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

Abstract

Honing processes are currently employed to obtain a cross-hatched pattern on the internal surfaces of cylinders that favors oil flow in combustion engines or hydraulic cylinders. The main aim of the present paper is to optimize the machining conditions in honing processes with respect to surface roughness, material removal rate and tool wear by means of the desirability function. Five process variables are considered: grain size, density, pressure, linear speed and tangential speed. Later, a sensitivity analysis is performed to determine the effect of the variation of the importance given to each response on the results of the optimization process. In the rough and semi-finish honing steps, variations of less than 5% of the importance value do not cause substantial changes in the optimization process. On the contrary, in the finish honing step, small changes in the importance values lead to modifications in the optimization process, mainly regarding pressure. Thus, the finish honing phase is more sensitive to changes in the optimization process than the rough and the semi-finish honing phases. The present paper will help users of honing machines to select proper values for the process variables.

An energy efficiency-based optimization of the rough honing process of hardened 5150 alloy

“…Higher MRR with increased linear speed was exhibited in the works of. 1,2,20 Moreover, 38.3% relatively higher MRR is obtained with the variety of the honing pressure from lowest to highest levels (Supplementary Figure 8c). Increased pressure causes a higher vibration during machining time, leading to higher errors of the honed diameters; hence, the MRR improves.…”

“…Higher surface roughness with increased honing pressure was exhibited in the works of. 1,6,20 Supplementary Figure 7d, higher honing depth causes an increased surface roughness. When the honing depth relatively changes from 0.01 mm to 0.03 mm, the surface roughness is relatively increased by 31.7%.…”

“…Higher MRR with increased honing pressure was exhibited in the works of. 1,20,21 The MRR is relatively enhanced by 36.6% when the honing depth changes from 0.1 mm to 0.3 mm (Supplementary Figure 8d). Higher machining depth increases the honing force, leading to a greater vibration; hence, higher machined diameters are obtained.…”

“…Similar influences of the tangential speed on the MRR can be found in the works of. 1,20,21 As the linear speed changes from 4 m/min to 6 m/min, the MRR is relatively improved by 48.9% (Supplementary Figure 8b). An increased linear speed increases the velocity and vibration of the honing tool, resulting in higher deviations of the honed diameters; hence, the MRR increases.…”

“…The RSM models of the R a , MRR , and TW were developed in terms of the G , L , T , P , and DE for the rough, semi-finishing, and finishing honing operations, while the desirability approach was used to determine the optimal data. 20 The outcomes indicated that the small change in parameter caused a large variety of the finishing honing responses. Moreover, the finishing honing operation is more sensitive to changes in the optimization process, as compared to the rough and semi-finishing processes.…”