EP2110204B1 - Procédé destiné à empierrer des trous de forage tout comme outil à empierrer - Google Patents

Procédé destiné à empierrer des trous de forage tout comme outil à empierrer Download PDF

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Publication number
EP2110204B1
EP2110204B1 EP09009260A EP09009260A EP2110204B1 EP 2110204 B1 EP2110204 B1 EP 2110204B1 EP 09009260 A EP09009260 A EP 09009260A EP 09009260 A EP09009260 A EP 09009260A EP 2110204 B1 EP2110204 B1 EP 2110204B1
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EP
European Patent Office
Prior art keywords
bore
honing
tool
honing tool
cutting
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
EP09009260A
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German (de)
English (en)
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EP2110204A1 (fr
Inventor
Uwe-Peter Weigmann
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Nagel Maschinen und Werkzeugfabrik GmbH
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Nagel Maschinen und Werkzeugfabrik GmbH
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Application filed by Nagel Maschinen und Werkzeugfabrik GmbH filed Critical Nagel Maschinen und Werkzeugfabrik GmbH
Priority to EP10010546.9A priority Critical patent/EP2277662B1/fr
Priority to EP10010544A priority patent/EP2279829B1/fr
Priority to EP10010545A priority patent/EP2277661B1/fr
Publication of EP2110204A1 publication Critical patent/EP2110204A1/fr
Application granted granted Critical
Publication of EP2110204B1 publication Critical patent/EP2110204B1/fr
Ceased legal-status Critical Current
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B33/00—Honing machines or devices; Accessories therefor
    • B24B33/02—Honing machines or devices; Accessories therefor designed for working internal surfaces of revolution, e.g. of cylindrical or conical shapes
    • B24B33/022—Horizontal honing machines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B33/00—Honing machines or devices; Accessories therefor
    • B24B33/02—Honing machines or devices; Accessories therefor designed for working internal surfaces of revolution, e.g. of cylindrical or conical shapes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B33/00—Honing machines or devices; Accessories therefor
    • B24B33/08—Honing tools
    • B24B33/088—Honing tools for holes having a shape other than cylindrical
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B33/00—Honing machines or devices; Accessories therefor
    • B24B33/10—Accessories
    • B24B33/105—Honing spindles; Devices for expanding the honing elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B49/00—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation
    • B24B49/02—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation according to the instantaneous size and required size of the workpiece acted upon, the measuring or gauging being continuous or intermittent

Definitions

  • the invention relates to a method for honing the inner surface of a bore in a workpiece, in particular for honing a cylinder surface in the manufacture of engine blocks for internal combustion engines. Furthermore, the invention relates to a honing tool which is particularly suitable and configured for carrying out the method.
  • the European patent application EP 1 321 229 A1 describes a method for producing a bore, which has an initial shape in the unloaded state and in the operating state a deviating from the initial shape desired shape.
  • the method includes determining the deformation of a hole with a desired shape in the operating state. By means of the desired shape and the determined deformation, the initial shape is determined and the bore is brought by a machining process in the initial shape.
  • the initial shape produced by the method should assume the desired nominal shape in the operating state.
  • the desired shape is cylindrical, while the starting shape has a substantially circular cylindrical portion, a substantially elliptical portion and an intermediate transition portion.
  • Form honing is explained using the example of deformed cylinder blocks in which the cylinder bores have a quadruple-symmetrical fourth-round runout, ie a bore shape with 4-fold radial symmetry with respect to the bore axis.
  • This non-round bore shape is controlled by the delivery force or the contact pressure of a simply expanding honing tool over the stroke and the angle of rotation achieved.
  • a honing tool has two or three honing stones on its circumference. On the opposite side of the honing stone of the tool body rollers are mounted, which roll during machining on the inner surface of the machined cylinder bore and serve to support the resulting during processing reaction forces against the inner surface of the bore.
  • a delivery system ensures the radial delivery of the honing stone and changes the infeed pressure during the rotation.
  • the delivery system has an electrically controllable piezoelectric element which is arranged between the body of the honing tool and the carrier for the honing stone.
  • two axially offset piezoelectric elements are provided for the delivery of a honing stone, so that the holder of the controlled honing stone is pivotable about an axis perpendicular to the tool axis of rotation axis. This makes it possible to produce conical bore shapes.
  • the invention provides a method having the features of claim 1 and a honing tool having the features of claim 8.
  • a honing tool is axially movable within the bore and driven to rotate about its tool axis and attached to the honing tool cutting group with at least a cutting material body for material-removing machining of the inner surface is pressed with a feed force to the inner surface.
  • a substantially rigid guidance of the axial movement of the honing tool to produce an axial movement of the honing tool is effected substantially parallel to the bore axis of the bore and a temporally asymmetrical control of the infeed force of a cutting group attached to the honing tool on one side as a function of the angular position and optionally performed by the stroke position of the honing tool such that the bore receives a non-circular cylindrical bore shape at least in an axial bore portion.
  • a shape of the cylinder bore should be created which, in the mounted and operating condition of the engine, results in a minimal error in cylinder shape (cylindricity error).
  • the negative shape of the defect caused by the deformations generated during assembly and during operation should be generated by the honing process and thus kept available.
  • the stiffness and thermal deformation is not symmetrical in structurally non-uniform workpieces, for example by differences in wall thickness and by different connections of the cylinder liners to the engine-internal cooling system o. The like. Therefore, for the ideal imaging of the negative mold a honing process is required, which allows the creation of any, usually asymmetrical bore shape.
  • the invention overcomes this limitation.
  • the essentially rigid guidance of the axial movement of the honing tool in conjunction with the control of the feed force of a cutting group mounted on one side of the tool axis on the honing tool ensures that this cutting group effects a removal of material in its pressure angle range, without necessarily leading to a comparable material removal at the diametral opposite side of the bore inner surface leads.
  • the opposing force counteracting the contact pressure of the cutting group is not applied by material-removing cutting body, but by the substantially rigid guidance of the axial movement of the honing tool, which prevents dipping of the honing tool transverse to the tool axis in one-sided pressing of the cutting material body to the bore inner surface.
