EP2976184B2 - Honverfahren und honwerkzeug - Google Patents

Honverfahren und honwerkzeug Download PDF

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Publication number
EP2976184B2
EP2976184B2 EP14708570.8A EP14708570A EP2976184B2 EP 2976184 B2 EP2976184 B2 EP 2976184B2 EP 14708570 A EP14708570 A EP 14708570A EP 2976184 B2 EP2976184 B2 EP 2976184B2
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EP
European Patent Office
Prior art keywords
honing
bore
tool
cutting
segments
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EP14708570.8A
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German (de)
English (en)
French (fr)
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EP2976184B1 (de
EP2976184A1 (de
Inventor
Fabio Antonio XAVIER
Oliver Bachmann
Florian KRANICHSFELD
Herbert Rauscher
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Elgan Diamantwerkzeuge GmbH and Co KG
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Elgan Diamantwerkzeuge GmbH and Co KG
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Application filed by Elgan Diamantwerkzeuge GmbH and Co KG filed Critical Elgan Diamantwerkzeuge GmbH and Co KG
Priority to PL14708570T priority Critical patent/PL2976184T5/pl
Priority to SI201430539T priority patent/SI2976184T2/sl
Publication of EP2976184A1 publication Critical patent/EP2976184A1/de
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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
    • 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

Definitions

  • the invention relates to a honing method for machining the inner surface of a bore in a workpiece using at least one honing operation according to the preamble of claim 1, as well as a honing tool according to the preamble of claim 6 that can be used when performing the honing method.
  • a preferred field of application is the honing of cylinder running surfaces the manufacture of cylinder blocks or cylinder liners for reciprocating piston engines.
  • Honing is a machining process with geometrically undefined cutting edges.
  • an expandable honing tool is moved up and down or back and forth within the bore to be machined to generate a stroke movement in the axial direction of the bore with a stroke frequency and simultaneously rotated at a rotational frequency to generate a rotary movement superimposed on the stroke movement.
  • the cutting material bodies attached to the honing tool are pressed against the inner surface to be machined via a feed system with a feed force acting radially to the tool axis.
  • the optimization of the tribological system piston / piston rings / cylinder running surface is of particular importance in order to achieve low friction, low wear and low oil consumption.
  • the proportion of friction in the piston group can be up to 35%, so that the reduction in friction in this area is desirable.
  • a cylinder bore should typically have a bore shape that is as little as possible, e.g. a maximum of a few micrometers, deviates from an ideal circular cylinder shape.
  • significant form errors can occur that can amount to several hundredths of a millimeter and reduce the performance of the motor.
  • the causes of distortion or deformation are different. It can be static or quasi-static thermal and / or mechanical loads or dynamic loads.
  • the construction and design of cylinder blocks also have an influence on the tendency to deformation.
  • the sealing function of the piston ring assembly is typically impaired by such deformations that are difficult to control, which can increase blow-by, oil consumption and also friction.
  • Another technology which by inverting the cylinder distortion (generating a negative shape of the defect) during machining, is supposed to guarantee or approximate the creation of an ideal shape after assembly or when the engine is in operation, is so-called form honing.
  • a bore shape that deviates from the circular cylinder shape is created on the unstressed workpiece by means of honing, for example a clover leaf shape.
  • honing for example a clover leaf shape.
  • Such bore shapes are usually asymmetrical because the deformations of the cylinder blocks are also usually not symmetrical.
  • the ideal circular cylinder shape should result, so that the piston ring package can seal well over the entire circumference of the bore.
  • Different variants of shape honing are for example in the EP 1 790 435 B1 and in the prior art cited therein.
  • the EP 1 321 229 A1 which forms the basis for the preambles of claims 1 and 6, describes a method for producing a bore that has an initial shape in the unloaded state and a desired shape that deviates from the initial shape in the operating state.
  • the deformation of a The nominal shape of the hole is determined in the operating state
  • the original shape is determined by means of the nominal shape and the deformation
  • the hole is brought into the original shape using a machining process.
  • the initial shape of the bore is largely cylindrical in an upper area and elliptical in a lower area. The two areas merge into one another in a central transition area.
  • a honing machine with one to four honing stones is used for processing. Since the bore geometry changes continuously in the middle area between the cylindrical and the elliptical area, honing stones with very low axial stretching are used.
  • the international patent application with publication number WO 01/76817 A1 discloses a hydraulically expandable honing tool with an annular cutting group at the end of the honing tool facing away from the spindle.
