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Optimization and Sensitivity Analysis of the Cutting Conditions in Rough, Semi-Finish and Finish Honing
Irene Buj-Corral1, Lourdes Rodero-de-Lamo2, Lluís Marco-Almagro2
1Department of Mechanical Engineering, Barcelona School of Industrial Engineering (ETSEIB), Universitat Politècnica de Catalunya (UPC), 08028 Barcelona, Spain.
Materials (Basel, Switzerland)
|January 11, 2022
Summary
This study optimizes honing processes for better cylinder surfaces by adjusting machining conditions. The finish honing stage is most sensitive to changes in process variable importance.
Area of Science:
- Manufacturing Engineering
- Materials Science
Background:
- Honing creates cross-hatched patterns crucial for oil flow in engine and hydraulic cylinders.
- Optimizing honing is key to improving component performance and longevity.
Purpose of the Study:
- To optimize machining conditions for honing processes.
- To enhance surface roughness, material removal rate, and tool wear.
- To analyze the sensitivity of optimization to process variable importance.
Main Methods:
- Utilized the desirability function for multi-objective optimization.
- Investigated five process variables: grain size, density, pressure, linear speed, and tangential speed.
- Conducted a sensitivity analysis on response importance variations.
Main Results:
- Identified optimal machining conditions for honing.
- Determined that the finish honing phase is more sensitive to changes in variable importance compared to rough and semi-finish stages.
- Quantified the impact of variable importance on optimization outcomes, particularly pressure in finish honing.
Conclusions:
- The desirability function effectively optimizes honing processes.
- Understanding phase-specific sensitivity is crucial for robust optimization.
- Provides guidance for selecting optimal honing process variables for improved cylinder performance.
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