Simulation of machined surface formation while honing

The dynamics of deep hole honing is considered. The mathematical model of the process including the dynamic model of the tool and the interaction of the workpiece surface and honing sticks is analyzed. The honing tool is modeled as a continuous slender beam with a honing mandrel attached at the intermediate cross section. A single row of stones tool rotates and has reciprocational motion in the axial direction. The honing stones are expanded to the machined surface by a special rigid mechanism that provides cutting of workpiece cylindrical surface. The removal of chip and the tool vibrations cause the variation of expansion pressure and depend on the surface state formed by previous honing stone. The equations of new surface formation are separated as a specific set of the dynamic model. These equations inherently consider the regenerative effect of oscillations during machining. The numerical algorithm of machined surface generation has been developed which facilitates the 3D graphical representation and evaluation of the topography of the generated surface. The simulation model accounts for not only the nominal tool motion but also takes into account errors during machining such as tool components deformations and vibrations, tool runout, as well as initial surface distortions produced by previous operation. Based on the surface formation model software for evaluation of typical surface quality and accuracy criteria such as eccentricity, out-of-round, conicity, barrel, axial waviness, misalignment, faceting has been developed. The expansion pressure, tool stiffness, and technology conditions are considered as varying parameters since their influence on the process are different. The process productivity and accuracy can be improved by choosing rational conditions evaluated by simulation. The corresponding models and results of numerical simulation are presented. All the results are given in dimensionless form and therefore they are applicable to a wide range of real manufacturing process conditions. The model of new surface formation presented allows the simulation of the machined surface topography variation in time and to predict workpiece accuracy and possible correction of surface errors.