  • the cutting surfaces are attached to the end of outwardly expandable tongues which are formed in one piece with the tool body.
  • the tongues are spread outward during delivery to enlarge the effective outer diameter.
  • German Offenlegungsschrift DE 16 52 074 A1 discloses a honing tool with a cutting group that consists of two diametrically opposed honing segments with external ribs on which the cutting surface sits.
  • the invention provides a honing method with the features of claim 1. Furthermore, a honing tool with the features of claim 6 is provided, which can be used in the context of the honing process.
  • a bottle-shaped bore i. a hole with a bottle shape.
  • a "bottle-shaped bore” has a first bore section with a first diameter directly adjoining a bore entry, a second bore section with a second diameter which is larger than the first diameter away from the bore entry and a transition section with between the first and the second bore section a continuous transition from the first diameter to the second diameter.
  • the first bore section and the second bore section generally have a circular cylindrical basic shape and are coaxial with one another.
  • the transition section can be partially conical and, at its ends facing the outer bore sections, merge with suitable radii into the adjacent bore sections.
  • the bottle-shaped macro-shape With a suitable design of the bottle-shaped macro-shape, significant advantages in terms of friction reduction, reduced blow-by and reduced oil consumption can be achieved. Furthermore, improvements in the wear resistance of the piston ring set and positive influences on the noise development during operation can result. A substantial part of the combustion takes place in an internal combustion engine in the relatively narrower first bore section near the bore inlet, that is to say in the "bottle neck". Any high oil supply in this section could lead to emissions and oil consumption problems. In this narrower first bore section, the ring set of the piston rings can fulfill its conventional functions (in particular the sealing against combustion gases and the stripping of the oil film in the backward movement) due to the relatively high ring tension.
  • the piston accelerates in the first bore section and reaches the transition section with a gradually increasing diameter.
  • the piston ring tension is reduced by increasing the diameter.
  • a smooth inlet and outlet of the piston rings at the transition section can be achieved, so that ring wear or engine seizure can be avoided.
  • the ring pack reaches its lowest tension when entering the second bore section, so that the friction loss is automatically reduced where the piston reaches its maximum speed.
  • a honing tool that is particularly suitable for this purpose is used in at least one honing operation, which is also referred to here as a "ring tool" due to its design.
  • a "ring tool” within the meaning of this application has at least one ring-shaped cutting group with three or more radially adjustable cutting material bodies distributed around the circumference of the tool body of the honing tool, which are designed as honing segments that are relatively wide in the circumferential direction of the honing tool and relatively narrow in the axial direction of the honing tool.
  • the one in the axial direction The axial length of the honing segments measured by the honing tool is smaller than the width measured in the circumferential direction and the axial length of the cutting area equipped with cutting material bodies is smaller than the effective outer diameter of the honing tool.
  • the machining forces can be distributed well and relatively evenly over the entire effective outer diameter range of the honing tool available through radial infeed.
  • E.g. exactly three, exactly four, exactly five or exactly six honing segments of the same or different circumferential width can be provided in a cutting group. More than six honing segments within a cutting group are possible, but make the construction more complicated and are usually not necessary.
  • the axial length of the honing segments can e.g. are less than 30% of the effective outer diameter of the honing tool, in particular between 10% and 20% of this outer diameter.
  • the axial length can e.g. range from 5 mm to 20 mm.
  • the axial length is typically less than 10% of this bore length. If the upper limits are clearly exceeded, the possibility of axial contour tracking or contour generation suffers.
  • short axial lengths are advantageous in order to generate sufficient surface pressure for machining.
  • a minimum length in the axial direction is advantageous in order to allow a honing overflow for machining the bore ends and to limit the tendency of the honing tool to tilt.
  • Such a ring tool represents a departure from conventional concepts of honing tool design, which assume that honing tools with honing stones that are relatively long in the axial direction and relatively narrow in the circumferential direction should be used in order to achieve low form defects in a honed bore.
  • a ring tool is particularly well adapted to the machining of bottle-shaped bore shapes or, in general, of bore shapes with a bore diameter that varies significantly in the axial direction.
  • the cutting material bound cutting grains of suitable grain size, density and hardness
  • is concentrated in an axially relatively narrow ring with typically more than half of the circumference of an annular cutting group being occupied by cutting means and accordingly contributing effectively to the removal of material.
