EP2277661B1 - 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
EP2277661B1
EP2277661B1 EP10010545A EP10010545A EP2277661B1 EP 2277661 B1 EP2277661 B1 EP 2277661B1 EP 10010545 A EP10010545 A EP 10010545A EP 10010545 A EP10010545 A EP 10010545A EP 2277661 B1 EP2277661 B1 EP 2277661B1
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EP
European Patent Office
Prior art keywords
honing
bore
shape
tool
cutting
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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.)
Expired - Fee Related
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EP10010545A
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German (de)
English (en)
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EP2277661A1 (fr
Inventor
Uwe-Peter Weigmann
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Nagel Maschinen und Werkzeugfabrik GmbH
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Nagel Maschinen und Werkzeugfabrik GmbH
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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 according to the preamble of claim 1. Furthermore, the invention relates to a honing tool, which is particularly suitable and configured for performing the method , according to the preamble of claim 11.
  • the Japanese patent application JP 2000-291487 A describes such a method and such a honing tool.
  • 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 four-fold symmetric out-of-roundness of fourth order, ie a bore shape with 4-fold radial symmetry with respect to the bore axis, have.
  • This non-circular bore shape is achieved by controlling the feed force or the contact pressure of a simply expanding honing tool on the stroke and the rotation angle.
  • the invention provides a method having the features of claim 1 and a honing tool having the features of claim 11.
  • 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.
  • the invention there is a substantially rigid guidance of the axial movement of the honing tool for generating an axial movement of the honing tool substantially parallel to the bore axis of the bore and there is a temporally asymmetric control of the feed force of a mounted on the honing tool cutting group in dependence on the stroke position and / or the angular position of the honing tool performed 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 created by the deformations generated during assembly and during operation should be generated by honing and thus maintained.
  • stiffness and thermal deformation are present in structurally nonuniform workpieces e.g. by wall thickness differences and by different connections of the cylinder liners to the engine-internal cooling system o. The like. Not symmetrical. 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 the cutting group attached to the honing tool ensures that this cutting group effects a removal of material in its pressure angle range, without necessarily leading to a comparable removal of material on the diametrically opposite side Bore inside 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, at any given time, only on one of the opposite sides should a cutting group be in material-removing engagement with the bore inner wall while the cutting group located on the opposite side is relieved of pressure and thus does not or no substantial material removal ,
  • 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.
  • at least one substantially shape-neutral (ie, the macro-shape of the bore not substantially changing) machining operation for processing near-surface areas of the inner surface is performed.
  • the inner surface is machined with a plurality of relatively movable, elastically mounted cutting bodies, which have a maximum extent of less than 3% of the effective circumference of the honing tool in the circumferential direction 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 honing tool which is particularly suitable for performing the shape-neutral machining operation in the method, has a tool body defining a tool axis, a cutting group attached to the tool body having at least one cutting material body for machining the inner surface, and a cutting group associated therewith Cutting group feed system for exerting a force acting radially to the tool axis feed force on the cutting material body of the cutting group.
  • the cutting group has a plurality of relatively movable, elastically mounted cutting bodies, which have in the axial direction of the honing tool a maximum extension of less than 10% of the length of the cutting area of the honing tool and / or in the circumferential direction of the honing tool a maximum Extension of less than 3% of the effective extent of the honing tool have.
  • 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 becomes 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.
  • ⁇ Z (D A -D I ) / 2, where D A is the diameter of the outer bore contacting cylinder and D I is the diameter of the bore bore internally contacting cylinder.
  • 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 strips 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 Ceramics exist or it can be honing stones with a high cutting material content.
  • the substantially rigid guidance of the axial movement of the honing tool is attained in that the honing tool is guided axially immovably outside the bore of the workpiece and substantially immovably transversely to the tool axis.
  • a one-sided guide exclusively on the inlet side of the bore a one-sided guide only on the inlet side gegenübexcellent outlet side of the bore (in through holes), or provided a two-sided guide both on the inlet side, as well as on the gegenübrace outlet side be.
