US20200156204A1 - Honing method and machine tool for contour honing - Google Patents

Honing method and machine tool for contour honing Download PDF

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Publication number
US20200156204A1
US20200156204A1 US16/624,405 US201816624405A US2020156204A1 US 20200156204 A1 US20200156204 A1 US 20200156204A1 US 201816624405 A US201816624405 A US 201816624405A US 2020156204 A1 US2020156204 A1 US 2020156204A1
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Prior art keywords
honing
stroke
diameter
bore
axial
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US16/624,405
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English (en)
Inventor
Ronald Angerbauer
Oliver Bachmann
Bernd Hieber
Steffen Hollank
Florian Kranichsfeld
Joachim Weiblen
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Elgan Diamantwerkzeuge GmbH and Co KG
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Elgan Diamantwerkzeuge GmbH and Co KG
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Publication of US20200156204A1 publication Critical patent/US20200156204A1/en
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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
    • B24B33/025—Internal surface of conical shape
    • 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
    • B24B33/06—Honing machines or devices; Accessories therefor with controlling or gauging equipment
    • 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
    • B24B33/087—Honing tools provided with measuring equipment
    • 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
    • B24B49/04—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 involving measurement of the workpiece at the place of grinding during grinding operation
    • 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
    • B24B49/08—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 involving liquid or pneumatic means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
    • B23Q15/00—Automatic control or regulation of feed movement, cutting velocity or position of tool or work
    • B23Q15/007—Automatic control or regulation of feed movement, cutting velocity or position of tool or work while the tool acts upon the workpiece
    • B23Q15/0075—Controlling reciprocating movement, e.g. for planing-machine
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
    • B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
    • B23Q17/20—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring workpiece characteristics, e.g. contour, dimension, hardness
    • 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

Definitions

  • the invention relates to a honing method for machining the internal face of a bore in a workpiece with the aid of at least one honing operation, as claimed in the preamble of claim 1 , as well as to a machine tool configured for carrying out the honing method, as claimed in the preamble of claim 14 .
  • a preferred field of application is the honing of cylinder running faces in the production of cylinder blocks or cylinder liners for reciprocating piston engines.
  • cylinder running faces in cylinder blocks (cylinder crank cases) or cylinder liners of internal combustion engines or other reciprocating piston engines in operation are exposed to a heavy tribological stress.
  • cylinder blocks or cylinder liners it is therefore important for said cylinder running faces to be machined such that adequate lubrication by way of a lubricant film is guaranteed later in all operating conditions, and the friction resistance between parts that move relative to one another is kept ideally minor.
  • Honing is a subtractive method having cutters that are not determined in geometric terms.
  • a flaring-capable honing tool is moved back and forth at a stroke frequency within the bore to be machined for generating a reciprocating movement in the axial direction of the bore, and is simultaneously rotated at a predefinable rotating speed for generating a rotating movement that superimposes the reciprocating movement.
  • the cutting material members that are attached to the honing tool are actuated by way of an actuator system having an actuating force and/or an actuation rate that act/acts radially in relation to the tool axis and are pressed against the internal face to be machined.
  • a cross-grinding pattern having mutually crossing machining traces which are also referred to as “honing furrows” is typically created on the internal face when honing, said cross-grinding pattern being typical for the machining by honing.
  • the piston group in terms of friction can have a proportion of up to 35% so that a reduction in terms of friction in this region is desirable.
  • a honing method in which a bottle-shaped bore that is rotationally symmetrical in terms of the bore axis and proximal to the bore entry is generated that is tighter than more distal from the bore entry is described in WO 2014/146919 A1.
  • a honing tool having relative long honing strips in axial terms is used.
  • the stroke length and/or the stroke orientation of the reciprocating movement are/is modified in a stroke modification phase.
  • an axial contour profile can be generated or modified.
  • Honing tools which have at least one annular cutting group which is relatively short in the axial direction are also described in the application. Bore shapes having an axial contour profile can be machined in a particularly precise and economical manner when using honing tools of this type. Air measurement nozzles of a diameter measurement system are integrated in the case of many of the honing tools described.
  • Controlling the torque transmitted by way of the spindle to the honing tool in the case of the methods is performed in a manner that the torque remains substantially consistent during the stroke modification phase.
  • bores which in the completely machine state have an axial contour profile and which comprise the desired contour profile with sufficient precision across the entire relevant bore length can be generated.
  • the honing method is associated with the generic type of honing methods in which a bore shape which is rotationally symmetrical in relation to the bore axis and has an axial contour profile is generated with the aid of a variable material removal in the axial direction of the bore.