  • the honing tool has only a single cutting group whose cutting material body (one or more) are all arranged on one side of the honing tool. It is also possible to provide a plurality of cutting groups which can be controlled independently of one another and, if appropriate, can also be arranged on diametrically opposite sides of the honing tool. If cutting groups are arranged on opposite sides, a cutting group should only be on one of the opposite sides at a given time be in material-removing engagement with the bore inner wall, while the arranged on the opposite side cutting group is withdrawn or depressurized and thus makes no or no substantial material removal.
  • the cutting group mounted on one side of the tool body is delivered into a predefinable radial position by means of a base delivery system, and radial delivery or radial retraction of the cutting group is effected by means of a dynamic fine delivery system which can be actuated independently of the base delivery system ,
  • the feed movement of the cutting material body of the cutting group is thus controlled by means of a cutting group delivery system, which is divided into two independently operable subsystem.
  • the basic delivery system is designed so that at a coarse feed the material-removing regions of the cutting material body can be approximated with the help of the base delivery system of the inner surface of the bore at a relatively large first adjustment to a small distance or to the touch.
  • the dynamic fine delivery system is designed for generating short-term change of the delivery pressure and short second adjustment travel relative to the first adjustment path.
  • the fine delivery system can be designed so that only relatively low moving masses are required, the fine delivery system can be designed highly dynamic.
  • the fine delivery system generates multiple, in particular now two and ten, periodic or aperiodic changes between increase and decrease in delivery force. This can also be complex curved and with a Variety of local maxima and minima provided contours of the bore inner wall can be generated with high accuracy.
  • the cutting group can be delivered by means of the base delivery system, for example via a first adjustment, which is at least 1 mm, preferably at least 4 mm.
  • the cutting group can be adjusted by means of the fine delivery system via a second adjustment path, which lies in the range below 100 ⁇ m, in particular in the range of 20 ⁇ m and 60 ⁇ m in radius.
  • the base delivery system is actuated via a drive located outside of the honing tool and the fine delivery system via a drive disposed within the honing tool.
  • the drive of the base delivery system may be located, for example, in the honing machine.
  • the drive arranged within the honing tool can be, for example, an electromechanical drive or a piezoelectric drive.
  • the honing tool is supported for substantially rigid guidance of the axial movement within the bore in an axially slidable manner and substantially immovably transversely to the tool axis. This makes it possible to dispense with outside of the workpiece to be arranged guide devices.
  • a honing tool is used for this purpose, which comprises a set of distributed around the circumference of the honing tool guide rails for axial guidance of the honing tool in the bore, which are preferably fed independently of the cutting group in the direction of the inner surface of the bore, wherein the substantially rigid guidance of the axial movement is achieved in that the guide rails are pressed during the movement of the honing tool in the bore to the inner surface of the bore.
  • the guide rails center the honing tool within the bore.
  • the guide rails are preferably designed so that they generate little or no material removal, which is referred to herein as "substantially non-cutting guide rails".
  • the guide rails can at least in the coming into contact with the inner surface of the bore areas of a plastic, rubber, an elastomer of suitable hardness (eg Vulkollan®), a metal, a hard metal or a ceramic or it can be honing stones with a act high proportion of cutting material.
  • the substantially rigid guidance of the axial movement of the honing tool can be attained in that the honing tool is guided axially immovably outside the bore of the workpiece and substantially immovably transversely to the tool axis.
  • this can be a one-sided leadership exclusively on the inlet side of the hole, a one-sided leadership exclusively at the inlet side opposite the exit side of the bore (in through holes), or a two-sided guide both on the inlet side, and be provided on the opposite outlet side.
  • a rigidly against transverse load coupling of the honing tool to a rigidly guided against transverse load honing spindle may possibly also be sufficient to ensure the rigid guidance of the axial movement of the honing tool. Then possibly can be completely dispensed with guide elements in the field of honing tool.
  • the exclusively external guidance of the axial movement of the honing tool requires the highest accuracy in the relative positioning between the workpiece and the honing tool.
  • a honing tool which has a single separately deliverable cutting group, which preferably has a pressure angle of less than 90 °.
  • the term "pressure angle” here describes the angular range along the circumference of the honing tool, are in the cutting material body of the cutting group in engagement with the bore wall. Often it is advantageous if the pressure angle between about 1 ° and about 70 °, it may for example be between 5 ° and 60 ° and / or between 20 ° and 45 °. The smaller the pressure angle, the more accurate is a complex shape of the contour of the inner surface to be achieved by controlling the feed force in dependence on the angular position of the honing tool.
  • honing tools with several independently deliverable cutting groups, provided that the control ensures that the contact pressure of one cutting group is independent of the contact pressure of other cutting groups arranged at other circumferential positions.
  • a honing tool with four circumferentially offset by 90 ° arranged cutting groups used, so their delivery pressure can be controlled so that each result in 90 ° out of phase Zustelltikverrise between circumferentially offset by 90 ° cutting groups. It can thereby be achieved that during a single revolution of the honing tool, the same peripheral portion of the bore inner wall is reworked by the four cutting groups in succession material removal. As a result, the removal rate can be increased overall.
  • the control of the feed force is carried out so that the feed force or the contact pressure during a full rotation of the honing tool to the tool axis in a predetermined axial bore area more than two, in particular more than four local maxima and minima passes.
  • the local maxima or minima result from a periodic or aperiodic change between increase and decrease in the feed force during a tool revolution.
  • the feed force of a honing tool with a single unilaterally arranged cutting group would require four uniformly spaced maxima and four intermediate, equally spaced local minima of the delivery force in one revolution of the honing tool to produce the quadruple symmetrical shape starting from an ideal circular cylindrical shape.
  • the control of the honing machine configured so that significantly higher numbers of local maxima and minima are generated, so for example a complex bore cross-sectional shape can be generated, the basic shape of the 4-fold symmetrical shape is similar, but the short-wave diameter or radius variations according to Art superimposed by "harmonics".
