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Engine Manufacturer Case Studies

Case Study # 8

Part Information:

Part Name
Bore Diameter
Operation

Cylinder Liner – Diesel Engine
175.025mm
Semi-finish/Plateau Hone

Material Specifications:

Material
Hardness

Fumel SM28
230 – 285 HB

Incoming Tolerances:

Stock to be Removed
Bore Length

0.10mm
365mm

Barnes Processing Machine & Tooling:

Model
Honing Work Stations
Honing Tool Abrasive
Coolant

HV-5000
1
B151, C400
Oil

Required Tolerances:

Bore Diameter
Roundness
Surface Finish(Plateau)
Cross Hatch

+0.025mm
.025mm
Rpk 0.6um Rvk 3+1um Rk 2+1um Mr1 8% Max. Mr2 75+6%
140 +5 degrees

Final Tolerances Achieved:

Bore Diameter
Roundness
Surface Finish (Plateau)
Cross Hatch
Processing Time/Bore

<0.020mm
<0.015mm
Rpk 0.6um Rvk 3um Rk 2um Mr1 7% Mr2 74%
140 degrees
90 seconds/bore average

Case Study # 9

Part Information:

Part Name
General Bore Size

Diesel Liner
101.55mm x 228.6mm long

Material Specifications:

Material
Hardness

Compacted Graphite Iron
40/55 Rc

Incoming Tolerances:

Bore Diameter
Surface Finish
Cylindricity

101.45 +/- .0015
< 3.0um
<.015mm

Barnes Processing Machine & Tooling:

Model
Honing Work Stations
Honing Tool
Honing Tool Abrasives
Coolant

HV-5000
Single Spindle
Rough Hone tool
Superabrasives 181 grit
Oil

Required Tolerances:

Bore Diameter
Roundness
Surface Finish
Cross-Hatch
Cylindricity

Target 101.55mm
0. 013mm
2.5um Ra max
40 to 60 deg included
0.013mm

Final Tolerances Achieved:

Bore Diameter

Rough hone
Surface Finish
Roundness
Cylindricity
Hone Cycle Time

101.55 +/- .008
< 2.3 um Ra
< 0.12mm
< .012mm
30/35 Sec

Case Study # 10

Part Information:

Part Name
Bore Diameter
Operation

Cylinder Liner – Diesel Engine
137.08mm
Rough Hone

Material Specifications:

Material
Hardness

Cast Iron
230 – 285 HB

Incoming Tolerances:

Stock to be Removed
Bore Length

.15mm to .23mm
272.4mm

Barnes Processing Machine & Tooling:

Model
Honing Work Stations
Honing Tool Abrasive
Coolant

HV-5000
1
D252
Oil

Required Tolerances:

Bore Diameter
Roundness
Surface Finish(Ra)
Cross Hatch

+0.03mm
0.025mm
2.5um
140 +5 degrees

Final Tolerances Achieved:

Bore Diameter
Roundness
Surface Finish (Ra)
Cross Hatch
Processing Time/Bore

<0.015mm
<0.015mm
<2.5um
140 degrees
60 seconds/bore average

Case Study # 11

Part Information:

Part Name
General Bore Size

Diesel Liner
101.6mm x 228.6mm long

Material Specifications:

Material
Hardness

Compacted Graphite Iron
40/55 Rc

Incoming Tolerances:

Bore Diameter
Surface Finish
Cylindricity

101.55 +/- .0013
< 2.5um
< 0.013mm

Barnes Processing Machine & Tooling:

Model
Honing Work Stations
Honing Tool
Honing Tool Abrasives
Coolant

HV5000
1
Finish hone tool
C320 Silicon Carbide
Oil

Required Tolerances:

Bore Diameter
Roundness
Surface Finish
Cross-Hatch
Cylindricity

Target 101.6mm +/- .010
0.010mm
.33 to .71 um
40 to 60 deg included
0.010mm

Final Tolerances Achieved:

Bore Diameter
Roundness
Cylindricity
Hone Cycle Time

101.6 +/- .010
< 0.010mm
< 0.010mm
20/25 Sec

Surface Finish

Ra
Rpk
Rk
Rvk

Goal

.33 to .71 um
.71 um max
.61 to 1.19 um
1.49 to 2.4 um

Achieved

.47 um
.61 um
1.16 um
1.63 um