  • a bore shape is a bore shape which is rotationally symmetrical in terms of the bore axis and which significantly deviates from a circular cylindrical shape.
  • the stroke length and/or the stroke orientation of the reciprocating movement are/is modified in at least one stroke modification phase. It can be achieved on account thereof that the cutting material members provided on the honing tool pass through, or overlap, respectively, some axial portions more often in total than other axial portions such that the material removal caused on account of the contact with the cutting material members is dissimilarly intense in dissimilar axial portions, primarily or substantially, respectively, by virtue of dissimilar numbers of overlapping honing actions.
  • a honing tool which has an annular cutting group having a plurality of radially actuatable cutting material members that are distributed about the circumference of the tool body is used.
  • Preferred design embodiments of honing tools of this type and advantages pertaining to this type of honing operations will be described in detail further below.
  • a particularity of the honing method lies in that during the stroke modification phase, thus during the phase in which the stroke length and/or the stroke orientation of the reciprocating movement changes, a measurement of the actual diameter of the bore is carried out for determining a diameter measurement signal which represents the actual diameter of the bore in an associated measurement plane, and in that consequently the stroke length and/or the stroke orientation of the reciprocating movement is variably controlled as a function of said diameter measurement signal.
  • a closed-loop control circuit feedback control
  • said closed-loop control circuit leading to the stroke length and/or the stroke orientation of reciprocating movements during the stroke modification phase as a controlled variable being influenced by the results of a diameter measurement carried out during the machining such that during the ongoing honing method influence is exerted automatically, that is to say in particular without any intervention of an operator, on the stroke, or on the stroke modification of the axial component of the honing tool movement by way of the diameter measurement.
  • the detection of the diameter measurement signal utilized for controlling takes place according to the stipulation of a predefinable measuring condition, for example in at least one predefinable phase of a reciprocating movement.
  • a reciprocating movement during the stroke modification phase comprises a multiplicity of successive strokes which run in each case between a lower reversal point and an upper reversal point, wherein the axial position of at least one of the reversal points of a stroke is dynamically modified as a function of a diameter measurement signal that is determined in a preceding stroke.
  • the term “upper reversal point” refers to that reversal point which lies closer to the bore entry through which the honing tool is introduced into the bore.
  • the honing method can be utilized not only in vertical honing but also in horizontal honing.
  • the axial position of at least one reversal point of a stroke is preferably modified as a function of a diameter measurement signal which has been determined in the directly preceding stroke, such that the stroke length and/or the stroke orientation of each individual double stroke can be influenced individually as a function of a diameter measurement value in the preceding double stroke.
  • rapid reaction times can be achieved in the case of potential diameter deviations, on account of which precise contour profiles can be generated.
  • the axial position of one of the reversal points prefferably fixed, and only the axial position of the other reversal point to be dynamically varied as a function of the diameter measurement signal.
  • Particularly simple and precise controlling can be implemented on account thereof.
  • a bore shape can in particular have the visual appearance that the axial contour profile has a portion (at least one portion) in which the nominal diameter continuously increases between a first axial position having a smallest diameter, and a second axial position having a largest diameter within the portion, wherein the reversal point associated with the second axial position is fixed and the axial position of the other reversal point is dynamically varied as a function of the diameter measurement signal.
  • a contour which is, for example, conical or truncated-conical, respectively, is thus present within such a portion when the nominal diameter varies in a manner linear with the axial position.
  • a non-linear variation of the diameter in the axial direction is also possible such that the shell line of a portion having an axially variable diameter does not have to be straight but can be curved in a convex or concave manner.
  • the variation of the axial position of the other reversal point typically leads to a shortening of the stroke which can also be described such that the reversal point associated with the smaller diameter moves in steps (in increments, incrementally) in the direction of the second axial position (having the relatively largest diameter).
  • the stroke length it is also possible for the stroke length to increase between a preceding stroke and a directly subsequent stroke when the in-process measurement indicates that this is conducive to the purpose of achieving an improved contour.
  • an axial nominal contour profile which represents a nominal diameter of the bore as a function of the axial stroke position is predefined, that in a stroke the actual diameter measured at a stroke position is compared with the nominal diameter associated with the stroke position, and that a diameter deviation for the stroke position is determined from the comparison, wherein the stroke length and/or the stroke orientation of a subsequent stroke in relation to a nominal stroke length and/or a nominal stroke orientation is modified as a function of the diameter deviation.
  • This controlling intervention is preferably not performed in the case of arbitrary small diameter deviations but only when the diameter deviation exceeds a predefinable limit value (thus a permissible control deviation). Unnecessary controlling interventions can be avoided in this way.
