Contour Honing with Feedback Stroke Control for Axial Bore Profiles
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Solution Overview
Problem
Existing honing methods struggle to achieve high precision in producing bores with axial contours over their entire length, as they lack sufficient accuracy and uniformity, especially with non-circular cylindrical shapes, due to limitations in in-process measurement systems and unpredictable cutting behavior.
Innovation Solution
The honing method employs automatic contour control using real-time diameter measurement signals to dynamically adjust the stroke length and position of the honing tool, ensuring that the actual contour profile closely matches the desired target contour through a closed-loop feedback control system, even accounting for variations in workpiece properties and cutting behavior.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional honing methods are used to machine bores with axial contours, then the machining process can be performed, but the contour accuracy and uniformity over the entire bore length are insufficient
Solution Approach 1:
The patent implements in-process diameter measurement during the stroke change phase to obtain actual diameter values, which are fed back to the control system. The control system compares measured diameters with target values and dynamically adjusts stroke length and/or stroke position to compensate for deviations, ensuring high contour accuracy and uniformity throughout the bore length
Solution Approach 2:
The patent dynamically changes stroke length and/or stroke position during the stroke change phase based on real-time measurement feedback. This dynamic adjustment allows the honing process to adapt to actual bore geometry deviations, maintaining precise contour control over the entire bore length rather than using fixed stroke parameters
2Manufacturing precision
If in-process diameter measurement is implemented during the stroke change phase, then contour accuracy is improved, but the device complexity increases
Solution Approach 1:
The patent replaces complex mechanical measurement systems with optical or sensor-based diameter measurement systems that can be integrated into the existing honing machine. This substitution provides accurate real-time diameter data during the stroke change phase without requiring complex mechanical measurement mechanisms
Solution Approach 2:
The control system serves multiple functions: it controls the spindle rotation, manages the stroke movement, processes diameter measurement signals, and dynamically adjusts stroke parameters. This multi-functionality reduces the need for separate dedicated control systems, thereby limiting the increase in device complexity while achieving high contour accuracy
3Manufacturing precision
If the stroke length and stroke position are dynamically adjusted during the stroke change phase, then the desired contour profile is achieved, but the process control complexity increases
Solution Approach 1:
The control system continuously receives diameter measurement signals during the stroke change phase, compares them with target contour values, and automatically adjusts stroke length and/or stroke position based on the deviations. This closed-loop feedback control achieves precise contour profiles while automating the complex adjustments, reducing the need for manual intervention and simplifying operational complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly enhances the accuracy of contour honing, allowing for precise production of rotationally symmetrical bores with axial contours, meeting stringent accuracy requirements by continuously adjusting the honing process based on actual diameter measurements during the machining process.
Implementation Method 1
at least one measuring sensor of a diameter measuring system is attached to the honing tool
Implementation Method 2
Honing is a machining process with geometrically undefined cutting edges... the cutting material bodies attached to the honing tool are fed via a feed system with a feed force and/or feed speed acting radially to the tool axis and pressed against the inner surface to be machined
Data Source
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AI summary
The invention relates to a honing method for machining the inner surface (214) of a bore (210) in a workpiece (200) by means of at least one honing operation, wherein, during a honing operation, an expandable honing tool (150) coupled to a spindle is moved back and forth inside the bore in the axial direction of the bore in order generate a reciprocating motion and, at the same time, is rotated in order to generate a rotational motion superposed on the reciprocating motion. A bore shape that is rotationally symmetrical with respect to a bore axis (212) and that deviates from the circular cylinder shape and that has an axial contour profile is produced. In order to generate axially varying material removal, a stroke length and/or a stroke position of the reciprocating motion is varied in at least one stroke variation phase. A honing tool (150) having an annular cutting group (155) having a plurality of cutting material bodies (156), which are distributed around the periphery of a tool body (152) and which can be radially advanced, is used. The honing method is characterized in that, during the stroke variation phase, the actual diameter of the bore (210) is measured in order to determine a diameter measurement signal, which represents the actual diameter of the bore in a measurement plane, and the stroke length and/or the stroke position of the reciprocating motion is controlled in accordance with the diameter measurement signal. The invention further relates to a machine tool suitable for carrying out the honing method. The honing method is particularly suited for honing cylinder walls in the production of cylinder blocks or cylinder liners for reciprocating-piston machines.