Multi-scale and multi-fractal analysis of abrasive wear signature of honing process

Abstract

Honing is an industrial alternative of internal grinding for finishing large-diameter bores of internal combustion engine cylinders. This paper introduces a hybrid approach for a multi-scale analysis of surface finish in abrasive honing. The methodology is based on morphological identification of scratch pattern of manufactured surfaces, produced at various honing conditions, and their 2D continuous wavelet decomposition. The activated abrasion mechanisms were then discussed based on quantitative analysis of geometrical scratch pattern and multi-scale surface modifications of honing signature. Results show clearly that honed surface finish is primarily controlled by the size and the geometry of abrasive grains (i.e. wear of abrasive sticks). Since the abrasive is in continuous balanced contact with the work in honing operating at constant-force grinding, there is less deflection of the work. Moreover, it appears that honing signature shows a multi-scale fractal structure along the observation scales. This makes it possible to identify an optimal honing route preserving honing sticks abrasiveness and increasing their texturing capacity to confer high volume of oil retention at honed surface finish.