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Free-floating dynamic material removal mechanism of the honing process

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Abstract

Honing is the typical flexible machining process characterized with a double hinge point structure, and the honing head is able to self-adaptively adjust its spatial pose inside the cylinder bore during the honing process. Therefore, it is of necessity to incorporate the free-floating mechanism of the honing head to establish an accurate honing material removal model. The material removal models in the literature currently have considered honing trajectory density, pressure, speed, and oilstone properties while failing to characterize the floating behaviors of the honing head and the dynamical associations of material removal of oilstones. Thus, this research proposed an original honing dynamical material removal model based on the minimum energy principle. The systematical objective function coupling material removal matrices of oilstones were established with the spatial pose of the honing head inside the bore as variables, and the consistency between minimizing the objective function and the free-floating tendency of the honing head toward the quasi-static spatial pose was theoretically verified based on the Cauchy-Schwarz inequality. Then, the gradient descent algorithm was applied to minimize the objective function to identify six floated spatial pose parameters of the honing head at the lowest energy state and the corresponding material removal matrices. Finally, force-controlled honing experiment was carried out to verify the accuracy of the proposed model. The simulated results agree well with the experimental results in terms of reaming effect, error reflection effect, and leveling effect, which were the fundamental functions achieved by the honing process. Further, the predicted error of average material removal depth fell within 6.6%, guaranteeing the authenticity of the proposed model.

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Funding

This research was supported by Xueping Zhang from the National Natural Science Foundation of China under the project No. 52075335 and No. 51675339.

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Authors and Affiliations

  1. School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai, 200240, China

    Xin Zhang & Xueping Zhang

Authors
  1. Xin Zhang
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  2. Xueping Zhang
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Contributions

Xueping Zhang, the corresponding author, is responsible for ensuring that the descriptions are accurate and agreed by Xin Zhang. The roles of all authors are listed below:

✓ Conceptualization: Xueping Zhang and Xin Zhang

✓ Methodology: Xin Zhang and Xueping Zhang

✓ Modeling based on software: Xin Zhang

✓ Validation: Xin Zhang

✓ Formal analysis: Xin Zhang and Xueping Zhang

✓ Investigation: Xin Zhang and Xueping Zhang

✓ Resources: Xin Zhang

✓ Data curation: Xin Zhang

✓ Writing—original draft: Xin Zhang

✓ Writing—review and editing: Xueping Zhang

✓ Visualization: Xin Zhang and Xueping Zhang

✓ Supervision: Xueping Zhang

✓ Project administration: Xueping Zhang

✓ Funding acquisition: Xueping Zhang

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Correspondence to Xueping Zhang.

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Cite this article

Zhang, X., Zhang, X. Free-floating dynamic material removal mechanism of the honing process. Int J Adv Manuf Technol 127, 4473–4489 (2023). https://doi.org/10.1007/s00170-023-11760-z

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