  • the cutting area in which one or more ring-shaped cutting groups are located is short or narrow in the axial direction compared to the effective outer diameter of the honing tool, which makes it possible to generate and / or follow a contour running in the axial direction.
  • a ring-shaped cutting group is distinguished from conventional honing stones in that the axial section covered by the ring-shaped cutting group has significantly more contact area between the cutting material bodies and the inner surface of the bore than in a comparatively narrow axial section of a conventional honing tool.
  • more than 60% of the circumference of an annular cutting group is occupied by cutting means, possibly even more than 70% or more than 80% of the circumference of the honing tool.
  • a cutting group is preferably arranged in the vicinity of an end of the tool body facing away from the spindle in such a way that the cutting group is located exclusively in the half of the tool body facing away from the spindle. If several annular cutting groups are provided, this condition can apply to all cutting groups.
  • An arrangement close to the end remote from the spindle enables, among other things, Machining with very little honing overflow.
  • the stroke position of the honing tool within the bore can be used as a guide variable in order to specify the contact pressure or the feed force as a function of the stroke position of the annular cutting group with high local resolution.
  • This makes it possible, with the aid of an adjustable ring-shaped cutting group, to produce a bore with an axially variable contour or to follow an axially varying contour that has already been produced beforehand without undesired pressure force peaks.
  • a ring tool it is possible to work with essentially the same overlap in all axial areas of the bore, so that, if necessary, very uniform roughness patterns or surface structures can be generated.
  • An electromechanical cutting group feed system is preferably used. In contrast to hydraulic expansion, this enables a precise specification of the infeed path (path control), whereby an axial contour is specifically generated and / or a given axial contour is precise can be tracked.
  • One or more sensors of a diameter measuring system can be arranged on the honing tool so that an in-process diameter measurement is possible.
  • measuring nozzles of a pneumatic diameter measuring system can be attached between adjacent honing segments on the tool body. In this way, the precision of the hole contours that can be achieved can be improved.
  • Using a ring tool ensures uniform wear of the cutting material body and very good shape values as well as uniform surface roughness of the bore over the entire service life of the ring-shaped cutting group.
  • the ring tool has a single ring-shaped cutting group, the honing segments of which can be radially advanced or withdrawn via a single common infeed system.
  • the annular cutting group has three or more honing segments evenly or unevenly distributed over the circumference of the honing tool, usually not more than six.
  • the single annular cutting group is arranged in the vicinity of the free end of the tool body remote from the spindle, e.g. flush with the face facing away from the spindle.
  • Such constructions are particularly suitable for the machining of cylinder bores with reduced honing overflow. Such restrictions in machining arise, for example, in the case of blind bores or cylinder bores in engine blocks for monoblock or V-engines.
  • an annular cutting group it is also possible for an annular cutting group to have two groups of honing segments that can be advanced independently of one another, the honing segments of the groups being arranged alternately in the circumferential direction.
  • This makes it possible to combine the advantages of a single ring-shaped cutting group (for example with regard to the machining of bores with a short honing overflow) with the advantages of a double feed of two independent groups of honing segments.
  • the honing segments of a group of honing segments normally have the same cutting surface, while the groups have mutually different cutting surfaces, for example diamond surfaces of different grain size.
  • a ring tool has a first ring-shaped cutting group and at least one second ring-shaped cutting group, which is arranged axially offset to the first ring-shaped cutting group and can be advanced independently of the first ring-shaped cutting group.
  • This also enables two consecutive honing operations with different cutting materials without an intermediate tool change. Since the different cutting materials are distributed over the at least two axially offset annular cutting groups, which can each cover a large part of the circumference of the honing tool, particularly high removal rates or relatively short honing times are possible in both honing operations.
  • Such ring tools can be used for all bores that allow sufficient honing overflow.
  • Such a ring tool preferably has exactly two ring-shaped cutting groups, whereby flexible use is possible despite its simple construction.
  • an integrated, multi-axis movable joint e.g. a ball joint or a cardan joint.
  • a ball joint or a cardan joint e.g. a ball joint or a cardan joint.
  • Such ring tools can be rigidly coupled to a honing spindle or a drive rod rigidly coupled to the honing spindle.
  • the bottle shape of the bore can be produced by any suitable machining process, for example by precision turning (fine spindles), that is to say with the aid of a machining process with a geometrically defined cutting edge, or by honing. This can be followed by one or more honing operations in order to arrive at the final desired bore geometry with a suitable surface structure.