  • a non-circular-cylindrical bore shape is generated, which deviates significantly from a shape that is 2-fold radially symmetrical with respect to the bore axis.
  • the shape deviations from a 2-fold radially symmetrical shape relative to the bore axis correspond to a cylindricity error of significantly more than 10 .mu.m, the cylindricity error preferably being more than 20 .mu.m, in particular between 20 .mu.m and about 60 .mu.m.
  • the cylindricity error is described here by the cylinder shape tolerance.
  • the associated tolerance zone is determined by two to the bore axis and mutually coaxial, the bore inner wall inside or outside touching cylinder, wherein the radial distance between the two cylinders is a measure of the cylinder quality.
  • a suitable for performing the method honing tool has a tool body which defines a tool axis; a cutting group attached to the tool body with at least one cutting material body for material-removing machining of the inner surface; and one of the cutting group associated cutting group delivery system for exerting a radially acting on the tool axis feed force on the cutting body of the cutting group, wherein the cutting material body of the cutting group are arranged exclusively on one side of the honing tool and wherein the honing an axial guide means for substantially rigid guidance of the axial movement of the honing tool is assigned substantially parallel to the bore axis.
  • the axial guide device is designed to receive the reaction force generated by the pressed-on cutting group.
  • the honing tool is characterized in that the cutting group delivery system acting on the cutting group comprises a combination of a basic delivery system with a dynamic fine delivery system, wherein the basic delivery system for the cutting group is designed so that the material-removing areas of the cutting material body of the bore inner wall to a small distance or can be approximated to touch (coarse feed).
  • the radial displacement of the base for example, mechanically, electromechanically or hydraulically operable basis delivery system can be in the range of one or more millimeters (eg up to 4 mm).
  • the dynamic fine delivery system in contrast, is subject to short-term load changes or short-term changes in the infeed pressure and relatively short adjustment paths optimized in order to be able to carry out many load changes, even when the honing tool is rotating rapidly, with one complete revolution of the honing tool.
  • Typical adjustment of the fine delivery system can be in the range of less than 100 microns, for example in the range between 20 microns and 60 microns radial displacement.
  • the dynamic fine delivery system comprises a piezoelectric system, which can be arranged, for example, between a carrier element which can be adjusted by the base delivery system into a predeterminable radial position and the cutting material bodies of the cutting group.
  • the cutting bodies can be driven in groups or individually, if necessary also out of phase with each other.
  • a combination of a base delivery system, e.g. with drive in the honing machine, with a dynamic fine delivery system, the drive is integrated into the honing tool is possible.
  • the honing tool may have a single cutting group, which preferably has an engagement angle of less than 90 °.
  • Such a honing tool can be controlled such that, when the cutting body of this cutting group engages the inner wall of the bore in a peripheral region of at least 270 ° of the circumference, no cutting material bodies are simultaneously in material-removing engagement with the bore wall.
  • the Axial Installations has guide rails for an axial guidance of the honing tool in the bore, wherein the guide powers are deliverable by means of a guide strip feed device in the direction of the inner surface of the bore.
  • the guide rails are deliverable independently of the cutting group in the direction of the bore inner surface.
  • the Axial Installations comprises a set of distributed around the circumference of the honing tool guide rails for axial guidance of the honing tool in the bore, wherein the guide rails are deliverable by means of a guide bar feed device regardless of the cutting material bodies of the cutting group in the direction of the inner surface of the bore.
  • a cardan, Doppelkardanisch or floating mounted honing tool with double widening i. be used with two independently activatable delivery systems.
  • a feed system activates the guide rails that center the honing tool in the hole.
  • the other feed system activates a cutting group mounted on one side of the honing tool, which causes the locally limited material removal in its pressure angle range.
  • the feed force of the cutting material body of the cutting group which corresponds to a corresponding contact pressure of the cutting material, is then controlled as a function of stroke position and / or angular position of the honing tool to cause targeted material removal in predetermined areas along the circumference and in the axial direction of the bore.
  • the reaction force of the cutting material body in cutting engagement with the bore inner wall is intercepted on the opposite side from the guide rails without affecting the bore shape.
  • guide rails in particular comprises strip-shaped guide elements, which ensure the centering. Also differently shaped guide elements should be detected, as far as they fulfill the function of the substantially rigid axial guidance of the honing tool by supporting on the inner wall of the bore.
  • the cutting group feed system acting on the cutting group can be controlled by a drive mounted in the honing machine, which acts on the cutting material body of the cutting group via a feed linkage or via a gear and determines its delivery force.
  • the cutting group feed system of the honing tool is designed for transmitting the feed force of a drive arranged outside of the honing tool. It is also possible for the cutting group feed system for the cutting group to have a drive arranged within the honing tool.
  • Hydraulic, electromechanical, piezoelectric, pneumatic and other suitable drives can be used in the feed systems for both the guide rails and the cutting bodies of the cutting group.
  • the substantially rigid axial guidance of the honing tool is achieved in some embodiments in that the axial guiding device comprises at least one guide unit to be arranged outside the bore during honing for substantially rigid guidance of the axial movement of the honing tool.
  • Honing tools with a rigid tool guide can be used. In this case, only the cutting group feed system is needed to operate the cutting group mounted on one side of the honing tool. The reaction forces of the pressed cutting material body are absorbed by the rigid tool guide. In this case honing tools with simple expansion can thus be used.
  • the complex, non-circular and possibly asymmetrical bore shape is produced by honing, starting from a bore shape produced by a pre-machining step.
  • this shaping by honing does not lead to the surface structure desired for the inner surface of the bore, which decisively influences the tribological properties of the inner surface. Therefore, in a preferred embodiment, after the shape-generating honing operation to produce the non-circular bore shape, at least one substantially shape-neutral (ie, the macro-shape of the Bore not significantly changing) machining operation for processing near-surface areas of the inner surface performed.
  • This may be, for example, a so-called "plateau honing" in which the tips of the roughness profile are cut to improve the motor enema.
  • a licehonriel or a sequence of insects and Plateauhonen is possible.