  • the stroke length and/or the stroke orientation of each individual stroke is preferably calculated based on the diameter deviation determined immediately prior thereto.
  • the nominal contour profile can be predefined, for example, in the form of an analytical formula (for example a linear equation or a non-linear equation), or as a point grid.
  • an analytical formula for example a linear equation or a non-linear equation
  • a control strategy is preferably programmed such that the stroke length and/or the stroke orientation of a reciprocating movement is modified as a function of the determined diameter deviation in such a manner that the diameter deviation associated with the axial position at the axial position is at least in part compensated for by modifying the number of overlapping honing actions at the axial position.
  • overlapping honing actions refers to the situation in which a cutting material member at a specific contact pressure runs across a surface region and on account thereof removes material. The material removal in the case of otherwise approximately identical conditions (for example, cutting rate, contact pressure) is the greater the more overlapping honing actions take place at one location.
  • the overlapping honing action can also be referred to as a subtractive stroke repetition.
  • a stroke increment can also be reduced when the measured diameter is too small at an axial position such that further machining can take place with the aid of the subsequent strokes in a measured region.
  • a measured value detection takes place by way of a floating mean value, for example by way of an adjustable quantity of measuring points, wherein forming the floating mean value can cover a portion of the bore or the entire currently machined portion of the bore.
  • Particularly robust values for controlling can be provided on account thereof.
  • diameter measurement values at the reversal points can thus be compared.
  • the measurement of the actual diameter is carried out when the honing tool is situated in the region of a reversal point of the reciprocating movement. It can be achieved on account thereof that a detection of a measured value takes place when an ideally low axial velocity, or no axial velocity, is present. An exact assignment of the diameter measurement value and the stroke position is achieved on account thereof. Moreover, the measuring accuracy can be particularly high at these conditions.
  • the measurement can be carried out such that the honing tool during the diameter measurement rotates in an axially narrow measurement zone in the region of a reversal point, such that a plurality of diameter measurement values can be detected within the narrow measurement zone. It is preferably provided that averaging across the plurality of diameter measurement values detected in short succession takes place in order for an averaged diameter measurement value subject to a minor measuring error to be obtained for the axially narrow region of the reversal point. Said averaged diameter measurement value is then utilized for controlling.
  • the diameter measurement signals utilized for the nominal/actual comparison and/or forming the mean value can be detected in an intermediate region between the reversal points, in particular in a central region between the reversal points.
  • Measurement signals which have been detected for axial positions in the region between the reversal points in comparison to measurement signals from the region of reversal points often have a more attenuated or more uniform, respectively, profile, on account of which better controlling is enabled. It is assumed that more attenuated measurement signals are present, since a reciprocating movement at a more or less constant velocity is present in the central region such that the measurement signals utilized for forming the mean value are detected during a “constant travel” in the axial direction.
  • Measuring and/or comparing can thus also take place in the center of the bore or at any other arbitrary axial position.
  • the reason for this lies inter alia in the particular approach when establishing the contour, as proposed in this application, in which a desired axial contour, that is to say the axial nominal contour profile, can be divided into many nested virtual cylinders, and in which the current machining at all times refers to a cylindrical portion of the bore.
  • the honing process can be managed such that a continuous actuation of cutting material members of the honing tool takes place during the stroke modification phase.
  • the continuous actuation can take place, for example, by way of a constant path or a constant force.
  • the actuation can in particular be controlled by way of a substantially constant actuation speed. It can be ensured on account thereof that any diameter deviations measured are addressed in a substantially exclusive manner by way of the controlled process variable, specifically a potential modification of the stroke length and/or the stroke orientation. This can contribute toward approximating the axial contour profile with high accuracy to the axial nominal contour profile across the entire length of the machined bore.
  • the honing method permits an arbitrary path-controlled or force-controlled actuation, corresponding to the specific application.
  • the honing process is controlled such that, additionally to the stroke length and/or the stroke orientation, also the contact pressure force of cutting material members on the bore internal wall is modified as a function of a command variable, for example as a function of the axial position.
  • controlling of the contact pressure force of cutting material members of the honing tool that is transmitted to the honing tool takes place in a manner that the contact pressure force remains substantially constant during the stroke modification phase. It can be achieved on account thereof that the cause for the dissimilar intense material subtractions is determined substantially only by travelling across axial portions by means of the cutting material members at dissimilar frequencies, but not on account of a modification of the contact pressure force.
  • a honing tool which has an annular cutting group having a plurality of radially actuatable cutting material members that are distributed on the circumference of the tool body is used, wherein the annular cutting group is relatively short in the axial direction.