  • a bore with a circular cylindrical bore shape is first produced by precision turning or honing and then a bottle-shaped bore shape is produced in a bottle honing operation by honing with axially varying honing removal.
  • honing can produce surfaces with a particularly uniform surface quality without any circumferential marks.
  • the self-sharpening effect of the cutting material body also contributes to the uniformity of the surface quality. Continuous process monitoring is possible during honing.
  • an expandable honing tool with at least one ring-shaped cutting group that is to say a ring tool, is used in the bottle honing operation.
  • honing segments of the cutting group are fed in a downward stroke according to the bottle shape and depending on the stroke position, in a path- and / or force-controlled manner radially outward retracted radially on an upward stroke according to the bottle shape depending on the stroke position.
  • This machining variant results in a relatively smooth contour from the start in the transition section, which is particularly difficult to machine.
  • the bottle honing operation it is also possible for the bottle honing operation to use an expandable honing tool with honing stones, the length of which is more than 50% of the length of the bore.
  • the length of the honing stones can for example be between 50% and 80% of the length of the bore.
  • the honing tool is moved back and forth in the second stroke position.
  • the basic shape of the transition section arises essentially during the second phase of the gradual shifting of the stroke position and the reduction in stroke height, with the increase in diameter in the second bore section being generated at the same time and also in the third phase.
  • a relatively rough surface structure with a profile similar to a saw profile can arise in the transition section.
  • a smooth honing operation is therefore preferably carried out after the bottle honing operation to smooth the bore profile in the transition area, a ring tool being used in the smooth honing operation, i.e. an expandable honing tool with at least one ring-shaped cutting group. With the help of the ring tool, grooves or burrs in the transition section can be removed and the radii of the transition section rounded.
  • the invention also relates to a honing tool which is particularly suitable for carrying out the honing process, but can also be used in other honing processes not according to the invention.
  • the invention also relates to a workpiece with at least one bore which has a honed inner surface, the bore being a bottle-shaped bore which, following a bore entry, has a first bore section with a first diameter, and remote from the bore entry a second bore section with a second diameter, which is larger than the first diameter, and between the first and the second bore section has a transition section with a continuous transition from the first to the second diameter, the workpiece having been machined using a honing tool according to the invention.
  • the workpiece can be a cylinder block or a cylinder liner for a reciprocating piston machine.
  • the reciprocating engine it can e.g. be an internal combustion engine (internal combustion engine) or a compressor.
  • honing methods and honing tools are described which can be used in the context of embodiments of the invention for material-removing machining of workpieces that have one or more bores which, in the finished state, should have the macro shape of a bottle.
  • Fig. 1 shows a schematic longitudinal section through such a bottle-shaped bore 110 in a workpiece 100 in the form of an engine block (cylinder crankcase) for an internal combustion engine.
  • the bore is rotationally symmetrical with respect to its bore axis 112 and extends over a bore length L from a bore inlet 114 facing the cylinder head in the installed state to the bore outlet 116 at the opposite end.
  • the bore can be divided into three adjoining sections of different functions, which merge into one another in a sliding manner, ie without the formation of steps or edges.
  • a first bore section 120 at the inlet end has a first diameter D1 and a first length L1.
  • a second bore section 130 extends over a second length L2, the inner diameter (second diameter) D2 of which is greater than the first diameter D1.
  • a partially conical transition section 140 in which there is a continuous transition from the first diameter to the second diameter.
  • a first radius R1 is formed between the central, essentially conical part of the transition section and the first bore section, while a second radius R2 is formed between the transition section and the second bore section.
  • the radii R1 and R2 can be essentially the same, but it is also possible for the first radius to be smaller or larger than the second radius.
  • the first length L1 can be between 15% and 40% of the bore length L, for example.
  • the second length L2 is typically greater than the first length and is frequently between 40% and 60% of the bore length L.
  • the transition section is normally relatively short compared to the bore sections adjoining it.
  • Typical third lengths L3 can be in the range from 5% to 20% of the bore length L. Deviations from these geometric relationships are also possible.
  • the difference in diameter between the first diameter D1 and the second diameter D2 lies well outside the tolerances typical for honing, which for a cylindrical shape are in the order of magnitude of a maximum of 10 ⁇ m (based on the diameter).
  • the difference in diameter can be between 20 ⁇ m and 90 ⁇ m, for example.
