Effect of Grain Size and Density of Abrasive on Surface Roughness, Material Removal Rate and Acoustic Emission Signal in Rough Honing Processes

Abstract

Honing processes provide a special cross-hatch pattern to the internal surface of cylinders that favors oil flow. However, along honing operation the abrasive grains wear out and lose their ability to cut material. The honing chips mixed with oil fill the pores of the abrasives and they start cutting in an incorrect way, leading to clogging. In the present paper, honing experiments were carried out according to a 32 factorial design, with different grain size and density of abrasive grains. Roughness, material removal rate, and tool wear were determined. Acoustic emissions were also measured and the chirplet concept was applied in order to detect differences between correct and incorrect cutting operations. As a general trend roughness and material removal rate increase with grain size and with density of abrasive. However, when clogging occurs roughness and material removal rate decrease, because the abrasive grains tend to deform the material instead of cutting it. When the honing process is working appropriately, the chirplet diagram of the harmonic part of the signal shows constant marks. On the contrary, when it does not work properly, marks disappear with time and their frequencies decrease. The results of the present paper will allow monitoring the honing process in order to change the abrasives when they are not working properly.

Optimization and Sensitivity Analysis of the Cutting Conditions in Rough, Semi-Finish and Finish Honing

“…Gs·Gs, Gs·Pr and Pr·Vt are also influential. Conversely, Bai et al [ 13 ] found that surface roughness depends on tangential speed. In plateau honing processes, Gunay and Korkmaz [ 35 ] observed that roughness depended mainly on grain size, linear speed and number of strokes.…”

“…Equations ( 11)- (13) show the regression models for tool wear, Qp, in the rough, semifinish and finish operations respectively. The main factor affecting tool wear in rough honing is the density of the abrasiv with a negative impact on tool wear.…”

“…The semi-finish process was also studied, in which, as a general trend, roughness and material removal rate increase with grain size and density [ 13 ]. The finish honing process has been less well studied in the literature.…”

Surface modification of wire-EDMed Ti6Al4V alloy by ultrasonic assisted magnetic abrasive finishing technique

“…When the figure is examined, it is seen that the white layer thickness decreases in both the MAF and UAMAF methods with the increase in the number of revolutions. Since the number of revolutions directly affects the way the abrasive particles travel per unit time, the amount of material removed per unit time increases with the increase in the number of revolutions and the white layer thickness decreases with this [40,49,50]. The effect of the number of revolutions on white layer thickness tends to be similar for both the MAF and the UAMAF methods.…”

Effect of machining parameters on surface quality of w-edmed Ti6Al4V alloy in ultrasonic assisted magnetic abrasive finishing technique

“…Şekil incelendiğinde manyetik alan miktarının artmasıyla hem MAİ hem de UDMAİ yönteminde talaş kaldırma oranının arttığı görülmektedir. Manyetik kuvvet, aşındırıcı taneciklerin iş parçası yüzeyine etkiyen baskı kuvvetini etkilediği için, artan manyetik kuvvetle birlikte aşındırıcı taneciklerin iş parçası yüzeyine uyguladığı kuvvet artmakta ve bunun neticesinde daha etkin bir talaş kaldırma gerçekleşmektedir[35,36]. Manyetik alan miktarının artmasıyla talaş kaldırma oranındaki değişim MAİ ve UDMAİ yöntemleri için benzer eğilim göstermektedir.…”