  • honing tools which are disclosed in WO 2014/146919 A1 can be used. The disclosed content of said document is to this extent incorporated in the present description.
  • the axial length of the cutting material members should preferably be less than 50%, in particular between 10% and 30%, of the effective external diameter of the cutting group.
  • the axial length of the cutting material members can be in the range from 5 mm to 90 mm, in particular in the range from 10 mm to 50 mm, for example.
  • the axial length of the cutting material members is referenced with the bore length, it is typically preferable for the axial length be less than 35% of the bore length so that the cutting material members can generate an axial contour profile with high accuracy.
  • At least one measuring sensor of a diameter measurement system is attached to the honing tool.
  • measuring nozzles of a pneumatic diameter measurement system can be attached to the honing tool.
  • the measuring sensors are preferably attached in the axial region of the cutting material members, for example approximately at half the height of the axial length of the cutting group.
  • the honing tool can be equipped having a simple flaring or having a double flaring (that is to say having two sub-groups of cutting material members within one annular cutting group that are actuatable in a mutually independent manner).
  • Non-cutting guide strips for guiding the honing tool in the bore can be provided on the honing tool.
  • the guide strips can be fixedly assembled on the tool body, or can be actuatable separately from the cutting material members (cf. DE 10 2014 212 941 A1, for example).
  • the invention also relates to a machine tool configured for carrying out the honing method.
  • This herein can be a specialized honing machine or any other machine tool which offers the functionalities required here.
  • FIG. 1 schematically shows some components of a honing machine when machining the internal face of a bore having an axial contour profile
  • FIG. 2 shows the decomposition of a conical bore portion into virtual circular cylinders
  • FIG. 3 shows the decomposition of a bore portion having a free-form contour profile into virtual circular cylinders
  • FIG. 4 shows a diagram having the profile of various process parameters while carrying out a honing method according to one exemplary embodiment
  • FIGS. 5 and 6 show fragments of the diagram from FIG. 4 in a modified illustration.
  • a honing machine 100 which in the context of various embodiments of methods according to the invention can be used as a machine tool for machining internal faces of bores in workpieces is schematically shown in FIG. 1 .
  • the honing machine can be operated such that one or a plurality of conventional honing operations can thus be carried out on the workpiece, on the one hand.
  • the honing machine is also specified for carrying out honing methods according to embodiments of the invention on the same workpiece.
  • a workpiece holding device 104 which supports a workpiece 200 clamped thereon is assembled on a workpiece support (not illustrated in more detail) of the honing machine.
  • the workpiece in the exemplary case is an engine block (cylinder crankcase) of a multi-cylinder internal combustion engine.
  • a plurality of bores 210 having a generally vertical alignment of the bore axes thereof are formed in the engine block.
  • the bores are also referred to as cylinder bores, even when the bore shape thereof significantly deviates from the shape of an ideal circular cylinder.
  • a bore shape which is rotationally symmetrical in terms of a bore axis 212 and deviates from the circular cylindrical shape and has an axial contour profile is generated by means of honing.
  • axial contour profile here means in particular that the bore has dissimilar diameters at different axial positions.
  • the cylinder running faces formed by the internal faces 214 of the cylinder bores are subjected to quality-determining final machining with the aid of the honing machine, wherein the macro shape of the cylinder running faces (thus the macroscopic design of the bore) as well as the surface topography thereof are generated by way of suitable honing operations.
  • the nominal shape of the bore is rotationally symmetrical in terms of the bore axis 212 thereof, and from a bore entry 214 that in the installed state faces the cylinder head extends across a bore length L to the bore exit 216 at the opposite end.
  • the bore in the completely honed state should have a substantially conical, or truncated conical, respectively, design.
  • FIG. 1 shows the bore in an intermediate phase of the machining by honing, in which an upper portion OA has already been conically honed, while the lower portion UA however still has the circular cylindrical initial shape which was present at the beginning of the stroke modification phase.
  • the nominal contour profile 215 of the bore can be seen by way of a dashed line in the lower portion of the bore 210 , said portion not yet having been machined.
  • the nominal diameter continuously increases in the linear manner from the bore entry to the bore end.
  • the cone angle (angle between the bore axis and a shell line of the bore running in an axial plane) can be, for example, in the range of less than 5°, even less than 1°, possibly even be 0.2° or less.
  • the diameter difference between the first diameter D 1 at the bore entry and the second diameter D 2 at the end remote from the entry is significantly outside the tolerances that are typical for the conventional cylindrical machining by honing, said tolerances for a cylindrical shape being in the magnitude of at most 10 ⁇ m (in terms of the diameter).