  • the radii R1, R2, the lengths of the outer bore sections and the transition section and the tangent angle T between the bore axis and a tangent to the transition section can be optimized so that in typical operating states of the engine there is low blow-by, low oil consumption and low wear of the Piston rings result.
  • the bottle shape of the bore means that the bore is comparatively narrow in the area near the inlet, so that the piston rings of the piston running in the bore are pressed against the inner surface 118 of the bore with high ring tension. In this way, where the combustion mainly takes place and high pressures occur, a reliable seal is achieved and the oil film is stripped off on the downward stroke.
  • the piston accelerated by the combustion then moves in the direction of the bore outlet, the piston rings first passing through the transition section with the continuously expanding inner diameter and then (partially) passing through the second bore section. In the transition section, the piston rings can gradually relax, with the seal remaining sufficient because the pressure difference across the piston rings drops.
  • the ring pack At the beginning of the second bore section, the ring pack reaches its lowest tension, so that friction losses due to reduced ring tension are reduced precisely in the area of maximum piston speed. During the upward stroke, the ring tension then increases again as soon as the piston rings reach the exit-side radius of the transition section and run through it in the direction of the first bore section.
  • a ring tool has at least one cutting group attached to the tool body in a ring shape with cutting material bodies distributed around the circumference of the tool body, which can be advanced or withdrawn in the radial direction by means of an associated infeed system.
  • the cutting material bodies are designed as honing segments with a width in the circumferential direction is significantly greater than its length in the axial direction.
  • the cutting material bodies responsible for removing material from the workpiece are concentrated in an axially relatively narrow zone (a ring of the cutting group) and take up a relatively large proportion of the circumference of the honing tool.
  • hole shapes can be produced with a relatively high material removal rate, in which hole sections of different diameters adjoin one another in the axial direction.
  • Fig. 2 2A shows a longitudinal section through an embodiment of a ring tool 200 with a single ring-shaped cutting group 220 and a simple expansion.
  • Figure 2B shows a cross section through the cutting group.
  • the ring tool 200 has a tool body 210 which defines a tool axis 212, which is at the same time the axis of rotation of the ring tool during the honing operation.
  • the ring-shaped cutting group 220 which has several (in the example three) cutting material bodies 220-1, 220-2, 220-3 evenly distributed over the circumference of the tool body, which are advanced radially to the outside of the tool axis 212 using a cutting material body infeed system can be used to press the abrasively acting outer sides of the cutting material body with a defined pressing force or pressing force against the inner surface of a hole to be machined.
  • Each of the three arcuately curved cutting material bodies is designed as a honing segment which is very wide in the circumferential direction but narrow in the axial direction and which covers a circumferential angle range between 115 ° and 120 °.
  • the honing segments are decoupled from the tool body and are displaceable relative to the latter radially to the tool axis 212.
  • the ring formed by the honing segments ends flush with the tool body on the side facing away from the spindle, so that the ring sits completely within the half of the tool body facing away from the spindle on the end of the ring tool facing away from the spindle.
  • the axial length LHS of the honing segments is less than 15%, in particular less than 10% of the bore length L.
  • the honing segments are approx. 4 mm to 35 mm, in particular approx. 10 mm high (in the axial direction), which in the example is between 5% and 30%, in particular between 10% and 20% of the effective outer diameter of the cutting group.
  • the axial length LHS here simultaneously corresponds to the axial length of the entire cutting area of the honing tool.
  • Each cutting material body is fastened by soldering to an outside of an associated support strip 224-1, 224-2 made of steel. Alternatively, the cutting material body can also be attached by gluing or by means of screws, which makes it easier to replace.
  • Each support strip has an inclined surface on its inside which cooperates with a conical outer surface of an axially displaceable feed cone 232 in such a way that the support strips with the cutting material bodies carried by them are fed radially outwards when the feed cone is countered by means of a machine-side feed device against the force of return springs 234, 226, 228 is pressed in the direction of the end of the ring tool facing away from the spindle.
  • the support strips with the honing segments are brought back radially inwards with the aid of revolving return springs 226, 228.
  • the radial position of the cutting material body is thereby controlled without play via the axial position of the feed cone 232.
  • This tool concept is particularly suitable for machining cylinder bores with reduced honing overflow, for example with a maximum honing overflow of 5 mm. Such geometries typically occur in blind bores or in monoblock or V-engines.
  • FIG. 3 An exemplary embodiment of a ring tool 300 is shown, which likewise has a single ring-shaped cutting group 320 which is arranged on the end of the tool body 310 facing away from the spindle.
