Control of Uncertainty in High Precision Cutting Processes: Reaming of Valve Guides in a Cylinder Head of a Combustion Engine

2015 ◽  
Vol 807 ◽  
pp. 153-161 ◽  
Author(s):  
Christian Bölling ◽  
Sebastian Güth ◽  
Eberhard Abele
Keyword(s):  
Automotive Industry ◽  
Cylinder Head ◽  
Combustion Engine ◽  
Production Costs ◽  
Process Chain ◽  
Hole Quality ◽  
Process Reliability ◽  
Cutting Edge Preparation ◽  
Cutting Processes ◽  
Edge Preparation

In production processes uncertainty has a great impact on the product quality as well as production costs. In automotive industry the reaming of valve guides in a cylinder head of a combustion engine is a quality determining process. Due to the force fitting of the valve guides into the cylinder head the final reaming process has to deal with increased uncertainty. On the other hand, the finished hole is closely tolerated. To ensure the process reliability the admissible tolerance must be strictly met even in case of uncertainty. This paper presents a possibility to achieve process reliability by a modified process chain with an additional pilot reaming tool. Thereby, the effect of different cutting edge preparation is also analyzed. Further, the influence of the pilot reamer geometry on the final hole quality is investigated.

Cutting Edge Preparation by Means of Abrasive Brushing

2010 ◽  
Vol 438 ◽  
pp. 1-7 ◽  
Author(s):  
Berend Denkena ◽  
Luis de Leon ◽  
E. Bassett ◽  
M. Rehe
Keyword(s):  
Tool Life ◽  
Cutting Tool ◽  
Market Competition ◽  
Cutting Edge ◽  
Production Costs ◽  
Tool Performance ◽  
Process Reliability ◽  
Cutting Edge Preparation ◽  
Edge Preparation

The need for new cutting tool technologies is driven by the constantly increasing performance of machine tools and the rising market competition. Current research results show that an improved combination of the cutting edge macro- and microgeometry, together with an appropriate substrate and coating, leads to a significant enhancement of cutting tool performance. Furthermore, inappropriate cutting edge microgeometries cause, in addition to the higher production costs, a reduction of the tool life. Hence, it is essential to produce tailored cutting edge microgeometries with high precision and process reliability. This paper presents the influence of brushing process parameters on the size and the form of produced cutting edges of indexable inserts. This leads to a better understanding and higher quality of the cutting edge preparation process by means of abrasive brushes. Furthermore, the process reliability of 5-axes brushing is analyzed. An example of a tool life map presents the significantly enhanced tool performance through cutting edge preparation and its sensitivity towards varying the cutting edge microgeometry.

Schneidkantenpräparation von VHM-Mikrofräsern*/Cutting edge preparation of cemented carbide micro milling tools – A comparison of different fine machining processes

2015 ◽  
Vol 105 (11-12) ◽  
pp. 805-811
Author(s):  
E. Uhlmann ◽  
D. Oberschmidt ◽  
A. Löwenstein ◽  
M. Polte ◽  
I. Winker
Keyword(s):  
Tool Wear ◽  
Milling Process ◽  
Cutting Edge ◽  
Micro Milling ◽  
Machining Processes ◽  
Process Reliability ◽  
Cutting Edge Preparation ◽  
Milling Tools ◽  
Edge Preparation

Die Prozesssicherheit beim Mikrofräsen lässt sich mit einer gezielten Schneidkantenverrundung erheblich steigern. Dabei werden durch verschiedene Präparationstechnologien unterschiedliche Geometrien und Einflüsse auf den Fräsprozess erzeugt. Der Fachbeitrag behandelt den Einsatz präparierter Mikrowerkzeuge in Zerspanversuchen, in denen auf die Zerspankräfte, den Verschleiß sowie die Oberflächengüten eingegangen wird.   Process reliability in micro milling can be increased by a defined cutting edge preparation. Different cutting edge preparations cause different effects on tool behavior in the downstream micro milling process. In this paper, the process forces, the tool wear and the surface quality of prepared micro milling tools are characterized in cutting tests.

Cutting Edge Preparation of PCBN Inserts

2013 ◽  
Vol 797 ◽  
pp. 183-188
Author(s):  
Berend Denkena ◽  
Jens Köhler ◽  
C.E.H. Ventura
Keyword(s):  
Surface Quality ◽  
Edge Chipping ◽  
Workpiece Surface ◽  
Abrasive Grains ◽  
Chip Flow ◽  
Edge Quality ◽  
Cutting Edge Preparation ◽  
Cutting Processes ◽  
Increase Tool Life ◽  
Edge Preparation

In order to increase tool life and workpiece surface quality, cutting processes with geometrically defined cutting edges demand inserts with a targeted prepared edge. For example, chamfers are largely used in many processes to provide edge strengthening without damaging the chip flow. In order to achieve a stable and reliable cutting process, small and uniform chamfers are necessary. In this context, the influence of grinding parameters on the edge quality and on the chamfer width deviations is investigated. It was found that larger abrasive grains increase edge chipping and that elastic deformation during chamfer grinding at insert corner radius is the main responsible for chamfer width deviation.

scholarly journals Monitoring the technological processes in the wood industry in order to make them more efficient through technical overhauling