  • the maximum diameter difference can be between 20 ⁇ m and 500 ⁇ m, for example.
  • the dimensions can be optimized such that a low blow-by, a low oil consumption, and low wear on the piston rings result in typical operating states of the engine.
  • the honing machine 100 has a plurality of honing units. A few components of a honing unit 110 are schematically illustrated in FIG. 1 .
  • the honing unit comprises a spindle box 120 which is fastened to a support construction of the honing machine and in which the honing spindle 140 serving as the tool spindle of the machine tool is rotatably mounted.
  • the honing spindle by means of a spindle drive fastened to the spindle box can be rotated about the longitudinal axis (spindle axis) 142 of said honing spindle.
  • the spindle drive has a servomotor which is controllable inter alia in terms of the rotating speed thereof and the torque generated.
  • a toggle link is attached at the lower end of the honing spindle, the honing tool 150 serving as the machining tool being mechanically coupled to the lower free end of said toggle link so as to be movable in a limited manner, said coupling being performed by way of a bayonet connection, for example.
  • the honing tool can have an integrated joint so as to enable a limited mobility in relation to the toggle link.
  • the honing tool is particularly suitable for machining rotationally symmetrical bores which have bore portions of dissimilar diameters and/or dissimilar designs, for example bottle-shaped bores, barrel-shaped bores, and/or bores which have at least one conical bore portion having a diameter which is continuously variable in axial terms.
  • the honing tool can however also be utilized for machining circular-cylindrical bores, thus rotationally symmetrical bores without an axial contour profile.
  • the honing tool has a tool body 152 which is made from a steel material and defines a tool axis which simultaneously is the rotation axis of the honing tool during the machining by honing.
  • a coupling structure for coupling the honing tool to a drive rod or an operating spindle of a honing machine is situated at the spindle-side end of the honing tool.
  • a single flaring-capable annular cutting group 155 is situated at the end portion of the tool body that faces away from the spindle, said cutting group 155 having a multiplicity of cutting material members 156 which are distributed about the circumference of the tool body, the axial length of said cutting material members 156 measured in the axial direction being smaller by a multiple than the effective external diameter of the cutting group 155 in the case of cutting material members that are fully retracted in the radial direction.
  • the cutting material members are configured as cutting material strips that are narrow in the circumferential direction, the width of said cutting material members measured in the circumferential direction being small in relation to the axial length of the cutting material strips.
  • An aspect ratio between the length and the width can be in the range from 4:1 to 20:1, for example.
  • the honing tool has only a single annular cutting group 135 .
  • Said cutting group 135 is disposed so as to be more or less flush with the end of the tool body that is remote from the spindle such that pocket hole bores can optionally also be machined down to the bore base.
  • the cutting group, or the cutting material members of the cutting group, respectively, is/are actuatable in a radial manner in relation to the tool axis by means of an actuator system assigned to the cutting group. Since the functionality typical of honing tools is known per se, the components provided to this end (for example actuator rod(s), flaring cone, etc.) are not described in more detail here.
  • the honing tool can be equipped with single flaring or double flaring.
  • all cutting material members of the cutting group are collectively actuated in a radial manner.
  • the cutting group has two sub-groups of cutting material members which can be actuated in a mutually separate manner.
  • the cutting material members of the sub-groups can have grit sizes of dissimilar fineness or coarseness, for example, such that, for example, after a pre-honing operation by means of a first sub-group having comparatively coarse cutting material members a final honing stage can be carried out using the cutting material members of the second sub-group without a tool change.
  • the flaring-capable annular cutting group 130 comprises a plurality of radially actuatable cutting material member supports 158 which cover in each case one circumferential angle range which is greater than the axial length of the cutting material members, or of the cutting group, respectively.
  • six cutting material member supports which cover in each case a circumferential angle range of between 45° and 60° and are disposed uniformly across the circumference of the honing tool are provided.
  • Each of the cutting material member supports two, three, four, or more, individual cutting material members 156 in the form of relatively narrow honing strips.
  • a reciprocating drive 160 of the honing machine is provided for causing vertical movements of the honing spindle in a manner parallel with the spindle axis 142 .
  • the reciprocating drive causes, for example, the vertical movement of the honing spindle when introducing the honing tool into the workpiece, or when retracting said honing tool from the workpiece, respectively.
  • the reciprocating drive during the machining by honing is actuated such that the honing tool within the bore 210 of the workpiece carries out an oscillating reciprocating movement, thus a back-and-forth movement in a manner substantially parallel with the spindle axis.
