Optimization and Sensitivity Analysis of the Cutting Conditions in Rough, Semi-Finish and Finish Honing

Honing processes are currently employed to obtain a cross-hatched pattern on the internal surfaces of cylinders that favors oil flow in combustion engines or hydraulic cylinders. The main aim of the present paper is to optimize the machining conditions in honing processes with respect to surface roughness, material removal rate and tool wear by means of the desirability function. Five process variables are considered: grain size, density, pressure, linear speed and tangential speed. Later, a sensitivity analysis is performed to determine the effect of the variation of the importance given to each response on the results of the optimization process. In the rough and semi-finish honing steps, variations of less than 5% of the importance value do not cause substantial changes in the optimization process. On the contrary, in the finish honing step, small changes in the importance values lead to modifications in the optimization process, mainly regarding pressure. Thus, the finish honing phase is more sensitive to changes in the optimization process than the rough and the semi-finish honing phases. The present paper will help users of honing machines to select proper values for the process variables.