Research on automatic switching of hydraulic feed dual process in honing processing

Abstract Honing is a finishing process used for the inner cylindrical surfaces of engine blocks or liners. The process involves abrasive particles bonded to the surface of a honing head, which come into contact with the inner bore surface, performing an oscillating and rotational motion. These motions follow a specific pattern, allowing for the creation of crosshatch patterns on the inner bore surface, thereby improving dimensional accuracy, form accuracy and reducing surface roughness. Common honing processes are divided into four distinct phases: material removal, crosshatching, finish honing, and plateau honing. Each phase corresponds to specific tasks such as material removal from the bore, creating crosshatch patterns, honing the peaks in the crosshatch, and final surface finishing. In computer numerical control (CNC)-based honing machine, individual control commands are typically used to manage each of these phases separately. The commands are combined according to process requirements to achieve the desired honing results. To enhance the efficiency of the honing process, this study focuses on the hydraulic feed of the abrasive strips on the honing head, specifically examining the automatic continuous switching between finish honing and plateau honing. The research analyzes the honing principles, develops a control algorithm for dual-process automatic switching, and validates the process through machining tests. Compared to single-process control, the proposed algorithm significantly improves processing efficiency. Additionally, this algorithm can be applied to other dual-process automatic switching controls, providing valuable insights for the design of CNC honing systems.