Study Of Material Removal In Honing By Grain Behavior

Honing is a material removal process widely used in manufacturing of matingparts such as engine cylinders, compressors, valves, bearings, and hydraulic cylinders.The surface topography generated by honing has a profound effect on the tribologicalperformance of the honed surface since the cross-hatch pattern on the workpiece surfacecan be used to retain oil or grease to ensure proper lubrication and minimize wear.Honing as finishing operation reflects the mechanics of material removal duringthe process depending on the process parameters used. Therefore, it is important tostudy the material removal during the process, so that the machining parameters can beoptimally selected to enhance the tribological performance by improve the cross-hatchpattern on the workpiece. Thus there still is a lack of knowledge on the mechanicalmicroscopic analysis of the material removal mechanism.This thesis presents a study of material removal in honing by grain behavior. Thismicroscopic analysis of this process consists in studying of the abrasive grains on thetool surface, effective grains during the honing process, material removal mechanism bysingle grain and grain dynamics.The grains on the tool surface are studied by a tool topography model; effectivegrains are obtained by a physics-based model on tool-workpiece interaction; materialremoval process by single grain is demonstrated through a3D finite element model; theeffect of grain dynamics on material removal is studied by a mathematic model. Finally,the models proposed in this thesis and the predicted results by these models are verifiedby pilot experiments. Other parameters, for example honing force and tool wear, arealso discussed through experiments.The results in this thesis can also be used to study more general abrasive process(as abrasive wear) and has led to a better understanding of plastic deformations andfailure local mechanisms encountered in this process.