WO2020011541A1 - Procédé de rodage et machine d'usinage pour le rodage de contours - Google Patents

Procédé de rodage et machine d'usinage pour le rodage de contours Download PDF

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Publication number
WO2020011541A1
WO2020011541A1 PCT/EP2019/067092 EP2019067092W WO2020011541A1 WO 2020011541 A1 WO2020011541 A1 WO 2020011541A1 EP 2019067092 W EP2019067092 W EP 2019067092W WO 2020011541 A1 WO2020011541 A1 WO 2020011541A1
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WO
WIPO (PCT)
Prior art keywords
honing
stroke
diameter
bore
speed
Prior art date
Application number
PCT/EP2019/067092
Other languages
German (de)
English (en)
Inventor
Ronald Angerbauer
Joachim Weiblen
Florian KRANICHSFELD
Original Assignee
Elgan-Diamantwerkzeuge Gmbh & Co. Kg
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Elgan-Diamantwerkzeuge Gmbh & Co. Kg filed Critical Elgan-Diamantwerkzeuge Gmbh & Co. Kg
Priority to EP19735261.0A priority Critical patent/EP3820646A1/fr
Publication of WO2020011541A1 publication Critical patent/WO2020011541A1/fr

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Classifications

    • 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
    • B24B33/02—Honing machines or devices; Accessories therefor designed for working internal surfaces of revolution, e.g. of cylindrical or conical shapes
    • B24B33/027—Honing machines or devices; Accessories therefor designed for working internal surfaces of revolution, e.g. of cylindrical or conical shapes using an unexpandable tool
    • 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
    • B24B33/083—Honing tools with different sets of honing stones
    • 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
    • B24B33/00—Honing machines or devices; Accessories therefor
    • B24B33/08—Honing tools
    • B24B33/088—Honing tools for holes having a shape other than cylindrical
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • 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

Definitions

  • the invention relates to a honing process for machining the inner surface of a bore in a workpiece with the aid of at least one honing operation according to the preamble of claim 1, and to a processing machine configured to carry out the honing process according to the preamble of claim 14.
  • a preferred field of application is the honing of cylinder running surfaces in the Manufacture of cylinder blocks or cylinder liners for reciprocating machines.
  • cylinder running surfaces in cylinder blocks (cylinder crankcases) or cylinder liners of internal combustion engines or other reciprocating piston machines are exposed to severe tribological stress during operation. Therefore, when manufacturing cylinder blocks or cylinder liners, it is important to machine these cylinder liners in such a way that sufficient lubrication is ensured by a lubricant film under all operating conditions and that the frictional resistance between parts moving relative to one another is kept as low as possible.
  • Honing is a cutting process with geometrically undefined cutting edges.
  • an expandable honing tool is moved back and forth within the bore to be machined to produce a lifting movement in the axial direction of the bore and rotated at the same time to produce a rotary movement superimposed on the lifting movement.
  • cutting material bodies attached to the honing tool are fed in via a feed system with a feed force and / or feed speed acting radially to the tool axis and pressed onto the inner surface to be machined.
  • a cross-cut pattern typical of honing is created on the inner surface with intersecting machining marks, which are also referred to as "honing grooves".
  • the proportion of friction in the piston group can be up to 35%, so that a reduction in friction in this area is desirable.
  • the shape (macro shape, shape) of the hole or its inner surface also plays a role.
  • the torque transmitted via the spindle to the honing tool is controlled in such a way that the torque remains essentially constant during the stroke change phase.
  • bores can be produced which, in the finished state, have an axial contour profile which have the desired contour profile over the entire relevant bore length with sufficient precision.
  • DE 10 2016 105 717 A1 describes a method for producing a rotationally symmetrical, non-cylindrical bore with a honing tool.
  • the procedure includes the steps: honing the hole with one stroke; Detecting the actual diameter of the bore during honing in a region between the reversal points of the honing stones of the honing tool; Comparing the actual diameter of the bore with the predetermined nominal diameters in at least one of the reversal points; and restricting the stroke to the area or areas of the bore in which the actual diameter is smaller than the desired diameter.
  • the method thus has a closed control loop, which in the
  • the result should be that the different diameters over the length of the bore to be machined are recorded during machining and the stroke of the honing tool is gradually reduced in accordance with the measured actual values of the diameter, so that only the areas of the bore are machined which the actual diameter of the hole is even smaller than the nominal diameter. No further machining of the bore takes place in the area or areas of the bore in which the actual diameter of the bore is equal to the target diameter specified there. This should make it possible to produce a wide variety of non-cylindrical surface lines easily, reliably and with the highest repeatability.
  • the honing process belongs to the genus of honing processes in which, with the aid of a material removal that varies in the axial direction of the bore, a bore shape that is rotationally symmetrical to the bore axis is produced with an axial contour profile.
  • a bore shape is a bore shape which is rotationally symmetrical with respect to the bore axis and which differs significantly from a circular cylinder shape.
  • a typical example of a bore shape with an axial contour is a conical bore, in which the diameter increases more or less linearly between a plane of the smallest diameter and a plane of the largest diameter of the section.
  • Non-linear changes in diameter are also possible in the axial direction.
  • a bore shape with an axial contour can also be a or have several sections with a circular cylindrical shape, that is to say those sections in which the nominal diameter does not vary in the axial direction.
