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

Abstract:

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.

• Periodical: Applied Mechanics and Materials (Volume 807)
• Pages: 153-161
• DOI: https://doi.org/10.4028/www.scientific.net/AMM.807.153
• Online since: November 2015
• Authors: Christian Bölling*, Sebastian Güth, Eberhard Abele
• Keywords: Automotive Industry, Hole Finishing, Reaming, Uncertainty

References

[1] F. Koppka: A contribution to the maximization of productivity and workpiece quality of the reaming process by analyzing its static and dynamic behavior, Shaker Verlag, Aachen (2009).

[2] K. Ishikawa: Guide to Quality Control, Asian Productivity Organization, Tokyo (1992).

[3] O. Bhattacharryya, S.G. Kapoor, R.E. DeVor: Mechanistic model for the reaming process with emphasis on process faults, International Journal of Machine Tools and Manufacture, 46 (2006), page 836-846.

DOI: 10.1016/j.ijmachtools.2005.07.022

[4] O. Bhattacharryya, M.B. Jun, S.G. Kapoor, R.E. DeVor: The effects of process faults and misalignment on the cutting force system and hole quality in reaming, International Journal of Machine Tools and Manufacture, 46 (2006), page 1281-1290.

DOI: 10.1016/j.ijmachtools.2005.11.002

[5] T. Hauer: Modellierung der Werkzeugabdrängung beim Reiben – Ableitung von Empfehlungen für die Gestaltung von Mehrschneidenreibahlen (engl. Modeling of tool deflection in reaming – Derivation of recommendations for the design of multi-blade reaming tools), Shaker Verlag, Aachen (2012).

[6] E. Pauksch, S. Holsten, M. Linß, R. Tikal: Zerspantechnik (engl. Cutting Technology), Vieweg + Teubner, Wiesbaden (2008).

[7] F. Klocke, W. König: Fertigungsverfahren I (engl. Manufacturing Processes 1), Springer-Verlag, Berlin Heidelberg (2011).

[8] E. Abele, T. Hauer, M. Haydn, C. Bölling: Reduzierte Unsicherheit bei der Bohrungsfeinbearbeitung - Neue Erkenntnisse zum Vorbohrungseinfluss auf den Reibprozess (engl. Reduced uncertainties during hole-finishing – New knowledge concerning the influence of pre-drilled holes on reaming process), wt Werkstattstechnik online, 101 (2011).

DOI: 10.37544/1436-4980-2011-1-2-81

[9] M. Haydn, T. Hauer, E. Abele: Methods for the control of uncertainty in multilevel process chains using the example of drilling/reaming, Applied Mechanics and Materials, 104 (2012), page 103-113.

DOI: 10.4028/www.scientific.net/amm.104.103

[10] R. Engelhardt, J. F. Koenen, G. C. Enss, A. Sichau, R. Platz, H. Kloberdanz, H. Birkhofer, H. Hanselka: A model to to categorise uncertainty in load-carrying systems, 1st MMEP International conference on modelling and management processes, Cambridge/UK, 19-20 July 2010, page 53-64.

[11] H. Hanselka, R. Platz: Ansätze und Maßnahmen zur Beherrschung von Unsicherheit in lasttragenden Systemen des Maschinenbaus (Approaches and procedures to control uncertainty in load-carrying structures in mechanical engineering), Konstruktion, 11/12 (2010).

[12] A. Bretz, S. Calmano, T. Gally, B. Götz, R. Platz und J. Würtenberger: Darstellung passiver, semi-aktiver und aktiver Maßnahmen auf Basis eines Prozessmodells (Representation of passive, semi-active and active systems based on a process model), unreleased paper by the SFB 805 on http: /www. sfb805. tu-darmstadt. de/media/sfb805/f_downloads/150310_AKIII_Definitionen_aktiv-passiv. pdf.

[13] K. Risse: Einflüsse von Werkzeugdurchmesser und Schneidkantenverrundung beim Bohren mit Wendelbohrern in Stahl (engl. Influence of tool diameter and cutting edge preparation when drilling steel using twist drills), Shaker Verlag, Aachen (2006).

[14] DIN EN ISO 1101: Geometrical Product Specifications (GPS) – Geometrical tolerancing – Tolerances of form, orientation, location and run-out, Beuth Verlag, Berlin (2013).

DOI: 10.3403/30244906