  • the inner surface is preferably machined with a plurality of relatively moveable, elastically mounted cutting material bodies in the substantially dimensionally neutral machining operation, which has a maximum extent of less in the circumferential direction of the honing tool than 3% of the effective range of the honing tool.
  • the cutting material body can also be very small in the axial direction, for example, their axial length may be less than 10% of the honing tool length.
  • a workpiece may be made having at least one bore having a honed inner surface, wherein the bore is in at least an axial bore portion has a non-circular cylindrical bore shape that deviates significantly from a relative to the bore axis 2-fold radially symmetric shape and in particular has a cylindricity error of more than 20 microns.
  • the workpiece may be a cylinder block for an internal combustion engine, wherein the bore is a cylinder bore of the cylinder block and the shape deviation is designed such that the cylinder bore in the ready-assembled state or in the operating state of the cylinder block with the cylinder head screwed onto the cylinder block a cylindricity of less than about 10 microns.
  • a honing machine suitable for carrying out the method has a feed force control device for controlling the feed force of a cutting group attached to a honing tool as a function of the angular position and possibly the stroke position of the honing tool in a bore, wherein the feed force control device is configured or configurable in that the bore receives a non-circular-cylindrical bore shape, at least in an axial bore section, which deviates significantly from a shape that is 2-fold radially symmetrical with respect to the bore axis.
  • the feed force control device for controlling the feed force of a cutting group mounted on one side on a honing tool can in particular be configured so that the delivery force during a full rotation of the honing tool around the tool axis in a predetermined axial bore area more than two, in particular more than four local maxima and Minima goes through.
  • Fig. 1 shows a schematic, oblique perspective view of a cylinder block (engine block) 100 for a 4-cylinder internal combustion engine.
  • the cylinder block consisting of a cast material or a light metal material
  • four axially parallel cylinder bores 101, 102, 103, 104 are arranged at equal distances in series next to one another such that their central bore axes 111 lie in a common plane (cylinder plane 112).
  • From the upper side of the cylinder block are provided internally threaded bores 115 axially parallel to the cylinder head bores so that in each case four of these bores are distributed uniformly around the circumference of a cylinder bore.
  • the holes 115 are used to receive cylinder head bolts, with the help of which, after completion of the processing of the cylinder block of the associated cylinder head is screwed onto the cylinder block 100 with the interposition of a cylinder head gasket.
  • the cylinder block 100 is a structurally nonuniform workpiece, in which in particular each of the cylinder bores 101-104 has a different workpiece environment, in particular with regard to the wall thickness in the region of the cylinder bores and also by different connections to the coolant channels of the engine block internal cooling system.
  • the inner cylinder bores 102 and 103 of the second and third cylinders each have two adjacent cylinder bores in the cylinder plane, while the outer cylinder bores (cylinders 1 and 4) have only one inner adjacent cylinder bore and on the opposite side to thicker wall sections of the workpiece.
  • the workpiece 100 formed by the cylinder block is clamped on a work table (not shown) of a honing machine, not shown, with two honing spindles, wherein only one honing spindle 120 is shown.
  • the cylinder surfaces formed by the inner surfaces 130 of the cylinder bores are subjected to a quality-determining finishing on the honing machine, in which both the macro-shape of the cylinder surfaces, as well as their surface topography is produced by suitable honing processes.
  • the honing machine comprises for each of its honing spindles a spindle motor for rotating the honing spindle about its longitudinal axis and a lifting drive for generating a vertical movement of the honing spindle when inserting the honing tool into the workpiece or when pulling out of the workpiece.
  • the lifting drive is controlled during machining so that the honing tool executes a vertical reciprocating movement within the bore, which is superimposed on the rotational movement of the workpiece (see arrows).
  • a honing tool 150 is coupled, which is at a gimbal-mounted honing tool with double widening acts.
  • the honing tool has a tool body 155 which carries on one side of its circumference a cutting group 160 formed by a single honing stone, which can be delivered or withdrawn in the radial direction to the bore inner wall by means of a not-shown cutting group delivery system.
  • a set of unevenly distributed around the circumference of the honing tool guide rails 170 is provided on the tool body, which can be delivered independently of the cutting group 160 in the direction of the inner surface of the bore by means of a guide rail delivery system.
  • substantially rigid guidance of the axial movement of the honing tool within the bore results parallel to the bore axis 113, so that the guide rails form an axial guide device for the honing tool.
  • the feed movement of both the guide rails and the cutting group and the respectively applied feed force are independently controlled by means of a Zustellkraft control device 180 of the honing machine, in particular the feed force of the cutting group 160 highly dynamically depending on the stroke position of the honing tool (measured along the bore axis) and the angular position of the cutting group (in the circumferential direction) can be selectively varied in rapid change.
  • the Fig. 2 to 4 show elements of various embodiments of inventive honing tools, which are designed especially for the processing of cylinder surfaces in cylinder blocks.
  • the honing tool 200 in Fig. 2 has arranged on one side of the tool axis 201 cutting group 260 with two peripherally offset on the circumference of the tool body 255 mounted, formed by honing strips cutting material body 261, which during honing in a pressure angle range 265 of about 45 ° attack on the bore inner wall.
  • Their axial length is between 30% and 50% of the axial length 266 of the honing tool.
  • the honing tool comprises an integrated axial guide device, which is formed in the example by a number of evenly distributed around the circumference of the honing tool guide rails 270 which are radially deliverable independently of the honing stones 261 of the cutting group 260.
  • the guide rails extend substantially over the entire axial length 266 of the honing tool, the honing stones 261 are mounted in the axial central region (in other embodiments in the lower end region) of the support length defined by the guide rails.
  • the honing tool 300 in Fig. 3 has arranged on one side of the tool axis 301 cutting group 360 with two peripherally offset on the circumference of the tool body 355 mounted, formed by honing strips cutting body 361 attacking during honing in an engagement angle range of about 45 ° on the bore inner wall.
  • Their axial length is between 60% and 80% of the axial length of the honing tool.