  • the reciprocating movement can be characterized by various parameters.
  • the stroke length herein corresponds to the axial spacing between an upper reversal point UO and a lower reversal point UU of the reciprocating movement (cf. FIG. 4 ).
  • the upper reversal point herein is that reversal point which is closer to the bore entry; the lower reversal point is the reversal point which is remote from the entry.
  • the reciprocating movement can also be characterized by the term “stroke orientation”.
  • stroke orientation refers to the region between the upper reversal point of a reciprocating movement (close to the bore entry) and the lower reversal point of the reciprocating movement (closer to the end of the bore that is remote from the entry) in terms of a fixed machine coordinate system.
  • Each axial relocation of at least one of the reversal points thus modifies the stroke orientation.
  • the stroke length is typically also modified, for example when the axial position of one of the reversal points remains unmodified, and only the axial position of the other reversal point is modified.
  • the honing machine is equipped with an actuating system which permits the effective diameter of the honing tool (plus the external diameter of the cutting group) to be modified by actuating in the radial direction cutting material members 156 attached to the honing tool.
  • This flaring can be implemented in a force-controlled or path-controlled manner, for example, by means of a servomotor.
  • An hydraulic actuation is also possible.
  • An actuating system having a single actuation or a double actuation can be provided. Since such actuating systems are known per se, a detailed description is dispensed with here.
  • the honing machine 100 is furthermore equipped with a diameter measurement system 170 for measuring the actual diameter of the bore in predefinable measurement planes or measurement zones during the machining by honing (in-process measurement).
  • a diameter measurement system 170 for measuring the actual diameter of the bore in predefinable measurement planes or measurement zones during the machining by honing (in-process measurement).
  • measuring sensors of the diameter measurement system are attached to the honing tool 150 .
  • the diameter measurement system in the exemplary case is conceived as a pneumatic diameter measurement system (air measurement system). Accordingly, the honing tool at two diametrically opposite positions between neighboring cutting material members has in each case one measuring nozzle 172 - 1 , 172 - 2 of the diameter measurement system.
  • a very exact diameter measurement of the currently machined bore portion is possible by virtue of the arrangement of the measuring nozzles in the axial region of the cutting material members, for example at mid-height, so as to be centric in the narrow zone of the ring occupied by the cutting material members.
  • the diameter measurement system can operate according to the nozzle/impact plate principle. Compressed air from the measuring nozzles for the measurement herein is blown in the direction of the bore wall, or the internal face 2014 , respectively. The backpressure resulting in the region of the measuring nozzles can serve as a measure for the spacing of the measuring nozzle from the bore wall.
  • a measurement transducer connected to the measuring nozzle by way of a pressurized line ensures the conversion of the (pneumatic) pressure signal to a voltage signal which can be electrically further processed and here is referred to as the diameter measurement signal.
  • the volumetric flow of the compressed air can also be used for the evaluation.
  • Diameter measurement systems which operate according to other principles, for example capacitive measurement systems or inductive measurement systems, or measurement systems using radar sensors (cf. DE 10 2010 011 470 A1, for example) can also be used in principle.
  • the spindle drive, the reciprocating drive, the at least one drive of the actuating system, as well as the converter of the diameter measurement system are connected to a control installation 180 which is a functional component part of the machine controller and can be operated by way of an operator installation 190 .
  • a control installation 180 which is a functional component part of the machine controller and can be operated by way of an operator installation 190 .
  • Numerous process parameters required for defining the honing process can be set by a machine operator by way of the operator installation.
  • An axial nominal contour profile which represents the nominal diameter as a function of the axial stroke position in the bore to be machined can inter-alia be predefined prior to the beginning of the honing operation.
  • the predefining of the nominal contour profile, thus the predefining of the contour honing can take place, for example, by defining the contour as an analytic formula (for example a linear equation or a non-linear equation) or as a point grid (for generating free-form curves).
  • the holding machine for generating a specific axial contour profile on the bore can be programmed such that an axially variable material removal can be generated in a targeted manner in at least one stroke modification phase by way of a targeted modification of the stroke length and/or the stroke orientation of the honing tool, so as to achieve in this way with high accuracy parameters in terms of the axial contour profile.
  • a measurement of the actual diameter of the bore is carried out during a stroke modification phase according to the stipulation of a pre-definable measuring condition, so as to determine a diameter measurement signal which corresponds to the actual diameter of the bore in that measurement plane or narrow measurement zone in which the measurement has been carried out.
  • the stroke length and/or the stroke orientation of the reciprocating movement are then variably controlled as a function of the diameter measurement signal.
