Optimization of Honing Surface Roughness of Carburized Holes Based on GRA-RSM

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.

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

“…Similar influences of the tangential speed on the surface roughness can be found in the works of. 1,6,15,18 Supplementary Figure 7b, an increased linear speed decreases the surface roughness. When the linear speed relatively changes from 4 mm/min to 8 mm/min, the surface roughness is relatively decreased by 18.2%.…”

“…Lower surface roughness with increased linear speed was presented in the works of. 1,2,15,18,19 Supplementary Figure 7c, higher honing pressure causes an increased surface roughness. When the honing pressure rises from 3 MPa to 5 MPa, the surface roughness is relatively increased by 43.8%.…”

“…Higher machining depth increases the honing force, leading to a greater vibration; hence, higher machined diameters are obtained. 18 Consequently, the MRR value increases.…”

“…Similar influences of the honing depth on the surface roughness can be found in the work of. 18 The main influences of process parameters on the material removal rate are shown in Supplementary Figure 8.…”

“…The GRA and RSM were employed to develop the R a model regarding the T , L , G , and honing depth ( D ) for the finishing honing operation of the carburized hole. 18 The authors stated that the R a was decreased by 25.0% with the aid of the optimizing approach, as compared to the original honing parameters. The impacts of the spindle speed ( S ), L , and retracting speed ( R ) on the R a , cutting force, bore diameter, and shape accuracy for the flexible single-pass honing having small tools were explored by Yang et al 19 The empirical models of the honing responses were proposed in terms of the optimizing inputs.…”