing head. In addition, multi-objective optimization was carried out with the aim of maximizing the material removal rate and minimizing tool wear. The results show that, within the range studied, the material removal rate depends mainly on tangential speed, followed by grain size and pressure. Tool wear is directly influenced by density of abrasive, followed by pressure, tangential speed, and grain size. According to the multi-objective optimization, if the two responses are given the same importance, it is recommended that high grain size, high density, high tangential speed, and low pressure be selected. Linear speed has less influence on both responses studied. If the material removal rate is considered to be more preponderant than tool wear, then the same values should be considered, except for high pressure. If tool wear is preponderant, then lower grain size of 128 (ISO 6106) should be selected, and lower tangential speed of approximately 166 min−1. The other variables, density and pressure, would not change significantly from the first situation.
Highlights
In the honing process, material is removed from the internal surface of cylinders by means of abrasive stones, which are attached to a honing head
This study focuses on obtaining regression models for material removal rate and tool wear in rough honing processes
Linear regression models were obtained for the material removal rate and tool wear in rough honing processes, considering five different variables: grain size, density of abrasive, pressure, linear speed, and tangential speed
Summary
Material is removed from the internal surface of cylinders by means of abrasive stones, which are attached to a honing head. The honing head combines alternate linear movement (which provides linear speed VL) and rotation movement (which provides tangential speed VT) [1] (Figure 1). This creates a cross-hatched pattern that favors oil flow [2,3]. The honing process, in addition, provides high dimensional precision [8] and requires different stages in order to achieve the final surface finish [9]. In the rough honing phase, one of the main requirements is to maximize the material removal rate, which is related to the productivity of the process, while minimizing tool wear, which will lead to lower tool costs
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