  • a controlled contour honing process can be implemented in this way.
  • FIG. 2 schematically shows this concept.
  • FIG. 2 shows a conical portion AB of a bore, thus an axial bore portion, in which the diameter changes in the axial direction AX, according to a linear function. Further bore portions can join at the top and/or at the bottom. It is also possible for the portion AB to comprise the entire bore length such that the bore overall is purely conical.
  • this rotationally symmetrical but non-circular cylindrical bore shape can be virtually divided into a multiplicity of circular cylinders Z 1 , Z 2 , . . . , Z n of dissimilar heights and dissimilar diameters.
  • a non-cylindrical bore is thus never to be measured despite such a non-cylindrical bore nevertheless being generated at the end of the honing process.
  • the contour honing by means of the modification of the stroke can thus be imagined as a series of classic cylindrical interlinked machining actions by honing.
  • such machining is implemented in that the axial position of the lower reversal point UU of the reciprocating movement of successive double strokes remains fixed, or unchanged, respectively, while the upper reversal point UO is dynamically relocated in a step-by-step manner (incrementally) in the direction of the lower reversal point.
  • the lower reversal point can remain fix and the upper reversal point is dynamically shortened.
  • the nested cylinders resulting on account thereof in the case of the honing method are not fixedly predetermined in terms of the diameter and the axial position of the upper end of said cylinders, but, by way of calculations within the control installation 190 , are dynamically determined anew after each stroke in a manner corresponding to the current measured result of the diameter measurement, and are set in a corresponding manner with the aid of the reciprocating drive.
  • an axial nominal contour profile which represents the nominal diameter of the bore as a function of the axial stroke position is predefined.
  • the controller can therefrom calculate a linear equation which represents the nominal contour profile.
  • the predefining of the nominal contour profile can generally take place, for example, by defining the contour as an analytical formula (for example a linear equation or a non-linear equation) or as a point grid which describes the correlation between the stroke position and the desired contour dimension.
  • an analytical formula for example a linear equation or a non-linear equation
  • a point grid which describes the correlation between the stroke position and the desired contour dimension.
  • the nominal contour profile can be indicated by a straight line.
  • More complex cases can be indicated by correspondingly more complicated analytic formulae such as, for example, non-linear equations or by a points grid, wherein interpolation optionally takes place between the points.
  • FIG. 3 shows an example of such a portion AB in which the diameter from the smallest diameter lying above to the largest diameter lying below does not change in a linear manner but according to a curved curve, wherein the increase of the diameter per axial increment continuously decreases from the smallest diameter to the largest diameter such that a radially outward curved contour results.
  • the actual diameter measured at a predefined stroke position in a stroke is then compared with the nominal diameter of the nominal contour profile associated with the stroke position in a comparison operation.
  • a diameter deviation for the stroke position is determined from the result of the comparison operation.
  • the stroke length and/or the stroke orientation of a subsequent stroke is then modified relative to a nominal stroke length and/or a nominal stroke orientation according to the nominal contour profile as a function of the diameter deviation.
  • a control intervention in the sense of a modification of the stroke parameters typically takes place only when the diameter deviation exceeds a predefinable limit value so as to generate control interventions only when significant diameter deviations are to be determined.
  • the controlling is particularly simple when a portion to be honed is chosen such that the diameter within the portion continuously changes, thus continuously decreases or increases, in one direction.
  • the stroke modification for the portion can be programmed such that one of the reversal points, specifically the reversal point associated with the larger diameter, remains fixed, while the other reversal point (closer to the tight end) by way of a variable step size moves step-by-step toward the fixed reversal point.
  • the bore for the purpose of controlling can be divided into a plurality of portions to which said preconditions then apply again. Said plurality of portions can then be sequentially worked according to the method described.
  • a special case is present, for example, when there are two such portions and one of the portions in terms of the diameter grows in a downward manner, and the lower portion in terms of the diameter grows in an upward manner. In this case, both reversal points at the top and at the bottom can be simultaneously shortened in a manner corresponding to the current measured results and the predefined profile curve (axial nominal contour profile).
  • FIG. 4 in an exemplary manner shows a diagram resulting therefrom, in which the honing time t H (in seconds) of the honing operation is illustrated on the x-axis, and various parameters as a function thereof are illustrated so as to be plotted conjointly on the y-axis.
  • the rotating speed of the honing spindle in an initial phase was increased to a nominal value and then remained substantially constant during the entire honing operation.
  • the reciprocating controller was set such that the stroke length (axial spacing between the upper and the lower reversal point) in an initial first honing phase PH 1 was so large that the honing tool with the aid of the annular cutting group machines the entire bore length between the bore entry and the bore exit by means of a few complete double strokes.