  • the stroke length and / or the stroke position of the stroke movement are changed in at least one stroke change phase. It can thereby be achieved that the cutting material bodies provided on the honing tool pass through or cover some axial sections more frequently than other axial sections, so that the material removal due to the contact with the cutting material bodies differs primarily in different axial sections or essentially due to the different number of honing overlaps is strong.
  • an axial target contour profile is specified, which represents the dependence of the target diameter on the axial position in the bore to be machined.
  • the axial target contour profile thus represents the desired bore shape or bore shape after the shape-changing honing operation has been completed.
  • the target contour course can e.g. in the form of an analytical formula (e.g. straight line equation, polynomial or curve equation) or as a point field.
  • a stroke change curve for the stroke change phase is predefined based on the target contour curve.
  • the stroke change course determines how the stroke length and / or the stroke position of the stroke movement should change during the honing operation.
  • the specified course of the stroke change should not change during the honing operation and is therefore an unchangeable or fixed variable after the definition.
  • a stroke change course can be described as a gradual or incremental change in stroke length and / or the stroke position during the honing operation.
  • stroke increments are fixed.
  • a stroke increment represents the absolute magnitude of a change in the axial position of a reversal point (upper reversal point or lower reversal point) of the stroke movement between a stroke and the immediately following next stroke in the same direction.
  • stroke increments depend on the format (depending on the desired bore shape) and can remain the same or vary from stroke to stroke. In principle, stroke increments with a value of zero are also possible, which then mean that the axial position of the reversal point under consideration should not change from one stroke to the next.
  • the incremental changes can only take place at upper reversal points or only at lower reversal points or at both upper and lower reversal points. Accordingly, stroke increments can be specified for upper and / or lower reversal points. For example, stroke changes for bores with a cone shape, hourglass shape or barrel shape can be specified.
  • the predefined course of the stroke changes can be calculated in advance on the basis of the contour specification (target contour course).
  • the respective stroke increments are preferably selected to be only as large as expected as material can be removed within a double stroke. Accordingly, in sections with the desired relatively larger material removal, the stroke increments will generally be smaller than where less material removal is required.
  • the stroke change can e.g. be a fixed function of the slope of the contour (of the target contour profile), in particular the gradient of the target contour at the upper or lower changeover point.
  • the course of the stroke change can be specified by the operator on the basis of experience gained in tests by inputs on the operating system. It is also possible for data to be entered which represent the axial target contour profile, a stroke change profile suitable for its production then being calculated in a computing unit of the processing machine. A stroke change course can e.g. can be calculated based on the slope of the target contour and the necessary removal. It is also possible to determine the course of the stroke change on the basis of a simulation.
  • a special feature of the honing process is that during the stroke change phase, i.e. during the phase in which the stroke length and / or the stroke position of the stroke movement changes gradually according to the fixed specification, a measurement of the actual diameter of the bore is carried out in order to To determine the diameter measurement signal, which represents the actual diameter of the bore in a measured bore section, that a target-actual comparison is also carried out between the determined actual diameter and an assigned target diameter to determine a diameter deviation and based on this the stroke change phase, at least one honing parameter influencing the material removal is variably controlled depending on the result of the target / actual comparison.
  • a closed control loop (feedback control) is thus provided, which means that at least one honing parameter that influences the material removal is influenced during the stroke change phase as a controlled variable by the results of a diameter measurement carried out during machining , so that during the ongoing honing process the diameter measurement is automatically exerted on the material removal during the strokes, in particular without intervention by an operator.
  • the diameter measurement signal used for the control is recorded in accordance with a predeterminable measurement condition, for example in at least one predeterminable phase of a stroke movement or during the entire stroke movement.
  • the stroke length and stroke position are controlled according to a preset setting (open loop control). The stroke length and the stroke position of the stroke movement are therefore not regulated variables, but follow the fixed specification regardless of the results of the diameter measurement.
  • the stroke-specific material removal is regulated with a fixed stroke change.
  • the material removal that can be achieved or achieved during a stroke is regulated depending on the diameter measurement.
  • the (stroke-specific) material removal is a measure of length that e.g. can be specified in micrometers (pm) and describes how much material is removed from the surface during the stroke or by how much the surface is reset on average by the stroke.
  • the material removal is usually related to the diameter.
  • a hub-specific material removal corresponds to e.g. a material removal in micrometers (pm) per stroke.
  • the actual contour profile present at the end of a honing operation can be systematically and evenly closer to the systematic and uniform over the machined length regardless of variations in the workpiece properties and / or variations in the environmental conditions and / or changes in the cutting behavior of the cutting material bodies during honing
  • the desired contour progression lies in the case of an exclusively controlled contour honing without feedback by an in-process measuring system. The method thus systematically meets the increased accuracy requirements for contour honing of rotationally symmetrical bores with an axial contour.
  • the honing parameter influencing the material removal which is to be used as a controlled variable, is selected from a specific honing parameter group.
  • the honing parameter group has exactly four "members”, namely the stroke speed of the lifting movement of the honing tool, the rotational speed of the rotating movement of the honing tool, the feed speed of an expansion of a cutting group of the honing tool and the feed force when an cutting group of the honing tool is expanded.
  • the first two honing parameters namely the lifting speed and the rotational speed, primarily influence the cutting speed that determines the material removal and the locally effective, that is to say effective on a surface element of the inner bore surface to be machined.
  • the infeed speed and infeed force primarily affect the cutting pressure effective for material removal or the specific contact pressure of the cutting bodies (e.g. honing stones).