  • the axial guidance device 370 of the honing tool comprises a guide section 371, which is attached to the spindle-side end of the tool body and has a circular-cylindrical outer surface, which is axially and rotationally guided in a guide unit 372 (upper guide) arranged outside the workpiece and fastened to the honing machine.
  • Fig. 4 shows a guided perpendicular to the tool axis 401 section through a honing tool 400, which is a variant of the in Fig. 2 shown double-expandable honing tool is.
  • the cutting group 460 mounted on one side of the tool axis 401 comprises two cutter bodies 461, 462 which are arranged offset by approximately 80 ° to 90 ° and can be controlled separately and which define an engagement angle range 465 of approximately 90 °.
  • the integrated axial guide device comprises six guide rails 471-476 distributed around the circumference of the tool body, which can be delivered in the radial direction to the bore inner wall with the aid of a force-limited guide rail feed system 480 in order to guide the tool substantially axially slidable within the bore, but axially transversely to the bore axis ,
  • the guide rails consist of a hard, abrasion-resistant elastomer (Vulkollan® here), have a substantially smooth pressure surface and exert no material removal during the axially oscillating and rotating movement of the honing tool in the cylinder bore.
  • the cutting group 460 is mounted on one side of the honing tool. This means, in particular, that all of the cutting material bodies standing in honing processing in material-removing engagement with the bore inner wall lie on the same side of the tool bisecting tool level 490, which contains the tool axis 401 and is perpendicular to the bisector of the cutting group 460. On the side of the cutting group is essentially only one, mounted between the cutting material body guide rails 471 and a part of the vertically aligned guide rails.
  • a high spatial density of guide rails corresponding to a comparatively large contact surface is provided, so that the opposing force acting on the opposite guide rails 473-475 when the cutting material body presses against the bore inner wall converts a relatively low contact pressure of these guide rails on the bore inner wall, whereby a bore wall gentle, smooth axial guidance of the honing tool is achieved within the bore.
  • the feed movement of the cutting bodies 461 of the cutting group 460 is controlled by means of a cutting group feed system 450, which is divided into two independently operable subsystems.
  • a Basiszustellsystem 452 has a relatively large displacement of several millimeters and serves to deliver the radial outer surfaces of the Schneidstoff emotions 461, 462 after applying the guide rails to the bore inner wall to a few microns to the bore inner wall.
  • the radial position of support elements 453 of the base delivery system achieved by this adjustment movement remains unchanged during honing.
  • the mechanical drive for the base delivery system is seated in the honing machine, the drive movement is achieved by suitable feed elements including a coaxially seated in the tool body Zustellkonus (see. Fig. 5 ) causes.
  • a dynamic fine delivery system 454 which, starting from the radial position predetermined by the base delivery system, permits radial delivery or radial retraction of the cutting material bodies.
  • the characterized by low moving masses Feinzustellsystem is designed in this way highly dynamic and allows during a single revolution of the honing tool several, eg between two and ten, periodic or aperiodic change between increase and decrease in the delivery force to complex curved and with a variety of local maxima and minima to create contours provided the bore inner wall with high accuracy.
  • the piezoelectric or otherwise driven fine delivery system can also above the Zustellkonus between this and the Grobzustellsystem be arranged. In this position, the fine delivery system can be arranged both on the rotating part of the honing spindle, as well as on the non-rotating part of the honing machine.
  • Fig. 5 Further details of a basic delivery system and a fine delivery system are shown schematically, which also in the honing tools according to Fig. 2 or Fig. 4 can be used in the illustrated or modified manner.
  • the cutting group 560 mounted on the honing tool on one side to the tool axis 501 comprises five axis-aligned honing strips 561 which are mounted on a common carrier 562 and define an overall pressure angle of approximately 30 °.
  • the BasisZustellsystem 552 of the cutting group delivery system 550 includes a parallel to the tool axis axially movable cone 554.
  • a piezoelectric drive element 555 of the fine delivery system 556 is attached, which is arranged between the carrier element 553 and the carrier element 562 for the honing stones.
  • the radial thickness of the piezoelectric actuator 555 is determined by applying appropriate control voltages provided by the controller 180 (FIG. Fig. 1 ) are provided, radially adjustable in an adjustment range of about 20 microns to about 60 microns to possibly allow a quick change of the delivery pressure of the cutting material body.
  • Fig. 6 (a) a schematic peripheral record and Fig. 6 (b) a schematic longitudinal section of the dimensions of a cylinder surface.
  • radial distances of the bore inner wall from the bore axis BA are shown as a function of the circumferential position along the bore inner surface, the zero point of the circumferential direction and the 180 ° position in the cylinder plane 112 defined by the bore axes of the cylinders (cf. Fig.
  • the 90 ° and 270 ° positions represent the perpendicular regions near the front and rear broad sides of the cylinder head.
  • the curves R O , R M and R U represent the radius in the vicinity of the upper inlet opening of the cylinder bore (R O ), in the axial center region of the cylinder bore (R M ) and in the vicinity of the lower end of the cylinder bore (R U ).
  • curves of the circumferential letter are each related to a zero line lying concentrically to the bore axis, which in the representation in Fig. 8 each dashed line is drawn. The same radial scale in the radial direction serves for all measuring curves.
  • the longitudinal letters in Fig. 6 (b) each show the course of the generatrices (parallel to the bore axis) in the selected peripheral areas at 0 °, 90 °, 180 ° and 270 °.
  • the schematic Messrume in Fig. 6 represent at the selected resolution, a substantially circular cylindrical shape of the bore inner surface with a cylindricity .DELTA.Z of about 10 microns.
  • a relatively small cylindricity error is considered sufficient in some applications to interact with substantially circular during operation of the internal combustion engine Piston rings over the entire length of the cylinder to ensure adequate sealing.
  • a cylinder block of a series of cylinder blocks to be manufactured is clamped in the honing machine.
  • the cylinder block is braced by means of a tensioning device, which essentially simulates the clamping forces acting on the cylinder block when a cylinder head is screwed onto the cylinder block.