  • the axial positions of the upper reversal point UO and of the lower reversal point UU herein remained constant across a plurality of double strokes.
  • the subsequent second honing phase PH 1 here is referred to as the stroke modification phase since the stroke orientation of the honing tool and/or the stroke length are modified, or can be modified, respectively, from one stroke to another stroke in said second honing phase.
  • the term “stroke orientation” herein refers to the region between the upper reversal point UO of a reciprocating movement (close to the bore entry) and the lower reversal point UU of the reciprocating movement closer to the end of the bore that is remote from the entry, in each case in relation to a fixed machine coordinate system. Each axial relocation of the position of a reversal point thus also changes the stroke orientation. In the exemplary case of FIG.
  • the axial position of the lower reversal point UU was kept constant across the complete second honing phase PH 2 , while the axial position of the upper reversal point UO was variably controlled by the control installation 190 as a function of the diameter measurement signal (DM-I).
  • the general trend in terms of the temporal profile of the upper reversal point herein is such that the axial position thereof across the honing time in a step-by-step manner approximates the lower reversal points such that the stroke length was reduced in a step-by-step manner from one stroke to another stroke.
  • the portion of the bore that is more remote from the entry is machined by way of more strokes than the portion closer to the entry such that a plurality of overlapping honing actions take place in the portion that is more remote from the entry and thus more material is subtracted there than in the region closer to the entry.
  • the diameter measurement value utilized for controlling is detected in a phase of a very low axial velocity of the honing tool such that the measuring sensors (air measuring sensors) are situated substantially in the same axial portion, or in an axially narrow measurement zone of the bore, respectively, over a comparatively long period, and the diameter present therein can thus be determined with high accuracy (possibly by way of forming a mean value).
  • the axial extent of the measurement zone can be, for example, 10 mm or less, and in particular be in the range from 3 mm to 8 mm.
  • the honing operation is terminated when the diameter measurement indicates that the targeted contour profile has been reached within the tolerances.
  • the switching-off thus takes place as a function of the in-process measurement.
  • the first correction value I 1 on the double stroke shown at the left is of approximately double the size of the correction value I 2 of the directly following, central, double stroke, while the following third correction value I 3 has an absolute value which lies between the absolute values of the two preceding correction values.
  • the nominal value of the diameter measurement (DM-S) as well as the diameter actual value (DM-I), thus the result of the current diameter measurement, are illustrated in the region of the respective upper reversal point of the reciprocating movement in FIG. 6 .
  • the comparison of the two upper curves DM-S and DM-I clearly visualizes that the nominal value DM-S should increase from one stroke to another stroke by the same amount so as to correspond to the linear profile of the oblique contour of the cone. This corresponds to the linear profile of the contour of a cone which in terms of parameters can be expressed, for example, by a linear equation.
  • the curve of the actual diameter values DM-I illustrated therebelow has steps of dissimilar heights. This proves that there are differences between the nominal contour and the measured actual contour that are locally dissimilar in size.
  • the curve OFF represents the correction values resulting from a comparison operation of the diameter values, said correction values leading to a corrective intervention in the honing process in the course of controlling taking place in a manner that the desired contour profile results in an ideally precise manner. It can also be seen herein by way of the curve OFF that the correction values which are added to a nominal value of the stroke relocation can assume positive as well as negative values such that the absolute variables of the stroke increments between successive strokes can be both smaller as well as larger than the stroke increments to be expected in the case of an ideal contour profile.
  • the variant described in more detail here provides a fixed predefining of nominal stroke shortenings (corresponding to the nominal contour profile) and a correction for determining the stroke shortenings actually implemented or set, respectively, in the process by way of the offset or the correction value, respectively, according to the current measured results.
  • a calculation of the stroke shortening according to the removal, and predefining the contour without a nominal stroke shortening, is also possible, for example.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Geometry (AREA)
  • Finish Polishing, Edge Sharpening, And Grinding By Specific Grinding Devices (AREA)
US16/624,405 2017-06-19 2018-06-13 Honing method and machine tool for contour honing Pending US20200156204A1 (en)

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DE102017210187.3A DE102017210187A1 (de) 2017-06-19 2017-06-19 Honverfahren und Bearbeitungsmaschine zum Konturhonen
PCT/EP2018/065619 WO2018234114A1 (de) 2017-06-19 2018-06-13 Honverfahren und bearbeitungsmaschine zum konturhonen

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WO2018234114A1 (de) 2018-12-27
HUE063653T2 (hu) 2024-01-28

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