  • the honing parameter group therefore only contains honing parameters that indicate the relevant intervention parameters for material removal.
  • the stroke length and the stroke position do not relate to these intervention variables, but are rather geometric parameters that determine in which area of the inner bore surface an engagement between the cutting material body and the inner bore surface should / can take place during a stroke.
  • the stroke speed or the stroke speed and at least one further honing parameter from the honing parameter group or to permit changes may be advantageous to regulate only the stroke speed or the stroke speed and at least one further honing parameter from the honing parameter group or to permit changes. This can be done in particular in such a way that when the stroke speed changes, the stroke speed is reduced if the actual diameter is smaller than the nominal diameter and is increased if the actual diameter is larger than the nominal diameter.
  • the lifting speed as the intervention variable to be controlled has the advantage, among other things, that with typical ratios between lifting speed and speed in honing operations, when changing a lifting speed there are only slight changes in the cutting speed and the specific contact pressure.
  • the speed is to be used as the honing parameter to be controlled (either alone or in combination with at least one second honing parameter), then the speed is preferably reduced when the speed changes, if the actual diameter is greater than the desired diameter, and increased , if the actual diameter is smaller than the nominal diameter.
  • This is particularly expedient in the case of processes in which a substantial proportion of the material removal is made via the rotation of the honing tool and, in comparison, less contribution is made by the axial lifting movement. Regulation of the speed is neutral to the cycle time, so it does not have the effect of changing the cycle time.
  • the control is preferably carried out in such a way that when the infeed speed changes, the infeed speed is increased if the actual diameter is smaller than the target diameter, and is reduced if the actual diameter is larger than the target diameter.
  • Regulating the delivery speed is cycle time-neutral, so it does not have the effect of changing the cycle time.
  • the infeed force is used as the honing parameter to be controlled (either alone or in combination with at least one other honing parameter from the honing parameter group)
  • the infeed force is generally increased when the infeed force changes, if the actual diameter is smaller than the nominal diameter and is reduced if the actual diameter is larger than the nominal diameter.
  • a regulation of the delivery staff is cycle time neutral, so it does not have the effect of changing the cycle time.
  • regulation can take place in such a way that only one of the honing parameters of the honing parameter group, for example only the speed, is regulated as a function of the diameter measurement if all other honing parameters follow a specification.
  • This procedure can e.g. are used in structurally uniform drilling environments, e.g. when machining cylinder bores that do not have any local weak points, e.g. caused by missing or different connections to the environment.
  • a second honing parameter of the honing parameter group is changed synchronously in order to at least partially compensate for any adverse effects of changing the first honing parameter.
  • at least a second honing parameter of the honing parameter group is changed synchronously such that a change in the torque transmitted to the honing tool via the spindle is at least partially compensated for .
  • the control intervention can take place, for example, in such a way that the torque remains essentially constant during the stroke change phase or is only subject to minor changes.
  • a torque is considered to be “essentially constant” when a deviation of the torque averaged over a stroke from a torque setpoint is less than 15%, in particular less than 10% or less than 5%.
  • Delivery speed compared to the previous delivery speed leads. In this case, it can make sense to simultaneously increase the speed compared to the previous speed in order to increase the chip removal volume acting on the workpiece, that is to say one removal per unit of time. This can increase the
  • Infeed speed leads to lower deformations being caused on the machined workpiece than in the case of an uncompensated increase in the infeed speed, which can lead to increased cutting pressure and thus to increased pressure on the workpiece or the bore inner surface or bore wall.
  • the control is preferably programmed in such a way that a control intervention by changing one of the honing parameters of the honing parameter group only takes place if the diameter deviation exceeds a predefinable finite limit value, that is to say a permissible control deviation. It can thereby be achieved that only significant deviations or a clear trend towards ever larger setpoint deviations lead to a control intervention. In this way, unnecessary control interventions can be avoided and the honing operation is thereby stabilized.
  • the workpieces to be machined are designed to be relatively complex, so that mechanical stability of the immediate vicinity of the inner bore surface to be machined varies, for example, in the longitudinal direction of the bore.
  • the bore wall can be relatively thin in the area of a water jacket and thicker outside the area of the water jacket.
  • Variants are particularly advantageous for the machining of such workpieces characterized by a bore-specific, axially selective programming of the honing operation, in which the bore is divided into a first bore section and at least one axially offset second bore section, different sub-groups of honing parameters of the honing parameter group as for the first bore section and the second bore section Control variables are specified or permitted.
  • a “sub-group” can contain a single honing parameter of the honing parameter group or also several, for example two or three.
  • the bore can have a relatively stable, thick-walled first bore section, which is followed by a more unstable, second bore section in the region of a thinner bore wall.
  • the honing operation can then be carried out, for example, in such a way that primarily the feed pressure is varied in the area of the first bore section, but the feed speed is reduced in the second bore section and the stroke speed is increased in order to achieve the desired stroke-specific material removal.
  • the axially selective programming can be the same for all bores or vary from bore to bore or from bore group to bore group.
  • a possible synchronous change of at least one second honing parameter can be restricted to certain axial regions, e.g. to counteract unstable spots in a cylinder bore. For example, If there is no cylinder connection or a thinner bore wall at a certain bore depth, the delivery speed can be reduced in this area while the stroke speed is reduced at the same time. After this range has been exceeded, only a regulation of the lifting speed or the delivery speed can take place. In this way, honing can be carried out particularly gently in critical areas. This would be e.g. also possible with connecting rod windows.
