Study of an Industrial FEM Tool for Line Boring Process of Cylinder Blocks

Abstract

The aim of this study is to realize a simple simulation tool, in order to predict the form defect of cylinder block bore liners in the moment of rough boring process. Geometrical defect prediction is critical for Process Engineering in order to optimize all machining sequences in the production line, to grantee the finale product, according to the norms defined by the Design Engineering. In revenge, Process Engineering can suggest a new product design according to geometrical defect predictions. Simulation can significantly reduce the time of Process-Product parameters adjustment (pre-project).In this study a simple static FEM model, based on the cylinder block geometry, is proposed to predict the form defect of the bore liners in the moment of process. The cutting tool is supposed as a rigid part in this model. The clamping condition and meshing information are applied on the part in the initial state. Calculation of cutting force components is performed through the Kienzle cutting law and applied on the bore liners by means of a Python script. The Python script runs the calculation automatically by means of ABQUS software. Another Python script is in charge of simulation results post-processing. The interface of this tool is an Excel sheet which allows us to inter the process parameters and automatically run the FEM calculation. Out-put excel file contains the form defect of each bore according to 3 levels of bore (top, middle and the bottom) and different angular position.The simulation results put forward that the clamping condition plays an import role in the bore distortion. Consequently, optimizing the clamping pressure and its localization is critical, before cutting parameters adjustment, in line boring process. Experimental validation is performed in parallel with the simulation. The first correlation between experimentation and simulation results shows that the first influent factor which disturbs the correlation is the initial form defect of rough part due to the casting process. Integration of casting form defect in the simulation is crucial and should be taken into account in the next studied.