Simulation of machined surface formation while honing

Alexander M. Gouskov, Eric Butcher, Sergey A. Voronov, Subhash C. Sinha

Research output: Chapter in Book/Report/Conference proceedingConference contribution

5 Citations (Scopus)

Abstract

The dynamics of deep hole honing is considered. The mathematical model of the process including the dynamic model of the tool and the interaction of the workpiece surface and honing sticks is analyzed. The honing tool is modeled as a continuous slender beam with a honing mandrel attached at the intermediate cross section. A single row of stones tool rotates and has reciprocational motion in the axial direction. The honing stones are expanded to the machined surface by a special rigid mechanism that provides cutting of workpiece cylindrical surface. The removal of chip and the tool vibrations cause the variation of expansion pressure and depend on the surface state formed by previous honing stone. The equations of new surface formation are separated as a specific set of the dynamic model. These equations inherently consider the regenerative effect of oscillations during machining. The numerical algorithm of machined surface generation has been developed which facilitates the 3D graphical representation and evaluation of the topography of the generated surface. The simulation model accounts for not only the nominal tool motion but also takes into account errors during machining such as tool components deformations and vibrations, tool runout, as well as initial surface distortions produced by previous operation. Based on the surface formation model software for evaluation of typical surface quality and accuracy criteria such as eccentricity, out-of-round, conicity, barrel, axial waviness, misalignment, faceting has been developed. The expansion pressure, tool stiffness, and technology conditions are considered as varying parameters since their influence on the process are different. The process productivity and accuracy can be improved by choosing rational conditions evaluated by simulation. The corresponding models and results of numerical simulation are presented. All the results are given in dimensionless form and therefore they are applicable to a wide range of real manufacturing process conditions. The model of new surface formation presented allows the simulation of the machined surface topography variation in time and to predict workpiece accuracy and possible correction of surface errors.

Original languageEnglish (US)
Title of host publicationAmerican Society of Mechanical Engineers, Manufacturing Engineering Division, MED
Pages947-954
Number of pages8
Volume15
DOIs
StatePublished - 2004
Externally publishedYes
Event2004 ASME International Mechanical Engineering Congress and Exposition, IMECE 2004 - Anaheim, CA, United States
Duration: Nov 13 2004Nov 19 2004

Other

Other2004 ASME International Mechanical Engineering Congress and Exposition, IMECE 2004
CountryUnited States
CityAnaheim, CA
Period11/13/0411/19/04

Fingerprint

Honing
Dynamic models
Machining
Surface states
Surface topography
Topography
Surface properties
Productivity
Stiffness
Mathematical models

Keywords

  • Dynamics
  • Honing
  • Simulation
  • Surface Generation

ASJC Scopus subject areas

  • Engineering(all)

Cite this

Gouskov, A. M., Butcher, E., Voronov, S. A., & Sinha, S. C. (2004). Simulation of machined surface formation while honing. In American Society of Mechanical Engineers, Manufacturing Engineering Division, MED (Vol. 15, pp. 947-954). [IMECE2004-59268] https://doi.org/10.1115/IMECE2004-59268

Simulation of machined surface formation while honing. / Gouskov, Alexander M.; Butcher, Eric; Voronov, Sergey A.; Sinha, Subhash C.

American Society of Mechanical Engineers, Manufacturing Engineering Division, MED. Vol. 15 2004. p. 947-954 IMECE2004-59268.

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Gouskov, AM, Butcher, E, Voronov, SA & Sinha, SC 2004, Simulation of machined surface formation while honing. in American Society of Mechanical Engineers, Manufacturing Engineering Division, MED. vol. 15, IMECE2004-59268, pp. 947-954, 2004 ASME International Mechanical Engineering Congress and Exposition, IMECE 2004, Anaheim, CA, United States, 11/13/04. https://doi.org/10.1115/IMECE2004-59268
Gouskov AM, Butcher E, Voronov SA, Sinha SC. Simulation of machined surface formation while honing. In American Society of Mechanical Engineers, Manufacturing Engineering Division, MED. Vol. 15. 2004. p. 947-954. IMECE2004-59268 https://doi.org/10.1115/IMECE2004-59268
Gouskov, Alexander M. ; Butcher, Eric ; Voronov, Sergey A. ; Sinha, Subhash C. / Simulation of machined surface formation while honing. American Society of Mechanical Engineers, Manufacturing Engineering Division, MED. Vol. 15 2004. pp. 947-954
@inproceedings{7175d3492f6f4e308a2cd7ace335e912,
title = "Simulation of machined surface formation while honing",
abstract = "The dynamics of deep hole honing is considered. The mathematical model of the process including the dynamic model of the tool and the interaction of the workpiece surface and honing sticks is analyzed. The honing tool is modeled as a continuous slender beam with a honing mandrel attached at the intermediate cross section. A single row of stones tool rotates and has reciprocational motion in the axial direction. The honing stones are expanded to the machined surface by a special rigid mechanism that provides cutting of workpiece cylindrical surface. The removal of chip and the tool vibrations cause the variation of expansion pressure and depend on the surface state formed by previous honing stone. The equations of new surface formation are separated as a specific set of the dynamic model. These equations inherently consider the regenerative effect of oscillations during machining. The numerical algorithm of machined surface generation has been developed which facilitates the 3D graphical representation and evaluation of the topography of the generated surface. The simulation model accounts for not only the nominal tool motion but also takes into account errors during machining such as tool components deformations and vibrations, tool runout, as well as initial surface distortions produced by previous operation. Based on the surface formation model software for evaluation of typical surface quality and accuracy criteria such as eccentricity, out-of-round, conicity, barrel, axial waviness, misalignment, faceting has been developed. The expansion pressure, tool stiffness, and technology conditions are considered as varying parameters since their influence on the process are different. The process productivity and accuracy can be improved by choosing rational conditions evaluated by simulation. The corresponding models and results of numerical simulation are presented. All the results are given in dimensionless form and therefore they are applicable to a wide range of real manufacturing process conditions. The model of new surface formation presented allows the simulation of the machined surface topography variation in time and to predict workpiece accuracy and possible correction of surface errors.",
keywords = "Dynamics, Honing, Simulation, Surface Generation",
author = "Gouskov, {Alexander M.} and Eric Butcher and Voronov, {Sergey A.} and Sinha, {Subhash C.}",
year = "2004",
doi = "10.1115/IMECE2004-59268",
language = "English (US)",
volume = "15",
pages = "947--954",
booktitle = "American Society of Mechanical Engineers, Manufacturing Engineering Division, MED",

