Applied Mechanics and Materials
ISSN: 1662-7482, Vol. 120, pp 381-384
doi:10.4028/www.scientific.net/AMM.120.381
© 2012 Trans Tech Publications, Switzerland
Online: 2011-10-24
Established and Experimental Study of ELID-Ultrasonic Honing System
Jicai Kuai1, a
1
School of Mechanical and Power Engineering, Henan Polytechnic University, Jiaozuo, 454000,
China
a
[email protected]
Keywords: ELID (Electrolytic in-process dressing), Ultrasonic vibration, Honing, Ultra-precision
machining
Abstract. The electrolytic in-process dressing (ELID) technology was combined with ultrasonic
honing technology and ELID-ultrasonic honing system was proposed. And the electrolysis
parameters, ultrasound parameters, honing parameters reasonable were matched for ELID- ultrasonic
honing system and the honing processing experiments were carried out. Studies have shown that
parameters in ELID-ultrasonic honing system are independent without disturbing each other.
Compared to traditional honing and ultrasonic honing, ELID-ultrasonic honing system has a
significant advantage in machining accuracy, surface roughness, processing efficiency and so on. The
feasibility of ELID- ultrasonic honing system is validated, which provided a new compound method
of honing for ultra-precision honing machining.
Introduction
Honing is the finishing processing method for cylinder and bush-type parts, but the ordinary honing
and ultrasonic honing can not avoid the problem of offline dressing after the oil stone passivation. The
offline dressing causes low honing efficiency, and at the same time, the quality of oil stone dressing
also seriously affects the honing accuracy [1-3].
ELID technology completely solved the dressing problem of whetstone in metal-binding agents.
Some researchers introduced the ELID technology on the basis of ordinary honing technology,
implementing the in-process dressing of honing whetstone, which greatly improved the honing
efficiency. In the electrolytic dressing process, the oxide film formed on the surface of oil stone slows
down the honing vibration and shock, reducing scratches, burns and other defects on the honing
surface, thereby significantly improving the surface quality of honing and honing precision [4].
ELID (Electrolytic in-process dressing, ELID) technology with ultrasonic honing is combined and
ELID ultrasonic honing system is established and carried out honing experiment on ZrO2 ceramic
bush; The ELID ultrasonic honing system with traditional honing and ultrasonic honing is compared
and the reasonable match rule of electrolysis parameters, ultrasound parameters, honing parameters is
studied, and then a set of electrolysis, ultrasound, honing parameters is proposed for ELID ultrasonic
honing.
Establishment of ELID Ultrasonic Honing System
As is shown in Fig.1, ELID ultrasonic honing system consists of the following four components: 1)
honing machine; 2) Ultrasonic honing head; 3) ELID electrolysis dressing electrode; 4) The on-site
measuring head.
Honing machine implements the basic rotation, feed movement and positioning of the workpiece
fixture; Ultrasonic honing head is connected to the main spindle of ultrasonic machine, the transducer
is placed in oil stone bed, it directly drives the whetstone vibrating to reciprocating longitudinal
direction, as shown in Fig.2; Electrolysis dressing electrode is fixed on the body of honing machine,
its location can be adjusted with the workpiece position changes; The on-site measuring head can be
placed in the reign of additional measurement arm of the machine, the measuring arm can be rotated
around the locating shaft, the measuring head can stretch along the measuring arm to realize the needs
for measuring different sizes of workpieces.
All rights reserved. No part of contents of this paper may be reproduced or transmitted in any form or by any means without the written permission of Trans
Tech Publications, www.ttp.net. (ID: 130.203.136.75, Pennsylvania State University, University Park, USA-04/03/16,21:03:28)
382
Product Design and Manufacture
Fig.1 ELID ultrasonic honing system
Fig.2 Ultrasonic honing head
Fig.3 is a composite diagram for electrolytic dressing and ultrasonic vibration of ELID- ultrasonic
honing device, honing head first passes through the electrolysis dressing electrode, processing
electrolytic dressing on honing head in accordance with the predetermined electrolysis parameters,
which is called electrolytic dressing station; Then the honing head descends to process honing on
workpieces, which is call honing station. An electrolytic dressing station and a honing station form a
processing stroke. After the end of a processing stroke, honing head turns back to the electrolytic
dressing station, continuing the electrolytic dressing, and then honing, so cyclical, until the
completion of honing.
Applied Mechanics and Materials Vol. 120
383
Fig.3 Composite diagram of ELID- ultrasonic honing device
Experimental Verification of ELID- Ultrasonic Honing System
Experimental Equipment and Parameters. Self-made simple honing machine; Ultrasonic honing
head: the bonding agent is iron-based; diamond for abrasive particle; and the particle size is W10,
W5, W1; Ultrasonic power: power 250W, frequency 19-21KHz; Pulse electrolysis power supply:
Voltage: 60V, 90V, 120V; Current: 10A; Pulse width range :1-99µs; Portable surface roughness
tester; The electronic balance accurate to 0.1mg; ZrO2 ceramic bush with a diameter Φ of 100mm.