  • 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 exact a complex shape of the contour of the inner surface to achieve by controlling the feed force as a function of the angular position of the honing tool.
  • honing tools with several independently deliverable cutting groups can be used, 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. If, for example, a honing tool is used with four cutting groups each offset by 90 °, their feed pressure can be controlled in such a way that in each case 90 ° out of phase delivery pressure curves are produced between cutting groups circumferentially offset by 90 °. 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.
  • a honing tool suitable for performing the shape-generating honing operation of the method has a tool body defining 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 feed system for exerting a radially acting on the tool axis feed force on the cutting body of the cutting group and is characterized in that the cutting material body of the cutting group are arranged exclusively on one side of the honing tool and that the honing an axial guide means for substantially rigid guide the axial movement of the honing tool is assigned substantially parallel to the bore axis.
  • 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 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 gimbal, Doppelkardanisch or floating mounted honing tool with double widening ie 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 body, 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 on the opposite side of the guide rails without effect on the Bore shape intercepted.
  • 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.
  • the basic delivery system for the cutting group is designed so that the material-removing regions of the cutting material body of the bore inner wall can be approximated to a small distance or 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 can be optimized for short-term load changes or short-term changes in the delivery pressure and relatively short adjustment paths in order to be able to carry out many load changes, even with a rapidly rotating honing tool during a complete revolution of the honing tool.
  • Typical adjustment of the fine delivery system can in 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 is arranged between a carrier element that 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.
  • Dividing the cutting group delivery system into a (coarse) base delivery system and a dynamic fine delivery system may be beneficial, but is not mandatory.
  • the cutting group delivery system is undivided and configured such that the delivery force provided by a drive arranged outside of the honing tool, in particular within the honing machine, is transmitted to the cutting group without intervening drives.
  • 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 guide 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 required for operating the cutting group mounted on one side of the honing tool. The reaction forces of the pressed cutting material body are of the rigid tool guide added. In this case honing tools with simple expansion can thus be used.
  • Producible is e.g. a workpiece having at least one bore, which has a honed inner surface, wherein the bore in at least one axial bore portion has a non-circular cylindrical bore shape, which deviates significantly from a relative to the bore axis 2-fold radially symmetric shape and in particular a cylindricity error of more than 20 has ⁇ m.
  • 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 so that the cylinder bore in the ready-assembled state or in the operating state of the cylinder block with screwed on the cylinder block cylinder head a cylindricity error of less than about 10 microns.
  • a honing machine having a feed force control means for controlling the feed force of a cutting group attached to a honing tool in response to the stroke position and / or the angular position of the honing tool in a bore, wherein the feed force control means is configured or configurable such that the bore receives a non-circular-cylindrical bore shape at least in an axial bore section, which deviates significantly from a 2-fold radially symmetrical shape relative 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 hold cylinder head bolts, with their help after completion of the processing of the cylinder block 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 a gimbal-mounted honing tool with double widening.
  • 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 cutting group not shown.
  • 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 one on one side of the tool axis 201 arranged cutting group 260 with two peripherally offset on the circumference of the tool body 255 mounted, formed by honing strips cutting material body 261 attack during honing in a pressure angle range 265 of about 45 ° 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 about 80 ° to 90 ° angularly offset arranged and separately controllable Schneidstoffmaschine 461, 462, which define an engagement angle range 465 of about 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 by means of a force-limited guide rail feed system 480, so as to be axially slidable within the tool, but substantially rigid within the bore axis to lead the bore.
  • 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 material body 461 of the cutting group 460 is controlled by means of a cutting group feed system 450, which is subdivided 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 be arranged above the Zustellkonus between this and the coarse delivery system. 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 of about 20 microns to about 60 microns, if necessary, a To allow 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 ).
  • the circulating measuring curves of the peripheral document are respectively related to a zero line lying concentrically to the bore axis, which in the illustration in FIG 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 cylindric error will in some applications considered sufficient to ensure adequate sealing during operation of the internal combustion engine in conjunction with substantially circular piston rings over the entire length of the cylinder.