  • Figure 3A shows a longitudinal section through the ring tool
  • Figure 3B a cross section through the cutting group.
  • the annular cutting group 320 has two groups of honing segments that can be advanced independently of one another, the honing segments of the groups being arranged alternately with one another in the circumferential direction.
  • a first group of honing segments has three first honing segments 320-1 arranged circumferentially offset from one another by 120 °.
  • Three second honing segments 320-2 of a second group of honing segments are arranged in between.
  • the first group has cutting material bodies with a relatively coarse cutting surface, while the second group has cutting material bodies with a relatively finer cutting surface.
  • Axial guide strips 326 are arranged between immediately adjacent honing segments.
  • a ball joint 350 is provided between the tool body 310 and the coupling structure 340 provided for coupling the honing tool to a work spindle or the like, so that the honing tool can move to a limited extent in several axes with respect to the honing spindle.
  • the first honing segments can be advanced radially with the aid of a first delivery system.
  • This includes a first feed rod 332-I running centrally on the tool body, which has a conical section at the end remote from the spindle, which is connected to the inclined surfaces of the support strips of the first group of honing segments interacts.
  • a second feed system is used to feed the second group of honing segments and has a tubular feed element 332-A, which surrounds the feed rod 332-I and at its end remote from the spindle has a conical outer surface which interacts with inclined surfaces on the support strips of the second honing segments.
  • the three honing segments of the first group of honing segments can be expanded in order to carry out a specific honing operation, for example a smooth honing operation or a structure honing operation. If the other group of honing segments is delivered instead, which has a different type of cutting surface, another honing operation, for example a deburring operation or a plateau honing operation, can be carried out. With the aid of the ring tool with double expansion, two different honing operations can be carried out one after the other without having to change tools or using another honing spindle for machining.
  • FIG. 4A shows a schematic longitudinal section through an embodiment of a ring tool 400 with double expansion, which differs from the embodiment of FIG Fig. 3 has two annular cutting groups 420-1 and 420-2, which are attached axially offset to one another in the part of the tool body 410 facing away from the spindle.
  • Each of the annular cutting groups (cross-section in Figure 4B ) has three joint adjustable honing segments, each covering between approx. 110 ° and 115 ° of the circumference.
  • the axial length of the honing segments is small and is typically less than 10% of the bore length and / or between 10% and 20% of the effective outer diameter of the honing tool in the area of the cutting material body.
  • Measuring nozzles 440 of a pneumatic diameter measuring system are attached to the tool body between adjacent honing segments.
  • the cutting groups are axially close to one another, so that the cutting area of the honing tool, in which the two annular cutting groups are located, is significantly shorter in the axial direction than the effective outer diameter of the honing tool.
  • the cutting material bodies are mounted in an elastically resilient manner with respect to the tool body. This can improve the ability to follow the contour during axial movement.
  • spring elements e.g. leaf springs, spiral compression springs, etc.
  • the support elements can be interposed between the carrier elements and the cutting material bodies. It is also possible to make the support elements inherently resilient, e.g. in that weakenings in the cross section of the carrier material in the form of slots or the like are structurally provided at suitable points.
  • a conventional honing tool with axially relatively long, narrow honing stones was initially used in order to produce a honed hole with a circular cylinder shape starting from a hole that was pre-machined, for example, by fine boring.
  • the axial strip length I was about 1/2 to 2/3 of the total bore length L.
  • a first honing operation pre-honing
  • diamond stones of the D107 type were used, a subsequent intermediate honing operation was carried out with fine grain (D54 grain).
  • D54 grain fine grain
  • the honing overflow S on the inlet and outlet side was approximately 1/3 of the last length, similar to conventional methods.
  • the honing overflow can be shortened when machining V or monoblock engines.
  • a subsequent third honing operation was designed as a bottle honing operation.
  • a bottle honing operation With the help of a bottle honing operation, a bottle-shaped bore shape is created by axially varying material removal with geometrically undefined cutting.
  • Fig. 6 shows schematically the stroke position HP of the honing tool as a function of the honing time t in the bottle honing operation.
  • the machining of the cylinder running surface initially runs from a first point in time t 1 to a second point in time t 2 with the same stroke length in a first stroke position, exactly as when machining a circular cylindrical bore.
  • the term "stroke position" here refers to the area between the upper reversing point UO and the lower reversing point UU of a stroke movement. Each shift of a reversing point therefore also changes the stroke position.