}

TY - GEN

T1 - Simulation of machined surface formation while honing

AU - Gouskov, Alexander M.

AU - Butcher, Eric

AU - Voronov, Sergey A.

AU - Sinha, Subhash C.

PY - 2004

Y1 - 2004

N2 - The dynamics of deep hole honing is considered. The mathematical model of the process including the dynamic model of the tool and the interaction of the workpiece surface and honing sticks is analyzed. The honing tool is modeled as a continuous slender beam with a honing mandrel attached at the intermediate cross section. A single row of stones tool rotates and has reciprocational motion in the axial direction. The honing stones are expanded to the machined surface by a special rigid mechanism that provides cutting of workpiece cylindrical surface. The removal of chip and the tool vibrations cause the variation of expansion pressure and depend on the surface state formed by previous honing stone. The equations of new surface formation are separated as a specific set of the dynamic model. These equations inherently consider the regenerative effect of oscillations during machining. The numerical algorithm of machined surface generation has been developed which facilitates the 3D graphical representation and evaluation of the topography of the generated surface. The simulation model accounts for not only the nominal tool motion but also takes into account errors during machining such as tool components deformations and vibrations, tool runout, as well as initial surface distortions produced by previous operation. Based on the surface formation model software for evaluation of typical surface quality and accuracy criteria such as eccentricity, out-of-round, conicity, barrel, axial waviness, misalignment, faceting has been developed. The expansion pressure, tool stiffness, and technology conditions are considered as varying parameters since their influence on the process are different. The process productivity and accuracy can be improved by choosing rational conditions evaluated by simulation. The corresponding models and results of numerical simulation are presented. All the results are given in dimensionless form and therefore they are applicable to a wide range of real manufacturing process conditions. The model of new surface formation presented allows the simulation of the machined surface topography variation in time and to predict workpiece accuracy and possible correction of surface errors.

AB - The dynamics of deep hole honing is considered. The mathematical model of the process including the dynamic model of the tool and the interaction of the workpiece surface and honing sticks is analyzed. The honing tool is modeled as a continuous slender beam with a honing mandrel attached at the intermediate cross section. A single row of stones tool rotates and has reciprocational motion in the axial direction. The honing stones are expanded to the machined surface by a special rigid mechanism that provides cutting of workpiece cylindrical surface. The removal of chip and the tool vibrations cause the variation of expansion pressure and depend on the surface state formed by previous honing stone. The equations of new surface formation are separated as a specific set of the dynamic model. These equations inherently consider the regenerative effect of oscillations during machining. The numerical algorithm of machined surface generation has been developed which facilitates the 3D graphical representation and evaluation of the topography of the generated surface. The simulation model accounts for not only the nominal tool motion but also takes into account errors during machining such as tool components deformations and vibrations, tool runout, as well as initial surface distortions produced by previous operation. Based on the surface formation model software for evaluation of typical surface quality and accuracy criteria such as eccentricity, out-of-round, conicity, barrel, axial waviness, misalignment, faceting has been developed. The expansion pressure, tool stiffness, and technology conditions are considered as varying parameters since their influence on the process are different. The process productivity and accuracy can be improved by choosing rational conditions evaluated by simulation. The corresponding models and results of numerical simulation are presented. All the results are given in dimensionless form and therefore they are applicable to a wide range of real manufacturing process conditions. The model of new surface formation presented allows the simulation of the machined surface topography variation in time and to predict workpiece accuracy and possible correction of surface errors.

KW - Dynamics

KW - Honing

KW - Simulation

KW - Surface Generation

UR - http://www.scopus.com/inward/record.url?scp=23244446041&partnerID=8YFLogxK

UR - http://www.scopus.com/inward/citedby.url?scp=23244446041&partnerID=8YFLogxK

U2 - 10.1115/IMECE2004-59268

DO - 10.1115/IMECE2004-59268

M3 - Conference contribution

AN - SCOPUS:23244446041

VL - 15

SP - 947

EP - 954

BT - American Society of Mechanical Engineers, Manufacturing Engineering Division, MED

ER -