2019 ◽  
Vol 290 ◽  
pp. 02007
Author(s):  
Radu Dan Paltan ◽  
Cristina Biriş ◽  
Loredana Anne-Marie Rădulescu
Keyword(s):  
Automotive Industry ◽  
Operating Mode ◽  
Solid Wood ◽  
Production Costs ◽  
Operating Costs ◽  
Future Research ◽  
Wood Industry ◽  
Research Article ◽  
State Of Research ◽  
The Cost

Of many techniques that are used to optimize production and costs, the studies conducted within a profile company lead to our choice for testing the 6Sigma method (the most used method in the automotive industry) in view of the economic efficiency applied in the wood Industry company. This method measures how many flaws exist in a process and determines in a systematic way how to improve it by technical overhauling and eliminating or minimizing the process for efficiency. This research article aims to study the state of research on the optimization of the production process through technical overhauling for panels reconstituted from solid wood and ways to make production more efficient by cutting costs through technical overhauling. From preliminary research, we estimate that all the items founded and others that will result from further research will result in a significant decrease in production costs that are reflected in the cost of the finished product and consequently in increasing the yield of the company by maximizing its profit. At the same time it may be the basis of future research studies in the field. The easier it is to maximize profits, the lower the operating costs are and the higher recovery rate of investments are, that will result a change in the operating mode: “working smarter not harder”.

Kantenpräparation durch Formschleifprozesse*/Cutting edge preparation by form grinding

2017 ◽  
Vol 107 (06) ◽  
pp. 453-460
Author(s):  
E. Prof. Uhlmann ◽  
J. Bruckhoff
Keyword(s):  
Tool Life ◽  
Cutting Tools ◽  
Cutting Edge ◽  
Grinding Processes ◽  
Form Grinding ◽  
Cutting Edge Preparation ◽  
Edge Preparation

Angesichts steigender Anforderungen an Zerspanwerkzeuge nimmt die Schneidkantenpräparation einen immer größer werdenden Stellenwert ein, da sich so die Standzeit von Zerspanwerkzeugen erhöhen lässt. Die bisher eingesetzten Präparationsverfahren eignen sich meist nur für einfache Verrundungen an der Schneidkante. In umfangreichen Untersuchungen wurde die Eignung von Formschleifprozessen zur Herstellung definierter Schneidkantenmikrogeometrien anhand von Arbeitsergebnissen analysiert.   Due to increasing demands on cutting tools cutting edge preparation has a high priority because it influences the tool life. Current cutting edge preparation processes can only generate simple roundings on the cutting edge. By extensive investigations the suitability of form grinding processes for the production of defined microgeometries on the cutting edge was analysed.

Research on the Parameter Optimization of Certain Complex Structure

2011 ◽  
Vol 268-270 ◽  
pp. 200-204
Author(s):  
Bao Cheng Zhang ◽  
Peng Fei Zhao ◽  
Peng Li
Keyword(s):  
Structural Design ◽  
Cylinder Head ◽  
Maximum Stress ◽  
Combustion Engine ◽  
Mechanical Load ◽  
Structural Parameters ◽  
Complex Structure ◽  
Parameter Study ◽  
Side Plate ◽  
Von Mises

Using the method of the parameter study, some important dimensions of the cylinder head of an internal-combustion engine are analyzed. Under the mechanical load, the variational rules of the Von Mises maximum stress on cylinder head are obtained, which are influenced by the thickness of the floor plate, head plate, jobbing sheet, standing partition board, and side plate of inlet port and exhaust port. A hypothesis is verified that there is an ideal matching point among those above-mentioned main parameters. The quantificational proportion relations, between these key structural parameters and Von-Mises maximum stress of cylinder head, can provide a good help for the cylinder head’s structural design.

scholarly journals Mechanical Assessment of Fuel Line Hoses under Variable Pressure

2019 ◽  
Vol 56 (2) ◽  
pp. 466-468
Author(s):  
Ramona Nagy ◽  
Remus Stefan Maruta ◽  
Mihai Hluscu ◽  
Karoly Menyhardt
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Automotive Industry ◽  
Production Costs ◽  
Variable Pressure ◽  
The Finite Element Method ◽  
Post Production ◽  
Element Method

The automotive industry is one of the largest consumer of flexible hoses for fluids such as fuel or cooling. In order to limit the post production costs, every aspect of a vehicle must be tested in advance, including the lifespan, durability or failure of hoses. Throughout this paper summary results are presented for 4 types of fuel line hoses tested under controlled displacement loads at various pressures in order to validate the Finite Element Method simulations.

Systematic Process Chain Creation for CFRP Structures in Early Product Development Stages

2016 ◽  
Vol 1140 ◽  
pp. 328-334
Author(s):  
Matthias Behr ◽  
Carsten Schmidt
Keyword(s):  
Composite Structures ◽  
Production Costs ◽  
Preliminary Design ◽  
Process Chain ◽  
Whole Process ◽  
Reinforced Plastic ◽  
Building Process ◽  
Process Chains ◽  
Carbon Fibre Reinforced Plastic ◽  
Specific Sequences

A planning method is presented which allows to systematically building process chains based on a preliminary design of composite structures. The method utilises the specific sequences of procedural steps that occur in the production of carbon fibre reinforced plastic (CFRP) structures, to build sub process chains for each component of the structure. Process restrictions are considered to evaluate the suitability of different production processes. To obtain the whole process chain of the structure, different joining methods are applied in addition to combine the components and its sub process chains. The results of the presented method are used in an overarching development procedure to investigate resulting impacts on the solution. Possible impacts could be the production costs or the material characteristics.

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