Full-scale cutting force measurement for the design and control of honing processes with a sensor integrated tool for machining cylinder liner surfaces to reduce friction and wear during engine operation

• Applicant: Dr.-Ing. Florian Welzel
• Subject Area: Metal-Cutting and Abrasive Manufacturing Engineering
• Term: from 2019 to 2022
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 415579441

The main objective of this research project is the transfer of the knowledge gained in the preceding project "resource efficient piston ring / cylinder mating" of the DFG Priority Programm SPP 1551 to complete the in-process measurement of the cutting forces and the development of a deformation simulation during longitudinal stroke honing of cylinder running surfaces. An in-situ measurement system of all cutting forces during honing in the industrial environment will be realized, which can be used for path- and force controlled infeed mechanisms at all honing steps. The evaluation of the project's success can be based on the following criteria:1. Construction and integration of the sensor in a honing tool under spatial limits,2. Functioning of the sensor integrated honing tool for in-process measurement of the normal force,3. Deformation simulation using the measured data and4. Identification of relationships and interactions to define a valid process model and integration into a control loop.

• DFG Programme: Research Grants (Transfer Project)
• Application Partner: DFH Honsysteme GmbH
• Co-Investigator: Professor Dr.-Ing. Bernhard Karpuschewski