Flexibles robotergeführtes Dornhonen*/Flexible, robot guided single-pass honing - Flexible honing of geometrically complex workpieces in small and medium lot size production

Das Fertigungsverfahren Honen kommt zur Anwendung, wenn an Bauteile hohe Anforderungen hinsichtlich Form- und Maßgenauigkeit, Oberflächenqualität sowie tribologische Eigenschaften gestellt werden. Insbesondere das Honen von Bauteilen mit Bohrungen in verschiedenen Positionen und Winkellagen stellt eine Herausforderung dar. Mithilfe eines 6-Achs-Industrieroboters wurde ein Verdichtergehäuse in W-Bauform bearbeitet. Anschließend wurden die Arbeitsergebnisse mit konventionell gefertigten Bauteilen verglichen.   In manufacturing, honing is used to meet high demands on shape and dimensional accuracy, surface quality, as well as tribological properties. In particular, the honing of workpieces with bore holes in various positions and angles represents a challenge. With the help of a six-axis industrial robot, a W-shaped compressor housing was machined and working results were compared with results produced on a machining center.

Analysis of a Compliant Honing Tool for Brushing Cylindrical Surfaces

In this paper, a mechanics-based model is developed and I used for analyzing the steady-state configuration of brush fibers during concentric brushing of a cylindrical surface. The geometry of the problem is generalized in order to facilitate the analysis of flexible honing tools, that is, brushing tools having a spherical volume of abrasive compound attached at the end of each fiber. The integrity of the model is evaluated by examining two special cases that have a known solution, namely, (i) quasistatic contact, and (ii) dynamic contact associated with successively reduced fiber stiffness. In each case, correct results are obtained for the contact forces generated at the interface of the filament tip/cylindrical workpart surface. Also, special attention is given to examining the role that brush rotational speed plays in the response of each fiber of the honing tool, including filament/workpart contact force, torque, and filament stress.