  • the honing machine automatically switches to an incremental change in the stroke position and after each stroke the upper reversing point UO is changed incrementally in the direction of the lower reversing point UU.
  • the temporal position of the second point in time t 2 can be defined, for example, via a certain number of strokes or via a predetermined honing time or via a predetermined material removal or another triggering parameter.
  • the extent of the increment IN by which the upper reversing point changes between two successive strokes can also be set as required.
  • the bottle honing operation is expediently carried out with honing stones whose cutting material grains are finer than those used for pre-honing or intermediate honing. For example, you can work with diamond grains in the area D35 in order to obtain a bottle shape with an already relatively fine surface structure.
  • a single expansion, double expansion with two cutting groups, arranged in a common ring, or double expansion with two cutting groups, arranged in two axially offset annular cutting groups depends, among other things, on the design of the cylinder block.
  • the tool selection can be based, for example, on the extent of the possible honing overflows and / or on the position and size of transverse bores. If, for example, a cylinder crankcase has a large cross bore, it usually makes sense to use a ring tool with a single expansion (cf. Fig. 2 ) to work.
  • a ring tool with an annular cutting group was used in order to smooth out grooves or burrs which were formed in the transition section during the machining of the bottle honing operation.
  • the radii of the transition area can also be rounded and the surface values can be changed so that they are essentially identical to the surface values in the adjacent first and third bore sections.
  • Fig. 7 shows a measurement diagram of a rounded profile of a bottle-shaped cylinder after using a ring tool with single expansion in the process shown here.
  • the scaling in the x-axis of the diagram is 5 mm per unit of measurement shown, in the y-axis (in the radial direction of the bore) a unit of measurement is 10 ⁇ m.
  • a ring tool with a single expansion instead of a ring tool with a single expansion, a ring tool with a single cutting group ring and double expansion (cf. Fig. 3 ) used for structuring, it will usually be necessary to increase the number of strokes compared to using a simply expanding ring tool in order to ensure even coverage.
  • the advantages of ring tools are retained, however, and the number of strokes required for an even structure of the inner surface of the bore will still be less than the corresponding number of strokes when using a conventional honing tool with long honing stones.
  • the infeed force can expediently be exerted by means of a hydraulic expansion so that the surface can be machined with essentially constant force.
  • the tracking of the contour, which varies in the axial direction, can then be set due to the type of construction alone due to the flexibility of the hydraulic expansion.
  • one or more further honing operations can be performed in order to produce the final desired surface structure on the bottle-shaped bore.
  • spiral structure honing with a ring tool The process described here by way of example is followed by a fifth honing operation, which is referred to here as "spiral structure honing with a ring tool".
  • the axial speeds and the rotational speed of the honing tool are coordinated with one another in such a way that relatively large honing angles, for example of the order of magnitude of 140 °, are generated.
  • relatively large honing angles for example of the order of magnitude of 140 °
  • other honing angles and / or roughness profiles can also be generated in other method variants.
  • spiral structure honing is designed so that virtually no global material removal is achieved, but rather grooves of suitable depth and distribution are created in the very smooth surface after the rounding with the aid of a relatively coarse-grained cutting material body with a low cutting grain density.
  • cutting material bodies with cutting material grain density 1.25 to 15 vol.% And / or grain size 35 to 200 ⁇ m can be used (cf. eg DE 10 2005 018 2
  • the previously structured surface is then deburred in a sixth and final honing operation (deburring).
  • a ring tool with fine cutting means is preferably also used, for example the same ring tool that was also used for the fourth honing operation (rounding of the radii and smooth honing).
  • Different types of expansion can be used here.
  • the type of expansion can be designed to be hydraulic / hydraulic, hydraulic / mechanical or mechanical / mechanical. In the case of mechanical expansion, e.g. be driven force-controlled via a servomechanical expansion (hydraulic-like) or position and force-controlled.
  • an expandable ring tool is used in the bottle honing operation, that is to say in the production of a bottle-shaped bore shape from a previously circular-cylindrical bore shape.
  • the control of the expansion system for the radial infeed of the honing segments is coupled with the control for the lifting position so that the ring tool can precisely generate the transition section with the changing diameter and also work with a suitable pressure force in the cylindrical first and second bore sections ( see. Fig. 8 ).
  • the bottle honing operation can be provided as a second honing operation immediately after the pre-honing and to this extent replace the second to fourth honing operations of the first exemplary embodiment.