  • a particularly precise control can be achieved in some embodiments in that an individual setting or change in a value of the at least one honing parameter of the honing parameter group is calculated for each double stroke.
  • an individual setting or change in a value of the at least one honing parameter of the honing parameter group is calculated for each double stroke.
  • a honing tool which has an annular cutting group with a plurality of radially adjustable cutting material bodies distributed around the circumference of the tool body, the annular cutting group being relatively short in the axial direction is.
  • honing tools can be used, which are disclosed in WO 2014/146919 A1 or DE 10 2015 203 051 A1. The disclosure content of these documents with regard to possible designs of the honing tool is thus made the content of the present description. Preferred configurations of suitable honing tools and advantages for this type of honing operations are described in detail below.
  • the axial length of the cutting material body should preferably be less than 50%, in particular between 10% and 30% of the effective outside diameter
  • Cutting material bodies are, for example, in the range from 5 mm to 90 mm, in particular in the range from 10 mm to 50 mm. If one relates the axial length of the cutting material body to the bore length, it can be advantageous if the axial length is less than 35% of the
  • Bore length is so that the cutting material body can generate an axial contour with high accuracy.
  • At least one measuring sensor of a diameter measuring system is preferably attached to the honing tool.
  • measuring nozzles of a pneumatic diameter measuring system can be attached to the honing tool.
  • Measuring sensors attached in the axial area of the cutting material body for example about half the height of the axial length of the cutting group. This enables a precise diameter measurement in the immediate vicinity of the location of the current material removal, which means that very precise current diameters (actual diameter values) are available for controlling the honing process, which can be assigned very precisely to the associated axial position.
  • the honing tool can be equipped with a single widening or with a double widening (i.e. with two subgroups of cutting material bodies which can be set independently of one another within an annular cutting group).
  • Non-cutting guide strips can be provided on the honing tool for guiding the honing tool in the bore.
  • the guide strips can be fixed to the tool body or can be delivered separately from the cutting material bodies (see e.g. DE 10 2014 212 941 A1).
  • the invention also relates to a processing machine configured to carry out the honing process. It can be a specialized honing machine or another machine tool that offers the functionalities required here, for example a machining center.
  • FIG. 1 schematically shows components of a honing machine that can be used in the context of various embodiments of the method according to the invention
  • FIGS. 2A and 2B schematically show bores with different axial contour profiles and sizes of stroke increments adapted to them to determine the course of the stroke change;
  • 3 to 7 describe exemplary embodiments for honing operations which can be carried out with the honing machine using diagrams which show the time profiles of relevant parameters as a function of the honing time;
  • FIG. 8 shows an example of a bore with a conical target shape in a workpiece with a bore wall of different thicknesses in the axial direction
  • FIG. 9 shows, analogously to FIGS. 3 to 7, a diagram which shows the time profiles of relevant parameters as a function of the honing time when machining the bore from FIG. 8.
  • FIG. 1 schematically shows some components of a honing machine 100 that can be used as a processing machine in the context of various embodiments of methods according to the invention for machining inner surfaces of bores in workpieces.
  • the honing machine can be operated so that on the one hand one or more conventional honing operations can be carried out on the workpiece.
  • the honing machine is also set up to also carry out honing processes according to embodiments of the invention on the same workpiece.
  • a workpiece holding device 104 is mounted on a workpiece carrier of the honing machine, not shown, which carries a workpiece 200 clamped thereon.
  • the workpiece is an engine block (cylinder crankcase) of a multi-cylinder internal combustion engine.
  • a plurality of bores 210 are in the engine block generally vertical alignment of their bore axes.
  • the bores are also referred to as cylinder bores, even if their bore shape differs significantly from the shape of an ideal circular cylinder.
  • honing produces a bore shape that is rotationally symmetrical with respect to a bore axis 212 and deviates from the circular cylinder shape with an axial contour profile.
  • axial contour profile here means in particular that the bore has different diameters in different axial positions.
  • the cylinder running surfaces formed by the inner surfaces 214 of the cylinder bores are subjected to a quality-determined finish using the honing machine, both the macro shape of the cylinder running surfaces (that is, the macroscopic shape of the bore) and their surface topography being generated by suitable honing operations.
  • the desired shape of the bore is rotationally symmetrical with respect to its bore axis 212 and extends over a bore length L from a bore inlet 214 facing the cylinder head in the installed state to the bore outlet 216 at the opposite end.
  • the bore should have an essentially conical or frustoconical shape in the fully honed state. 1 shows the bore in an intermediate phase of honing, in which an upper section OA has already been honed conically, but the lower section UA still has the circular-cylindrical initial shape that existed at the beginning of the stroke change phase.
  • the target contour profile 215 of the bore can be seen in the lower, not yet machined section of the bore 210 with a dashed line.
  • the nominal diameter increases continuously linearly from the hole entry to the hole end.
  • the cone angle (angle between the bore axis and a surface line of the bore running in an axial plane) can e.g. are in the range of less than 5 °, even less than 1 °, possibly also 0.2 ° or less.
  • the difference in diameter between the first diameter D1 at the bore inlet and the second diameter D2 at the end remote from the inlet is clearly outside the tolerances typical for conventional cylindrical honing, which for a cylindrical shape are of the order of 15 pm maximum (based on the diameter).
  • the maximum diameter difference can be, for example, between 20 pm and 500 pm.
