Analysis of the effect of machining parameters on the surface roughness in bore honing

Abstract

Honing is a wide-spread applied machining procedure in finish manufacturing of high precision bores (for example surfaces in internal combustion engines). Machining procedures can be analysed from the point of view of the energy efficiency, productivity, surface quality, etc. In this paper the achievable surface quality after the honing process is studied on sleeves with EN-GJL-250 lamellar cast iron alloy material. The cutting experiments were planned according to the 23 full factorial design of experiments method. Two levels of the analysed factors were chosen in this study. The pressure on the honing stone, the feed of the tool and the average grain size are changed, which resulted in 8 experimental setups. After the roughness measurement and profile evaluation, the main effects are analysed of these 3 parameters. Equations were determined according to the principle of the design of experiment method. The effect of the studied machining parameters is analysed by the application of these equations. The findings in this paper make it possible to explain some phenomenon in the honing process and allow the planning of future experiments in this topic. It was found that lower pressure, higher feed, and finer grains are favourable to achieve low roughness values.