  • the stroke-dependent control of the widening is then carried out in such a way that the honing segments of the cutting group are delivered radially outwards in a way and force-controlled manner during a downward stroke according to the bottle shape depending on the stroke position and again in the area of the transition section in an upward stroke according to the bottle shape depending on the stroke position be retracted radially.
  • a smooth contour can be achieved in the transition section right from the start.
  • Fig. 8 shows an example of a schematic diagram which shows the dependency of the axial stroke position HP (solid line) and the radial expansion position AP (dashed line) as a function of the honing time t during bottle honing with a ring tool.
  • Ring tools of the type described here can not only be used for producing or machining bottle-shaped bores, but can also bring considerable advantages without modification when machining bores with a different geometry.
  • a ring tool with double expansion and a single cutting group ring identical to or similar to the exemplary embodiment from Fig. 3 to use to create a free form with a non-circular bore cross-section on a bore. This is commonly referred to as form honing.
  • a bore section with a clover leaf shape or an elliptical cross section can be produced.
  • the honing machine must be able to control the first infeed system and the second infeed system at the same time, depending on the stroke position and angular position of the cutting group in relation to the hole, the widenings must be controlled with different forces / positions so that the free form can arise.
  • a ring tool to create and / or machine a bore shape that has a frustoconical bore section (conical section) that merges relatively abruptly or with a transition radius into an adjacent cylindrical bore section without being followed by a further bore section.
  • a bore with a funnel shape can be produced, which has an inlet-side cylindrical first bore section with a first diameter, which in an adjacent second bore section increases conically towards the bottom of the bore up to a maximum diameter.
  • the difference in diameter between the cylindrical first bore section and the maximum diameter in the conical second bore section can e.g. between approx. 20 ⁇ m and approx. 90 ⁇ m.
  • the axial length of the cylindrical first bore portion can e.g. between 20% and 80% of the total bore length.
  • a ring tool it is possible, with the aid of a ring tool, to create a barrel-shaped bore section in a bore, i. to produce a bulge in an otherwise largely cylindrical bore.
  • the bulge can be approximately in the middle or in the vicinity of one of the bore ends.
  • strip honing When using a ring tool, it is also relatively inexpensive to machine a cylinder running surface in such a way that narrow strips with different surface structures are present in the area of the top dead center and / or in the area of the bottom dead center than in the middle area of the highest piston speed.
  • This variant is referred to here as "strip honing".
  • a conventional misalignment suitable for this and a correspondingly adapted honing tool are for example in the DE 195 42 892 C2 described.
  • a short-stroke honing process with the aid of short honing stones is carried out, this honing process only covering the area of top dead center or bottom dead center.
  • Corresponding surface treatments are also possible.
  • long-stroke machining of the entire length of the bore can be carried out with the first annular cutting group, before short-stroke machining is then carried out, for example, with the second cutting group in the area of top dead center to produce a special structure in the area of top dead center.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Geometry (AREA)
  • Finish Polishing, Edge Sharpening, And Grinding By Specific Grinding Devices (AREA)
  • Constituent Portions Of Griding Lathes, Driving, Sensing And Control (AREA)
  • Acyclic And Carbocyclic Compounds In Medicinal Compositions (AREA)
EP14708570.8A 2013-03-18 2014-03-10 Honverfahren und honwerkzeug Active EP2976184B2 (de)

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JP2016516595A (ja) 2016-06-09
SI2976184T2 (sl) 2021-03-31
BR112015023549A2 (pt) 2017-07-18
JP6092461B2 (ja) 2017-03-08
DE102013204714A1 (de) 2014-10-02
EP2976184B1 (de) 2017-10-04
US20160303702A1 (en) 2016-10-20
DE202014010306U1 (de) 2015-03-06
ES2652645T3 (es) 2018-02-05
CN105246649B (zh) 2018-01-05
WO2014146919A1 (de) 2014-09-25
PL2976184T3 (pl) 2018-03-30
BR112015023549B1 (pt) 2021-02-02
SI2976184T1 (en) 2018-02-28
ES2652645T5 (es) 2021-08-02
EP2976184A1 (de) 2016-01-27
KR101844124B1 (ko) 2018-03-30
CN105246649A (zh) 2016-01-13
HUE035781T2 (hu) 2018-05-28
PL2976184T5 (pl) 2021-04-19
DE102013204714B4 (de) 2024-06-06
KR20150132548A (ko) 2015-11-25

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