  • the dimensions can be optimized in such a way that there are low blow-by, low oil consumption and low wear of the piston rings in typical operating conditions of the engine.
  • the honing machine 100 has several honing units.
  • Fig. 1 some components of a honing unit 1 10 are shown schematically.
  • the honing unit comprises a headstock 120 fastened to a support structure of the honing machine, in which the honing spindle 140 serving as the tool spindle of the processing machine is rotatably mounted.
  • the honing spindle can be rotated about its longitudinal axis (spindle axis) 142 by means of a spindle drive attached to the headstock.
  • the spindle drive has a servo motor which can be controlled, inter alia, with regard to its speed and the torque generated.
  • an articulated rod or another drive rod e.g. a floating head rod
  • the honing tool 150 serving as a machining tool is mechanically coupled to a limited extent, for example via a bayonet connection.
  • the honing tool can have an integrated joint in order to allow limited mobility with respect to the joint rod.
  • the honing tool is particularly well suited for machining rotationally symmetrical bores which have bore sections of different diameters and / or different shapes, for example bottle-shaped bores, barrel-shaped bores and / or bores which have at least one cone-shaped bore section with an axially continuously variable diameter.
  • the honing tool can also be used to machine circular cylindrical bores, i.e. rotationally symmetrical bores without an axial contour.
  • the honing tool has a tool body 152 made of a steel material, which defines a tool axis, which is also the axis of rotation of the honing tool during honing.
  • a coupling structure for coupling the honing tool to a drive rod or a work spindle of a honing machine.
  • a coupling structure in the manner of a hollow shaft cone or another cone can be provided.
  • a single expandable annular cutting group 155 with a plurality of cutting material bodies 156 distributed around the circumference of the tool body, the axial length of which in the axial direction is several times smaller than the effective outer diameter of the cutting group 155 at completely in Radially retracted cutting material bodies.
  • the cutting material bodies are designed as narrow cutting material strips in the circumferential direction, whose width measured in the circumferential direction is small compared to the axial length of the cutting material strips.
  • An aspect ratio between length and width can be, for example, in the range from 4: 1 to 20: 1.
  • the honing tool has only a single annular cutting group 135. This can be arranged more or less flush with the end of the tool body remote from the spindle, so that blind holes can also be machined as far as the bottom of the hole.
  • the cutting group is or the cutting material bodies of the cutting group can be advanced radially to the tool axis by means of an infeed system assigned to the cutting group. Since this functionality, which is typical for honing tools, is known per se, the components provided for this purpose (for example feed rod (s), feed cone or expansion cone etc.) are not described in more detail here.
  • the honing tool can be equipped with a single expansion or double expansion. With a simple expansion, all cutting material bodies of the cutting group are fed together radially. In the case of double expansion, the cutting group has two sub-groups of cutting material bodies that can be fed separately from one another.
  • the cutting material bodies of the subgroups can e.g. have differently fine or coarse grain, so that e.g. after a pre-honing operation using a first subgroup of coarser cutting material bodies, a finished honing step can be carried out with the cutting material bodies of the second subgroup without changing tools.
  • the expandable annular cutting group 155 of the embodiment comprises a plurality of radially adjustable cutting material body carriers 158, each of which covers a circumferential angle range which is greater than the axial length of the cutting material body or the cutting group.
  • six cutting material body carriers are provided, each of which covers a circumferential angle range of between 45 ° and 60 ° and are arranged uniformly over the circumference of the honing tool.
  • Each of the cutting material body carriers carries two, three, four or more individual cutting material bodies 156 in the form of relatively narrow honing stones. Non-cutting guide strips (not shown) etc. can be attached to the tool body between immediately adjacent cutting material body carriers.
  • the cutting material body carriers 158 are made in one piece from a steel material and are therefore essentially rigid in themselves.
  • Each cutting material body carrier has a carrier section which is relatively wide in the circumferential direction with a cylindrically curved outer side and an essentially flat inner side facing the tool body, on which a plate-shaped feed section projects inwards.
  • the feed section of the cutting material body carrier sits in a radially movable manner in a substantially rectangular recess in the tool body, so that radial movement is possible, but tilting movements in the transverse and longitudinal directions are largely avoided.
  • the cutting material body carriers are pretensioned into the inwardly retracted position with the aid of several spiral springs, so that the radial inward movement takes place against the force of these return springs.
  • the exemplary embodiment of the honing tool 150 in FIG. 1 is a honing tool with a double expansion.
  • the ring-shaped cutting group 155 has two independently deliverable groups of cutting material body carriers, the three cutting material body carriers of one group each being offset by 120 ° relative to one another, so that a cutting material body carrier of the other group is arranged between two adjacent cutting material body carriers of one of the groups is.
  • Other even or uneven divisions are possible, e.g. with four cutting material body carriers in a first and two cutting material body carriers in a second group or with four cutting material body carriers in a first and four cutting material body carriers in a second group.
  • a lifting drive 160 of the honing machine is provided to cause vertical movements of the honing spindle parallel to the spindle axis 142.
  • the lifting drive causes, for example, the vertical movement of the honing spindle when the honing tool is inserted into the Workpiece or when pulling out of the workpiece.
  • the lifting drive is controlled in such a way that the honing tool executes an oscillating lifting movement, that is to say a back and forth movement, essentially parallel to the spindle axis within the bore 210 of the workpiece.
  • the stroke movement can be characterized by different parameters.