  • a tensioning device which essentially simulates the clamping forces acting on the cylinder block when a cylinder head is screwed onto the cylinder block.
  • a tensioning device which essentially simulates the clamping forces acting on the cylinder block when a cylinder head is screwed onto the cylinder block.
  • a tensioning device which essentially simulates the clamping forces acting on the cylinder block when a cylinder head is screwed onto the cylinder block.
  • a tensioning device which essentially simulates the clamping forces acting on the cylinder block when a cylinder head is screwed onto the cylinder block.
  • a clamping device according to the patent DE 28 10 322 C2 are used, the content of which
  • the cylinder bores of the strained and possibly heated cylinder block are honed in a single-stage or multi-stage honing process to obtain a possible circular cylindrical bore shape.
  • a cylinder shape error ⁇ Z of less than 10 ⁇ m is achieved in this phase of machining.
  • Typical calipers used to determine the shape of the bore can be found in Fig. 6 show characteristics shown.
  • a typical machined cylinder bore has after this production step in all axial positions a substantially circular circumference with a surface contour without pronounced maxima, minima or inflection points and in the axial direction (longitudinal) at different positions along the circumference practically no or only a very slight, gradual variation of the radius or of the diameter ( Fig. 6 (B)).
  • the clamping device After completion of this phase of processing, the clamping device is removed, so that the elastic deformation produced by the clamping device and possibly by the action of temperature are reduced in the workpiece and this assumes a relaxed state.
  • Fig. 7 shows an example of the corresponding Fig. 6 recorded measurement records in the circumferential direction ( Fig. 7a ) and in the axial direction ( Fig. 7b ) of the marginal fourth cylinder bore 104 in Fig.
  • the hole in the vicinity of the cylinder head side entrance side (represented by the curve R O ) has an approximately 2-fold radial symmetry about the bore axis BA, in which the largest diameter obliquely to the cylinder plane in the range of the circumferential angle 135 ° or 315 ° results, while perpendicular thereto (corresponding to angular positions 45 ° and 225 °) also form local maxima of the radius, but are at smaller absolute radius values.
  • the approximately 2-fold symmetrical basic shape are superimposed on smaller radius fluctuations, for example in the range of 180 °.
  • curve R M In the axial center region of the bore (curve R M ) results in a much more complex relationship between circumferential position and bore radius or bore diameter. In the example shown, approximately eight local maxima of the inner radius, which are separated by local minimums of the inner radius, result in the circumferential direction. The largest radii tend to remain inclined to the cylinder plane.
  • the bore cross section is also asymmetrical, but the 2-fold radial symmetry still indicated at the cylinder head end no longer dominates and dominates an almost completely irregular bore cross-sectional shape.
  • the asymmetrically warped hole shape that can be characterized in this way corresponds to a cylindricity ⁇ Z of between 30 ⁇ m and 40 ⁇ m.
  • This complex and asymmetrically deformed bore geometry will be deformed when placing and screwing a cylinder head and heating the resulting hull motor in the range of operating temperatures back to a largely cylindrical bore shape, as shown by Fig. 6 was explained.
  • the complexly deformed bore geometry is now measured after removal of the clamping device in order to determine in this way the local radii of the distorted shape as a function of the axial position and the circumferential position.
  • a data set is determined, which represents the relaxation, complex and asymmetrically deformed bore geometry.
  • This complex bore shape corresponds to a "negative mold” that is to be achieved in the machining of the other cylinder blocks of the series by shaping honing machining, if the machined cylinder bores in the mounted state of the engine should have a largely cylindrical shape with low cylindricity.
  • the geometry data representing the complex unsymmetrical bore shape separately for each cylinder bore is stored in the controller 180 in a suitable form.
  • they can be compared with measured values of a dimensional measuring system with tool-internal sensors (eg air measuring system) and converted into corresponding data for the delivery pressure with which a one-sided attached to a honing tool cutting group must be acted to axially rigid guide the honing tool and control of Feed force of the cutting group as a function of the axial position and the angular position of the honing tool to achieve the complex asymmetrically shaped bore shape.
  • tool-internal sensors eg air measuring system
  • Fig. 8 shows exemplary for two axial positions of the cylinder (represented by the curves R O and R M in Fig. 8 (a) ) the stroke and rotation angle-dependent radius profile of the bore (in Fig. 8 (a) ) and in Fig. 8 (b) the course of the feed force F on the rotation angle ⁇ , respectively in the corresponding axial heights.
  • the dashed curve F O represents the variation of the feed force over the rotation angle that would be required when a honing tool whose cutting group rotates in the upper end portion of the cylinder bore processes the inner surface.
  • the solid line F M corresponds to the temporal variation or angle variation that would be required in the middle region of the bore (R M ).
  • the cylinder bore can be measured by means of a shape measuring system.
  • a possibly existing, measured difference of the actual shape from the desired shape can be used to correct the infeed system as a function of stroke position and angle of rotation.
  • a measurement of the bore shape can thus be carried out for determining actual shape values, and a difference between the shape Is values and the desired shape can be processed to correct the control of the delivery force.
  • the material-removing machining steps for generating the complex, non-circular and possibly asymmetrical bore shapes are produced with the aid of a honing tool (or with the aid of a plurality of honing tools used in succession), the cutting group of these honing tools being designed for a substantial material removal, around the macro-shape of the bore in the desired manner.
  • the microstructure of the machined inner bore surface may not meet the operational requirements for surface roughness and / or surface texture. Therefore, in preferred methods after the predetermining processing steps at least one substantially form-neutral, ie the macro-shape of the bore substantially non-changing machining operation is performed.
  • This honing tools with correspondingly adapted to the surface requirement grit of the cutting material body and / or brush or Plateauhontechnikmaschinee and / or other surface structure changing processing tools are used, for example, non-contact tools, such as laser and / or water jet generator, which can change the surface structure of the bore inner surface without affecting the macro-shape ,
  • FIGS. 9 and 10 show in plan view and cross-section, a cutting group 960, which is optimized for a "Plateauhonbearbeitung" unsymmetrical bore shapes to cut the still present after the shaping honing tips of the roughness profile and thereby increase the bearing ratio of the surface. Since in the previous processing steps a bore shape with possibly very small local radii in the range of local minima or maxima can be generated, a honing tool is provided whose cutting group 960 is capable of the corrugated surface of a targeted non-circularly machined bore with a cylindricity of to process substantially uniformly over 10 ⁇ m.
