Faceted Honing Strip for Rapid Bore Run-In
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Solution Overview
Problem
Honing tools equipped with new honing strips require a lengthy run-in phase to achieve optimal abrasive removal performance, resulting in initial scrap production and inefficiency.
Innovation Solution
A honing strip with a cutting layer carrier featuring a convex macroscopic form defined by multiple planar facets, allowing for rapid adaptation to the bore surface through high surface pressure and wear on edges, facilitating quick areal contact and improved cutting properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If new honing strips are installed in a honing tool, then the tool is ready for machining operations, but a lengthy run-in phase is required to achieve optimal abrasive removal performance
Solution Approach 1:
The working surface of the honing strip is pre-shaped with a convex macroscopic form featuring multiple planar facets before installation. This preliminary geometric configuration enables immediate areal contact with the bore inner surface, eliminating the need for a lengthy run-in phase and allowing optimal abrasive removal performance from the start.
Solution Approach 2:
The invention changes the geometric parameters of the working surface by introducing a convex macroscopic form with multiple planar facets. This parameter modification allows the surface to adapt rapidly to the bore geometry through controlled wear on the facet edges, achieving optimal performance quickly without extended run-in time.
2Productivity
If new honing strips are installed in a honing tool, then machining operations can begin, but scrap production occurs during the run-in phase
Solution Approach 1:
The convex macroscopic form with multiple planar facets is prepared in advance on the honing strip. This preliminary configuration ensures that from the first machining operation, the working surface achieves proper areal contact with the bore, producing high-quality parts immediately and eliminating scrap generation during the run-in phase.
3Loss of time
If the working surface is made to adapt rapidly to the bore surface, then high-quality machining is achieved quickly, but the surface geometry becomes more complex
Solution Approach 1:
The convex working surface is segmented into multiple planar facets instead of being a single continuous curved surface. This segmentation creates distinct flat areas that can adapt to the bore geometry through controlled wear on the facet edges, achieving rapid areal contact while maintaining a manufacturable geometric structure.
Solution Approach 2:
The working surface is given a convex macroscopic form that approximates the curvature of the bore inner surface. This curved configuration, realized through multiple planar facets, enables the surface to conform to the cylindrical geometry of the bore, facilitating rapid adaptation and areal contact during the run-in phase.
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
The honing strip enables high-quality bore machining after a short run-in phase with reduced scrap production and increased efficiency, achieved through simpler and cost-effective manufacturing of faceted working surfaces.
Implementation Method 1
Honing is a cutting machining method using geometrically undefined cutting edges carried out by a generally expandable honing tool
Implementation Method 2
The machining method honing operates using bound cutting grain with constant areal contact between the abrasive working surfaces of the honing tool and the bore surface
Implementation Method 3
The cutting grains are bound in a bonding system (also 'bond') and form, together with the bonding system, a cutting layer. In that example, the function of the bonding system is to firmly hold the bound cutting grains until they are blunted by the cutting process
Data Source
AI summary
A honing strip for use in a honing tool for machining an inner surface of a bore includes a cutting layer carrier that carries, on an outer side, a cutting layer including cutting grains bound within a bond and an abrasive working surface that engages on the inner surface of the bore, wherein the honing strip defines a longitudinal direction (L) to be oriented parallel to a bore axis and the working surface extends in a width direction (B), perpendicular to the longitu-dinal direction, between a first side surface and a second side surface of the cutting layer, and the working surface has a generally convex macroscopic form with at least two macroscopically planar facets of different orientation which transition, along edges running in the longitudinal direction, to an adjacent facet or a side surface.