Assessment of the effect of cutting parameters on roughness in flexible honed cylinders
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This study aims to investigate the effect of the three cutting parameters (rotation, feed rate, and number of tool strokes) on the values of roughness (Rk, Rpk, Rvk, Mr1, Mr2, Rp/Rt ratio, and Vo) in flexible honed crankcase cylinder of hermetic compressors. The study was based on a full factorial design 2 × 2 × 3, where the rotation and the feed rate were investigated in two levels and the number of tool strokes in three levels. The cylinders were initially honed using a multi-spindle honing machine, Gehring model. A set of three honing tools was used each with two strokes, the first for roughing (120 mesh), the second for semi-finishing (270 mesh), and the third for finishing (600 mesh). For conventional honing (CH), the depth of the cut and the feed rate were kept constant. The flexible honing process was carried out after conventional honing (C+FH) in a CNC milling machine using a Silicon Carbide flex hone tool 800 mesh and 24.2 mm nominal diameter considering 12 different cutting conditions. An electromechanical surface roughness tester was used to carry out roughness measurements. The measurement uncertainty was assessed following the recommendations of the GUM-JCGM 101. The analysis of variance (ANOVA) technique was applied, and it was observed that the number of the tool strokes was the factor that contributed the most to the improvement of the surface finish of the cylinders.
KeywordsHoning Silicon carbide ANOVA
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The authors would like to thank the Brazilian financing agencies Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES), Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq), and Fundação de Amparo à Pesquisa de Minas Gerais (FAPEMIG) for supporting the development of this research and EMBRACO for providing the workpieces.
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