  • a more segmented honing system in which the cutting material bodies 961 formed by honing stone segments are applied to an inherently elastic base body 965, for example a plate made of a rubber-like material.
  • This intrinsically elastic base body is applied to the actual base material 966 of the honing stone, for example a support made of steel, copper or the like, by gluing or in some other way.
  • the square honing stone segments 961 have an extension of 10mm x 10mm.
  • Honing tools with one or more such cutting groups can be used regardless of the other features of the invention and the method described herein in other honing process for the final machining of holes in workpieces.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Geometry (AREA)
  • Finish Polishing, Edge Sharpening, And Grinding By Specific Grinding Devices (AREA)

Claims (11)

  1. Procédé de honage de la surface interne d'un alésage dans une pièce, en particulier pour le honage d'une surface de roulement d'un cylindre dans la fabrication de blocs-cylindres de moteurs à combustion interne, dans lequel un outil de honage est déplaçable axialement à l'intérieur de l'alésage et est entraîné en rotation autour de son axe d'outil, et un ensemble de coupe (160, 260, 460, 560) monté sur l'outil de honage est pressé avec une force d'avance contre la surface interne avec au moins un corps en matière coupante pour l'usinage par enlèvement de matière de la surface interne, un guidage sensiblement rigide du mouvement axial de l'outil de honage a lieu au moyen d'un dispositif de guidage axial (170, 270, 471-476) pour produire un mouvement axial de l'outil de honage sensiblement parallèlement à l'axe d'alésage de l'alésage, et une commande asymétrique dans le temps de la force d'avance d'un ensemble de coupe monté d'un côté de l'axe d'outil sur l'outil de honage est mise en oeuvre en fonction de la position angulaire et éventuellement de la position de la course de l'outil de honage de telle sorte que l'alésage acquière au moins dans une portion d'alésage axiale une forme d'alésage non cylindrique circulaire, l'ensemble de coupe monté d'un côté sur le corps d'outil étant avancé au moyen d'un système d'avance de base (452, 552) sur une grande première course de réglage jusqu'à une position radiale prédéfinissable, une avance ou un retrait radial(e) de l'ensemble de coupe sur des deuxièmes courses de réglage courtes par rapport à la première course de réglage ayant lieu au moyen d'un système d'avance fine dynamique (454, 556) pouvant être commandé par le système d'avance de base à partir de la position radiale prédéfinie par le système d'avance de base, et le dispositif de guidage axial recevant la force de réaction produite par l'ensemble de coupe pressé.
  2. Procédé selon la revendication 1, dans lequel le système d'avance fine (454, 556) produit plusieurs changements périodiques ou non périodiques, notamment entre deux et dix changements, entre l'augmentation et la réduction de la force d'avance, pendant une rotation unique de l'outil de honage.
  3. Procédé selon la revendication 1 ou 2, dans lequel le système d'avance de base (452, 552) est commandé par le biais d'un entraînement disposé à l'extérieur de l'outil de honage et le système d'avance fine (454, 556) est commandé par le biais d'un entraînement disposé à l'intérieur de l'outil de honage, l'entraînement disposé à l'intérieur de l'outil de honage fonctionnant de préférence de manière électromécanique ou piézoélectrique.
  4. Procédé selon l'une quelconque des revendications précédentes, dans lequel l'ensemble de coupe est avancé au moyen du système d'avance de base (452, 552) sur une première course de réglage qui mesure au moins un millimètre, de préférence au moins 4 mm, l'ensemble de coupe (460, 470) étant déplacé au moyen du système d'avance fine sur une deuxième course de réglage qui est de l'ordre de moins de 100 µm, notamment qui est comprise entre 20 µm et 60 µm de rayon.
  5. Procédé selon l'une quelconque des revendications précédentes, dans lequel l'outil de honage est supporté de manière déplaçable en coulissement axial par rapport au guidage sensiblement rigide du mouvement axial à l'intérieur de l'alésage et de manière sensiblement immobile transversalement à l'axe de l'outil, un outil de honage comprenant des nervures de guidage (471 - 476) pour le guidage axial de l'outil de honage dans l'alésage étant de préférence utilisé, les nervures de guidage pouvant être avancées de préférence indépendamment de l'ensemble de coupe (460, 470) dans la direction de la surface interne de l'alésage, le guidage sensiblement rigide du mouvement axial étant réalisé de telle sorte que les nervures de guidage soient pressées pendant le mouvement de l'outil de honage dans l'alésage contre la surface interne de l'alésage.
  6. Procédé selon l'une quelconque des revendications précédentes, dans lequel une forme d'alésage non cylindrique circulaire est produite, laquelle s'écarte considérablement d'une forme à symétrie radiale centrale par rapport à l'axe de l'alésage, des écarts de forme étant de préférence produits sur l'alésage, lesquels correspondent à un défaut de cylindricité ΔZ de plus de 10 µm, le défaut de cylindricité ΔZ étant de préférence supérieur à 20 µm, notamment compris entre 20 µm et environ 60 µm, le défaut de cylindricité étant défini comme ΔZ=(DA-DI)/2, DA étant le diamètre d'un cylindre en contact avec l'extérieur de la surface interne de l'alésage, et DI étant le diamètre d'un cylindre en contact avec l'intérieur de la surface interne de l'alésage.