  • 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 clamping device according to the patent DE 28 10 322 C2 be used.
  • a bracing can be made, as in the Japanese patent application JP 11 267960 is described.
  • the cylinder block can still be heated well above the ambient temperature in
  • 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 bore in the vicinity of the cylinder head side entry side (represented by the curve R O ) is an approximately has countless radial symmetry about the bore axis BA, in which the largest diameter obliquely to the cylinder plane in the range of circumferential angles 135 ° and 315 ° results, while perpendicular thereto (corresponding to angular positions 45 ° and 225 °) also form local maxima of the radius however, 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)
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  • Finish Polishing, Edge Sharpening, And Grinding By Specific Grinding Devices (AREA)

Claims (12)

  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 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 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 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,
    caractérisé en ce que la forme d'alésage non cylindrique circulaire s'écarte considérablement d'une forme à symétrie radiale ponctuelle en miroir par rapport à l'axe de l'alésage et en ce qu'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, lors de l'opération d'usinage n'affectant pas sensiblement la forme, la surface interne de l'alésage étant usinée avec une pluralité de corps en matière coupante mobiles les uns par rapport aux autres et supportés élastiquement, qui ont dans la direction périphérique de l'outil de honage une étendue maximale inférieure à 3 % de la périphérie fonctionnelle de l'outil de honage et/ou qui ont dans la direction axiale de l'outil de honage une étendue maximale inférieure à 10 % de la longueur de la région de coupe de l'outil de honage.
  2. Procédé selon la revendication 1, dans lequel l'opération d'usinage n'affectant pas la forme est un usinage par honage à plateau, dans lequel des pointes du profil de rugosité produit par les opérations de honage précédentes sont coupées.
  3. Procédé selon l'une quelconque des revendications précédentes, dans lequel dans le cas de l'opération d'usinage n'affectant pas sensiblement la forme, au moins l'un des outils d'usinage suivants est utilisé :
    un outil brossant ;
    un outil d'usinage fonctionnant sans contact, qui modifie la structure de surface de la surface interne de l'alésage sans affecter la forme au niveau macroscopique, en particulier un laser ou un générateur de jet d'eau.
  4. Procédé selon l'une quelconque des revendications précédentes, dans lequel, dans le cas de l'opération d'usinage n'affectant pas sensiblement la forme, on utilise un outil d'usinage dans lequel des corps en matière coupante sont appliqués au moyen d'un ressort métallique ou similaire contre la surface interne de l'alésage.
  5. Procédé selon l'une quelconque des revendications précédentes, dans lequel dans le cas de l'opération de honage produisant la forme réalisée avant l'opération d'usinage n'affectant pas la forme, des écarts de forme sont 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 Dr étant le diamètre d'un cylindre en contact avec l'intérieur de la surface interne de l'alésage.
  6. Procédé selon l'une quelconque des revendications précédentes, dans lequel pour l'opération de honage produisant la forme réalisée avant l'opération d'usinage n'affectant pas la forme, on utilise un outil de honage avec un ensemble de coupe monté sur l'outil de honage d'un côté de l'axe de l'outil, lequel présente un ensemble de coupe unique avec un ou plusieurs corps en matière coupante qui sont tous disposés sur un côté de l'outil de honage, ou lequel présente plusieurs ensembles de coupe pouvant être avancés indépendamment les uns dés autres, la commande faisant en sorte que la pression d'application d'un ensemble de coupe soit indépendante de la pression d'application d'autres ensembles de coupe disposés dans d'autres positions périphériques.
  7. Procédé selon l'une quelconque des revendications précédentes, dans lequel pour l'opération de honage produisant la forme réalisée avant l'opération d'usinage n'affectant pas la forme, on utilise un outil de honage qui 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 un jeu de nervures de guidage réparties sur la périphérie de l'outil de honage 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 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.