Experimental parameters are in Table 1.
Table 1 Experimental parameters of ELID- Ultrasonic Honing System
Honing parameters
Ultrasonic parameters
Electrolytic parameters
Revolving Feed speed
Power
Frequency
Current
Voltage
Pulse
speed
width
[r/min]
[Stroke/min]
[W]
[KHz]
[A]
[V]
[µs]
80
30
250
19-21
20
60-120
20
Experimental Method. (1) ZrO2 ceramic bush can be tightly griped by positioning, make the end
face as the positioning in axial direction, the three-jaw chuck is tightly griped in centering. (2) Set the
parameters of ultrasonic vibration. (3) Set the parameters of electrolytic dressing, first use the EDM
shaping system, for the shape of honing head to make its precision of external shape meet the
requirements. And then keep electrolytic dressing for 30 minutes to ensure uniform oxide film on the
surface of honing head’s oil tone and evenly emergence of oil tone abrasive particle. (4) Set the
honing process parameters. (5) ELID ultrasonic honing. (6) Stop and on-site to detect the part’s
precision P, surface roughness Ra, processing efficiency V and compared to the required accuracy to
determine the feed rate of honing oil stone, continuing honing, and so forth, until meeting the
requirements.
384
Product Design and Manufacture
Experimental Results. First carry out the parameter matching experiments, respectively adjust the
electrolysis parameters, ultrasonic parameters, honing parameters, testing their impact on other two
parameters. Experiments show that, honing, electrolytic dressing and ultrasonic vibration are
independent without disturbing each other, which ensures the implementation of ELID-ultrasonic
honing system. Second, use the same experimental parameters, respectively proceed honing
experiment on the ceramic bush before and after the composition, the experimental results are shown
in Table 2.
Table 2 Experimental results of ELID ultrasonic honing and ultrasonic honing and ordinary honing
Honing Parameters
Rev
Feed
Speed
Speed
[r/min]
[St/min]
Ordinary
Honing
Ultrasonic
Honing
ELID
Ultrasonic
Honing
Ultrasonic Parameters
Power
Frequency
[W]
[KHz]
80
30
80
30
250
19-21
80
30
250
19-21
Electrolytic Parameters
Current
Pulse
Voltage
Width
[V]
[A]
[µs]
20
60120
20
Experimental Results
Ra
P
V
[µm]
[µm]
[g/min]
0.4
5
2.2
0.2
1
4.5
0.10.01
0.5
6.9
Seen from Table.2, ELID-ultrasonic honing system’s machining accuracy P, surface roughness Ra,
machining efficiency V and other indicators are better than those of ordinary honing and ultrasonic
honing. This is because the dressing accuracy of ELID technology is far superior to other methods of
dressing, and the oxide film generated by electrolysis on the surface of honing oil stone has played a
supporting role in polishing. Therefore, machining accuracy, surface roughness are better; In addition,
the ELID method does not need offline dressing, which makes processing efficiency more superior.
Conclusion
This paper presented a new honing system, and conducted experiments. The results showed that:
1) This paper initially established the ELID-ultrasonic honing system.
2) This paper explored the reasonable match law of ultrasound parameters, electrolysis parameters,
honing parameters, the three are independent with non-interference.
3) ELID-ultrasonic honing system has improved significantly in machining accuracy, surface
roughness, honing efficiency compared with ordinary honing and ultrasonic honing: honing precision
improves from 5µm ~ 1µm to 0.5µm, the surface roughness from Ra0.4 ~ Ra0.2 to Ra0.1 ~ 0.01, the
honing efficiency from 2.2g/min ~ 4.5g/min to 6.9g/min.
4) ELID-ultrasonic honing system is suitable for ultra-precision honing, it provides a new approach
for the ultra-precision ceramic bushings, cylinder, engine block and other difficult materials.
Acknowledgements
This work was financially supported by the Henan Polytechnic University Doctoral Foundation
(B2010-30/648436).
References
[1]
[2]
[3]
[4]
A.K. Dubey, H.S. Shan, N.K. Jain: Int. J. Manuf. Technol. Manag. Vol. 17(2009), p.364
B. Zhao, C.S. Liu, G.F. Gao, et al: J. Mater. Process. Technol. Vol. 123(2002), p.54
A. YAMAMOTO, Y. MAEDA, K. IKUTA: JSPE Vol. 38(2009), p.518
W. LIN, H. OHMORI, Y. YAMAMOTO, et al: JSAT Vol. 52(2008), p.543
Product Design and Manufacture
10.4028/www.scientific.net/AMM.120
Established and Experimental Study of ELID-Ultrasonic Honing System
10.4028/www.scientific.net/AMM.120.381
DOI References
[2] B. Zhao, C.S. Liu, G.F. Gao, et al: J. Mater. Process. Technol. Vol. 123(2002), p.54.
10.1016/S0924-0136(02)00041-9