  7. Procédé selon l'une quelconque des revendications précédentes, dans lequel, après l'opération de honage produisant la forme, pour produire la forme non ronde de l'alésage, au moins une opération d'usinage n'affectant pas sensiblement la forme a lieu pour usiner des régions proches de la surface de la surface interne, l'opération d'usinage n'affectant pas la forme étant de préférence un usinage par honage à plateau, dans lequel les pointes du profil de rugosité produit par les opérations de honage précédentes sont coupées et/ou dans lequel de préférence dans l'opération d'usinage n'affectant pas sensiblement la forme, la surface interne de l'alésage est usinée avec une pluralité de corps en matière coupante (961) montés élastiquement et déplaçables les uns par rapport aux autres.
  8. Outil de honage, en particulier pour la mise en oeuvre du procédé selon l'une quelconque des revendications précédentes, comprenant un corps d'outil qui définit un axe d'outil (201, 401, 501), un ensemble de coupe (160, 260, 460, 560) monté sur le corps d'outil avec au moins un corps en matière coupante pour l'usinage par enlèvement de matière de la surface interne, et un système d'avance des ensembles de coupe (450, 550) associé à l'ensemble de coupe pour exercer une force d'avance agissant radialement par rapport à l'axe de l'outil sur les corps en matière coupante de l'ensemble de coupe, les corps en matière coupante de l'ensemble de coupe étant disposés exclusivement d'un côté de l'outil de honage et un dispositif de guidage axial (170, 270, 471-476) étant associé à l'outil de honage pour le guidage sensiblement rigide du mouvement axial de l'outil de honage sensiblement parallèlement à l'axe de l'alésage, le dispositif de guidage axial étant conçu pour recevoir la force de réaction produite par l'ensemble de coupe pressé, caractérisé en ce que le système d'avance des ensembles de coupe (450, 550) agissant sur l'ensemble de coupe comprend une combinaison d'un système d'avance de base (452, 552) et d'un système d'avance fine dynamique (454, 556), le système d'avance de base (452, 552) étant conçu de telle sorte que dans le cas d'une avance grossière, les régions enlevant la matière des corps en matière coupante puissent être rapprochées à l'aide du système d'avance de base de la surface interne de l'alésage sur une première grande course de réglage jusqu'à une faible distance ou jusqu'à venir en contact, et le système d'avance fine dynamique (454, 556) étant conçu pour produire un changement rapide de la pression d'avance et des courtes deuxièmes courses de réglage par rapport à la première course de réglage.
  9. Outil de honage selon la revendication 8, dans lequel la première course de réglage du système d'avance de base (452, 552) mesure au moins un millimètre, de préférence au moins 4 mm, et la deuxième course de réglage du système d'avance fine (454, 556) est de l'ordre de moins de 100 µm, notamment est comprise entre 20 µm et 60 µm de rayon.
  10. Outil de honage selon l'une quelconque des revendications 8 ou 9, dans lequel le système d'avance de base (452, 552) de l'outil de honage est réalisé pour transférer la force d'avance d'un entraînement disposé à l'extérieur de l'outil de honage, de préférence mécanique ou hydraulique, et le système d'avance fine (454, 556) possède au moins un entraînement (455, 555) disposé à l'intérieur de l'outil de honage, de préférence électromécanique ou piézoélectrique.
  11. Outil de honage selon l'une quelconque des revendications 8 à 10, dans lequel le dispositif de guidage axial comprend des nervures de guidage (170, 270, 471 - 476) pour le guidage axial de l'outil de honage dans l'alésage, les nervures de guidage pouvant être avancées dans la direction de la surface interne de l'alésage au moyen d'un dispositif d'avance à nervures de guidage (480), de préférence indépendamment de l'ensemble de coupe.
EP09009260A 2005-11-25 2005-11-25 Procédé destiné à empierrer des trous de forage tout comme outil à empierrer Ceased EP2110204B1 (fr)

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EP10010546.9A EP2277662B1 (fr) 2005-11-25 2005-11-25 Procédé destiné à empierrer des trous de forage tout comme outil à empierrer
EP10010544A EP2279829B1 (fr) 2005-11-25 2005-11-25 Procédé destiné à empierrer des trous de forage tout comme outil à empierrer
EP10010545A EP2277661B1 (fr) 2005-11-25 2005-11-25 Procédé destiné à empierrer des trous de forage tout comme outil à empierrer

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EP20050025813 EP1790435B1 (fr) 2005-11-25 2005-11-25 Procédé de rodage d'alésages, et outil de rodage

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EP10010546.9A Ceased EP2277662B1 (fr) 2005-11-25 2005-11-25 Procédé destiné à empierrer des trous de forage tout comme outil à empierrer
EP20050025813 Expired - Fee Related EP1790435B1 (fr) 2005-11-25 2005-11-25 Procédé de rodage d'alésages, et outil de rodage
EP10010544A Ceased EP2279829B1 (fr) 2005-11-25 2005-11-25 Procédé destiné à empierrer des trous de forage tout comme outil à empierrer
EP09009260A Ceased EP2110204B1 (fr) 2005-11-25 2005-11-25 Procédé destiné à empierrer des trous de forage tout comme outil à empierrer
EP10010545A Ceased EP2277661B1 (fr) 2005-11-25 2005-11-25 Procédé destiné à empierrer des trous de forage tout comme outil à empierrer

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EP10010546.9A Ceased EP2277662B1 (fr) 2005-11-25 2005-11-25 Procédé destiné à empierrer des trous de forage tout comme outil à empierrer
EP20050025813 Expired - Fee Related EP1790435B1 (fr) 2005-11-25 2005-11-25 Procédé de rodage d'alésages, et outil de rodage
EP10010544A Ceased EP2279829B1 (fr) 2005-11-25 2005-11-25 Procédé destiné à empierrer des trous de forage tout comme outil à empierrer

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EP2277662A1 (fr) 2011-01-26
EP2279829A1 (fr) 2011-02-02
DE502005008150D1 (de) 2009-10-29
EP1790435B1 (fr) 2009-09-16
EP2279829B1 (fr) 2012-06-06
EP1790435A1 (fr) 2007-05-30
EP2277661B1 (fr) 2012-12-26
EP2110204A1 (fr) 2009-10-21
EP2277662B1 (fr) 2013-09-25
EP2277661A1 (fr) 2011-01-26

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