  • the “stroke length” corresponds to the axial distance between an upper changeover point UO and a lower changeover point UU of the stroke movement (cf. FIG. 3).
  • the upper changeover point is the changeover point that is closer to the hole entry, the lower changeover point is the changeover point remote from the entry.
  • the stroke movement can also be characterized by the “stroke position”.
  • the term “stroke position” refers to the area between the upper changeover point of a stroke movement (near the hole entry) and the lower changeover point of the stroke movement (closer to the end of the hole away from the entry), based on a machine-fixed coordinate system.
  • Each axial displacement of at least one of the reversing points thus changes the stroke position.
  • the stroke length is also changed, for example if the axial position of one of the reversing points remains unchanged and only the axial position of the other reversing point is changed.
  • the honing machine is equipped with an infeed system which allows the effective diameter of the honing tool (ie the outside diameter of the cutting group) to be changed in the radial direction by infeed of cutting material bodies 156 attached to the honing tool.
  • the delivery system can therefore also be referred to as an expansion system. This expansion can be implemented, for example, by means of a servo motor - force-controlled or path-controlled. Hydraulic infeed is also possible.
  • a delivery system with single delivery or with double delivery can be provided. Since such delivery systems are known per se, a detailed description is omitted here.
  • the honing machine 100 is equipped with a diameter measuring system 170 for measuring the actual diameter of the bore in predeterminable measuring planes or measuring zones during honing processing (in-process measurement).
  • measuring sensors of the diameter measuring system are attached to the honing tool 150.
  • the diameter measuring system is designed as a pneumatic diameter measuring system (air measuring system).
  • the honing tool has a measuring nozzle 172-1, 172-2 of the diameter measuring system at two diametrically opposite positions between adjacent cutting material bodies. Due to the arrangement of the measuring nozzles in the axial area of the cutting material body, for example halfway up the center in In the narrow zone of the ring covered with cutting material bodies, a very exact diameter measurement of the section of the hole being machined is possible.
  • the diameter measuring system can work according to the nozzle-flapper principle. Compressed air is blown out of the measuring nozzles in the direction of the bore wall or inner surface 214 for the measurement. The resulting dynamic pressure in the area of the measuring nozzles can serve as a measure of the distance between the measuring nozzle and the bore wall.
  • a measuring transducer connected to the measuring nozzle via a pressure line ensures the conversion of the (pneumatic) pressure signal into an electrically processable voltage signal, which is referred to here as the diameter measuring signal.
  • the volume flow of the compressed air can also be used for evaluation.
  • Diameter measuring systems operating according to other principles for example capacitive measuring systems or inductive measuring systems or measuring systems with radar sensors (cf. for example DE 10 2010 011 470 A1) can also be used in principle.
  • the spindle drive, the linear drive, the at least one drive of the delivery system and the converter of the diameter measuring system are connected to a control device 180, which is a functional component of the machine control and can be operated via an operating device 190.
  • a machine operator can set numerous process parameters required to define the honing process via the control device, including: Position of the upper reversing point and the lower reversing point of lifting movements. This enables the stroke length and stroke position to be defined. Stroke intervals and increments. As a result, time-varying strokes can be programmed. Speed, speed increment, minimum speed and maximum speed of a speed window.
  • Start of a honing phase start of one or more further honing phases.
  • the course of the stroke change to be specified can be entered, e.g. through support points along the target contour or on the basis of a calculation.
  • those honing parameters can be selected that are to serve as controlled parameters (selection from lifting speed, infeed speed, infeed force, speed).
  • the honing machine can be programmed to generate a specific axial contour profile on the bore such that in at least one stroke change phase, a specific change in the stroke length and / or the stroke position of the honing tool is directed axially Varying material removal can be generated in order to achieve specifications with regard to the axial contour course with high accuracy.
  • an axial target contour profile can be specified before the honing operation begins, which represents the dependence of the target diameter on the axial position in the bore to be machined.
  • the target contour profile can be specified, for example, by defining the target contour as an analytical formula (for example straight line equation or curve equation) or as a point field (for generating free-form curves).
  • FIG. 2A shows an example of a continuously conical bore 210, in which the axial target contour course 215 can be described by a straight line equation for a surface line with a defined orientation to the bore axis 212.
  • 2B shows an example of an approximately bottle-shaped bore 210, in which the slope ST of the desired axial contour profile (for example given by the angle between the bore axis and tangent to the surface line) changes with the axial position. The slope is greater in a central area MB than in the areas closer to the bore ends.
  • a stroke change profile is then predetermined for the stroke change phase of the honing operation.
  • the stroke change course determines how the stroke length and / or the stroke position of the stroke movement of the honing tool should change during the honing operation.
  • so-called stroke increments INK between immediately successive strokes are fixedly predefined for the definition or determination of the stroke change course.
  • the stroke displacement during the honing operation is then controlled via the fixed stroke increments.
  • the stroke increments INK represent the absolute magnitude of a change in the axial position of a reversal point (in the example, the upper reversal point) of the stroke movement between a stroke and the immediately following stroke in the same direction.
  • FIG. 2B illustrates a variant in which stroke increments INK of different sizes lie between some successive strokes, so that the support points defined thereby STP are distributed unevenly along the nominal axial contour in the axial direction.
  • the respective stroke increments are preferably selected to be only as large as expected as material can be removed within a double stroke. A greater slope of the contour is to be generated in the central area MB than closer to the bore ends, which requires a correspondingly greater material removal in the central area. The stroke increments are therefore smaller than where less material removal is required.
