3D Multi-Scale Topography Analysis in Specifying Quality of Honed Surfaces

Abstract

The quality of the surface texture on cylinder liners of engines has an important influence on oil consumption and running performance. This texture is generated with a succession of three honing operations (rough, finishing and plateau honing). These honing steps are difficult to optimize due to the large number of process variables (Velocity of the rotational motion, velocity of the axial motion ...) and their complex interrelation. This paper discusses the use of the multiscale topographic parameter of the honing process as a new concept to identify the relation between the process variables and the resulting performances in terms of form and surface finish. To achieve this objective, a multi-scale decomposition method of surface topography based on 2D continuous wavelets transform was performed to analyze the evolution of the topographic honing. This approach also shows a good indication of the dependence between the honing steps and the roughness scales. Finally, it provides an efficient tool to predict the surface characteristics corresponding to given process variables and can be extended to optimize other multi-stage abrasive machining processes.

Performance impact of honing dynamics on surface finish of precoated cylinder bores

“…Finally, the impact of the dynamics on the surface appearance of surfaces obtained after the plateau honing stage on cylinder no. 1 will be investigated with the 3D multiscale analysis [11].…”

“…Low inversion acceleration of the stroke motion leads to traces of horizontal grooves with α close to zero at the base and top of the cylinder liner. In order to study the quality of the texture obtained through honing, the method developed by Sabri et al [11], was implemented. The frequential breakdown of the surface topography in 3D leads to the identification of four digital criteria: the cross angle of the groove, the angle of the grooves (left or right), the groove density and the m-turn criterion.…”

“…The frequential breakdown of the surface topography in 3D leads to the identification of four digital criteria: the cross angle of the groove, the angle of the grooves (left or right), the groove density and the m-turn criterion. The "m-turn" parameter is developed by Sabri et al [11] to detect the presence of residual turning grooves. It is defined by the following expression:…”

“…Optical micrographs of the surface grooves and m-turn criteria[11]. Surface aspects at 3 levels and 3 acceleration speeds[11].…”

Influence of Honing Parameters on the Quality of the Machined Parts and Innovations in Honing Processes

“…As described by Sabri et al [97], some engine parts, such as cylinder liners, have a value for their honed surfaces like an Rpk parameter around 0.3-0.5 µm, an Rk around 1 µm, and an Rvk around 1-1.5 µm. They reported that some manufactures in the automotive industry, such as Renault or PSA Citroen, introduced other parameters describing the functionality parameters, such as Cr (Running-in criterion), Cf (operating criterion), and Cl (lubricating criterion).…”