  8. Procédé selon l'une quelconque des revendications précédentes, dans lequel, dans le cas de l'opération de honage produisant la forme réalisée avant l'opération d'usinage n'affectant pas la forme, on prévoit un accouplement rigide vis-à-vis des contraintes transversales de l'outil de honage à une broche de honage guidée de manière rigide vis-à-vis des contraintes transversales, afin de garantir le guidage rigide du mouvement axial de l'outil de honage.
  9. Procédé selon l'une quelconque des revendications précédentes, dans lequel, dans le cas de l'opération de honage produisant la forme réalisée avant l'opération d'usinage n'affectant pas la forme, l'ensemble de coupe est avancé au moyen d'un système d'avance de base jusque dans une position radiale prédéfinissable et à partir de la position radiale prédéfinie par le système d'avance de base, une avance radiale ou un retrait radial de l'ensemble de coupe a lieu au moyen d'un système d'avance fine dynamique pouvant être actionné indépendamment du système d'avance de base.
  10. Procédé selon l'une quelconque des revendications précédentes, dans lequel pendant et/ou après une opération de honage produisant la forme, une mesure de la forme de l'alésage est effectuée pour déterminer des valeurs réelles de la forme, et une différence entre les valeurs réelles de la forme et la forme de consigne est traitée pour corriger la commande de la force d'avance.
  11. Outil de honage, en particulier pour la mise en oeuvre de l'opération d'usinage n'affectant pas la forme au cours du procédé selon l'une quelconque des revendications précédentes, comprenant un corps d'outil qui définit un axe d'outil, un ensemble de coupe 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 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, caractérisé en ce que l'ensemble de coupe (960) présente une pluralité de corps en matière coupante mobiles les uns par rapport aux autres et supportés élastiquement, qui ont dans la direction axiale de l'outil de honage une étendue maximale inférieure à 10 % de la longueur de la région de coupe de l'outil de honage et/ou qui ont, dans la direction périphérique de l'outil de honage une étendue maximale inférieure à 3 % de la périphérie fonctionnelle de l'outil de honage, des corps en matière coupante (961) formés par des segments de nervures de honage étant appliqués sur un corps de base élastique en soi (965), le corps de base étant appliqué sur un matériau de base (966) de la nervure de honage, notamment un support en acier, en cuivre ou similaire.
  12. Outil de honage selon la revendication 11, dans lequel le corps de base élastique en soi est une plaque en matériau ayant l'élasticité du caoutchouc.
EP10010545A 2005-11-25 2005-11-25 Procédé destiné à empierrer des trous de forage tout comme outil à empierrer Expired - Fee Related EP2277661B1 (fr)

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EP20050025813 EP1790435B1 (fr) 2005-11-25 2005-11-25 Procédé de rodage d'alésages, et outil de rodage
EP09009260A EP2110204B1 (fr) 2005-11-25 2005-11-25 Procédé destiné à empierrer des trous de forage tout comme outil à empierrer

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EP10010545A Expired - Fee Related EP2277661B1 (fr) 2005-11-25 2005-11-25 Procédé destiné à empierrer des trous de forage tout comme outil à empierrer
EP20050025813 Active EP1790435B1 (fr) 2005-11-25 2005-11-25 Procédé de rodage d'alésages, et outil de rodage
EP09009260A Expired - Fee Related EP2110204B1 (fr) 2005-11-25 2005-11-25 Procédé destiné à empierrer des trous de forage tout comme outil à empierrer
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EP1790435B1 (fr) 2009-09-16
EP2279829B1 (fr) 2012-06-06
EP2277661A1 (fr) 2011-01-26
EP2279829A1 (fr) 2011-02-02
EP2277662A1 (fr) 2011-01-26
EP1790435A1 (fr) 2007-05-30
EP2110204B1 (fr) 2012-04-25
EP2277662B1 (fr) 2013-09-25
DE502005008150D1 (de) 2009-10-29
EP2110204A1 (fr) 2009-10-21

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