  • the change in stroke or the size of the stroke increments can be a fixed function of the slope of the contour (the desired contour profile).
  • Unevenly distributed support points can be particularly useful in the case of non-linear axial contour profiles, i.e. those contour profiles that cannot be described by a simple straight line equation, for example to create a bore with a bottle shape or a bore with a cylindrical and a conical section or to create a bore with a barrel shape or with a waisted shape (hourglass shape).
  • FIGS. 3 to 7 describe some exemplary embodiments for honing operations that can be implemented with the honing machine.
  • the honing time t H (in seconds) of a honing operation is plotted on the x-axis in the diagrams.
  • Several parameters characterizing the honing operation are plotted on the y-axis together. These include: the stroke position HP of the honing tool, the infeed position ZP (or expansion position) of the cutting group delivered in each case, the stroke speed VH of the spindle; the spindle speed DZ, the infeed speed or expansion speed VZ or the infeed force or expansion force FZ of the cutting group delivered in each case.
  • Selected honing parameters are shown in the following diagrams together with the courses of the setpoint DSW of the diameter of the bore and the actual value DIW of the diameter determined by means of diameter measurement in suitable combinations.
  • the setpoint DSW represents the desired axial contour profile.
  • the preprogrammed course of the stroke change can be clearly seen from the curve HP for the stroke position.
  • the stroke control is set in such a way that the honing tool, after the honing tool has been moved into the bore, processes the bore over its entire length over five successive double strokes in a first honing phase PH1.
  • the circular cylindrical shape of the exit bore is essentially retained, with the shape accuracy possibly being increased.
  • the subsequent second honing phase PH2 is the stroke change phase, in which the stroke position of the honing tool changes from stroke to stroke.
  • the axial position of the lower changeover point UU remains constant, while the axial position of the upper changeover point UO is changed incrementally by the control with a predetermined stroke increment in the direction of the lower changeover point. In this way, the section furthest from the entrance tends to be processed with more strokes than the section closer to the entry.
  • Honing operations of this type in which the cutting material bodies are intended to follow the contour of the bore as well as possible without changing the macroscopic shape of the bore, are also referred to here as “post-honing”.
  • the end surface can be smoothed by means of smooth honing or a honing structure with a certain honing angle and a certain base surface can be created by honing.
  • at least one honing operation can follow, for example plateau honing or deburring, and possibly also descaling.
  • the cutting material bodies of the cutting group for the second expansion can be individually flexibly or resiliently mounted in order to adapt particularly well to the inclinations of the inner bore surface that change in the axial direction of the bore.
  • the honing process shown is also programmed in such a way that within the first honing phase PH1 and within the second honing phase PH2 (stroke change phase) the feed speed is always constant, so that the infeed position ZP (or expansion position) increases linearly within these phases.
  • the infeed position changes more slowly in the first honing phase than in the second honing phase PH2, in which the conical shape is to be generated by honing.
  • the diameter measurement system of the honing machine is active during the entire honing operation, so that measurements of the actual diameter of the bore can be carried out during all honing phases in order to determine diameter measurement signals which represent the actual diameter of the bore in the respectively measured bore section.
  • the curve DIW represents the actual values of the diameter measurement.
  • the curve DSW represents the associated nominal values of the diameter, which result from the desired nominal contour profile. It can be seen that there may be deviations in diameter in both directions during the stroke change phase. These diameter deviations are determined by a target-actual comparison between the determined actual diameter and an assigned target diameter in a computing unit of the control.
  • the lifting speed VH of the honing tool during the stroke change phase is used as the variable to be controlled or the honing parameter to be controlled. It can be seen from curve VH that the stroke speed remains constant during the first honing phase PH1, while during the stroke change phase (second honing phase PH2) it has phases with increasing stroke speed as well as phases with decreasing stroke speed.
  • the control is configured so that the lifting speed is reduced compared to the previous lifting speed when the actual diameter becomes smaller than the target diameter by a predetermined value. Conversely, the lifting speed is increased when the actual diameter becomes significantly larger than the associated target diameter. Since the infeed takes place at a constant infeed speed, more material is removed when the stroke speed is reduced in the section of the hole being machined than without this reduction.
  • T H 25 s.
  • an individual setting or change in the value of the honing parameter to be controlled (here: stroke speed) is calculated for each double stroke.
  • the control intervenes in such a way that the speed is increased (in the case of an example with a Honing time of approx. 21 s). If the target-actual comparison shows that the actual diameter DIW tends to be too large, the control intervenes in such a way that the speed is reduced (for example control intervention at approx. T 25 s). This regulation is useful because when the speed increases (with unchanged stroke speed) the cutting speed increases and thus a greater material removal per unit of time can be achieved.
  • the infeed speed or expansion speed VZ is used as the stroke parameter to be controlled.
  • the target contour profile and the predetermined stroke change profile (represented by curve HP) remain unchanged compared to the previous examples.
  • the honing operation can be carried out in a corresponding manner if the expanding force of the honing tool is used as the variable to be controlled. This is explained using the example of the diagram in FIG. 6.
  • the courses of the stroke position HP, the widening position ZP and the nominal diameter and the actual diameter (DSW and DIW) of the bore are the same as in the previous examples.
  • the feed rate is changed at a constant feed rate in the stroke change phase.
