Abstract
The carburized holes processed by ordinary internal grinding are prone to burn, crack, and low efficiency. Honing has a superior machining efficiency and cooling effect compared to traditional internal grinding. In this paper, we innovatively apply honing to carburizing hole grinding and propose an effective optimization scheme to enhance the surface finish of carburized holes. We set up an experimental system to explore the influence law of honing head rotation speed, axial reciprocating speed, grain size, and single grinding depth on surface roughness. Based on the grey correlation and response surface method, we propose a method to optimize the honing parameters of carburized holes and establish a prediction model, which has an R2 value of 0.9887, indicating that the model fits well. We verify the validity of the model by the root mean square error of 0.012 between the measured and calculated values. Based on the model, the optimal parameters of roughness (Ra) is obtained and verified by experiments. Compared with the original honing parameters, the surface roughness quality is improved by 25.8%. It shows that the optimized honing process based on the GRA-RSM method improves the surface quality of carburized holes significantly.
Highlights
Carburized alloy, an essential material for aero-engines, which is hard on the outside and tough on the inside, is used for wear parts that withstand impacts
Buj-Corral et al [8] investigated the effect of abrasive density on process parameters and concluded that the oilstone density was selected according to the acoustic emission of the grinding
This study aims to obtain the optimal process for carburized holes with the minimum Ra value
Summary
Carburized alloy, an essential material for aero-engines, which is hard on the outside and tough on the inside, is used for wear parts that withstand impacts. If the machining efficiency is low, the parts are prone to burns and micro-cracks This is due to the instantaneous high temperature in the grinding zone, which exceeds the martensitic transformation initiation temperature (TMS) or the austenitic transformation end temperature (TAc3), and cools rapidly. The authors of [2,7] reviewed the application of honing technology in the machining of internal combustion engine cylinders, analyzed the surface wear mechanism, and concluded that the size and the shape of the abrasive grains mainly affect the surface quality. The authors of [9,10,11] investigated the application of honing techniques in hardened steel, CuNiCr copper-nickel alloy, analyzed the effects of honing angle and abrasive size on roughness and residual stress, and obtained the optimized process parameters. Yang and Su et al [13] applied the honing technology to the essential parts of the fuel nozzles of aero-engines, established the honing cutting force model, and obtained the optimal surface honing process
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