  • the above diagrams illustrate exemplary embodiments in which only a single honing parameter is used as a controlled variable, while all other honing parameters follow a specification and are not varied depending on the result of the diameter measurement. It can often make sense to synchronously change at least two, i.e. two or more, honing parameters of the honing parameter group depending on the diameter measurement signals in order to achieve a specific machining result.
  • the diagrams in FIGS. 7 and 9 show exemplary embodiments.
  • the courses of the stroke position, the actual diameter value and the desired diameter value are the same as in the other exemplary embodiments.
  • the honing parameter lifting speed (curve VH) and the honing parameter speed (curve DZ) are regulated depending on the results of the diameter measurement and may be varied according to these results.
  • the speed and the lifting speed are not controlled independently of one another, but in such a way that the torque acting on the honing tool (curve DM) remains largely constant in all three phases of honing processing or varies only slightly by a few percent. This is an indication that the conditions of engagement between the cutting material body and the inner wall of the bore can be kept relatively constant. It has been shown that As a result, the shape accuracy is particularly high and the deviations between the achievable actual shape and the desired shape remain very small.
  • FIG. 8 shows an example of a bore BO which, in the finished state, is said to have a continuously conical shape and which has a relatively thick bore wall in a first bore portion BA1 near the inlet, while a second bore portion BA2 exists near the bore exit away from the bore inlet, where the wall is much thinner, so that the workpiece is more unstable in this area than closer to the hole entry.
  • a bore-specific, axially selective programming of the honing operation can be advantageous, in which different sub-groups of honing parameters of the honing parameter group are specified or permitted as a controlled variable for the first bore section BA1 and the second bore section BA2.
  • a honing operation can, for example, be such that primarily the feed pressure is varied as a control variable in the relatively more stable first bore section BA1, while the feed pressure or feed speed is reduced in the second bore section BA2 and a higher stroke speed is used to achieve the desired stroke-specific material removal.
  • the diagram in FIG. 9 shows, in a representation corresponding to the above diagrams, an exemplary honing process with the time profiles of certain honing parameters that determine the material removal.
  • a hole is machined which has a relatively more unstable second hole section BA2 in a lower region near the hole exit, which is mechanically weaker than a first hole section BA1 located closer to the hole entry (cf. FIG. 8).
  • the infeed speed curve VZ
  • the lifting speed curve VH
  • the lifting speed (curve VH) can be regulated accordingly in this area.
  • the infeed speed was reduced by around one m / s and the lifting speed was increased by around two m / min. If the diameter in this area is too small, the lifting speed can be increased by an additional two m / min, for example.
  • the lifting speed can be increased by an additional two m / min, for example.
  • a axially selective intervention i.e. different Honing parameter combinations in different axial sections of the bore, basically all combinations between speed, lifting speed, infeed speed and infeed force can be used.
  • a consistently conical bore shape is only mentioned as an example in the exemplary embodiments.
  • a hole can also have an axial contour, which e.g. corresponds to the shape of a barrel (diameter in the middle larger than the top and bottom) or a bottle shape (top and bottom cylindrical with different diameters and a conical transition between them).

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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)

Abstract

L'invention concerne un procédé de rodage destiné à usiner la surface intérieure d'un alésage dans une pièce ouvrée à l'aide d'au moins une opération de rodage, procédé lors duquel un outil de rodage pouvant être élargi, accouplé à une broche, est déplacé à l'intérieur de l'alésage pendant une opération de rodage selon un mouvement de va-et-vient en vue de générer un mouvement de course dans la direction axiale de l'alésage et est en même temps mis en rotation en vue de générer un mouvement de rotation superposé au mouvement de course. Une forme d'alésage ayant un tracé de contour axial, à symétrie de rotation par rapport à un axe de l'alésage et différente de la forme cylindrique circulaire, est ainsi obtenue. En vue de produire un enlèvement de matière variable dans le sens axial, une longueur de la course et/ou une position de la course du mouvement de course est modifiée dans au moins une phase de variation de la course. Un tracé de contour de consigne axial est prédéfini avant le début de l'opération de rodage, lequel représente la dépendance du diamètre de consigne à la position axiale de l'alésage à usiner. Un tracé de variation de la course est prédéfini de manière fixe pour la phase de variation de la course sur la base du tracé de contour de consigne. Une mesure du diamètre réel de l'alésage est effectuée pendant la phase de variation de la course en vue de déterminer un signal de mesure de diamètre qui représente le diamètre réel de l'alésage dans une portion d'alésage mesurée, et une comparaison consigne-réel est réalisée entre le diamètre réel déterminé et un diamètre de consigne associé en vue de déterminer un écart de diamètre. Pendant la phase de variation de course, au moins un paramètre de rodage qui influence l'enlèvement de matière, par exemple la vitesse de course, la vitesse de rotation, la vitesse d'approche et/ou la force d'approche, est commandé de manière variable en fonction du résultat de la comparaison consigne-réel.
PCT/EP2019/067092 2018-07-13 2019-06-26 Procédé de rodage et machine d'usinage pour le rodage de contours WO2020011541A1 (fr)

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CN111922445A (zh) * 2020-06-18 2020-11-13 西安理工大学 一种锥形珩轮及珩齿加工方法
CN114833712A (zh) * 2022-04-18 2022-08-02 南京航空航天大学 一种实时调节珩磨压力的控制系统及其运行工艺

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CN114833712A (zh) * 2022-04-18 2022-08-02 南京航空航天大学 一种实时调节珩磨压力的控制系统及其运行工艺

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