Experimental investigation and simultaneous optimisation of honing parameters of dry cast iron cylinder relining sleeves of motor vehicle engine blocks for surface finish and energy use

Abstract

Machining based manufacturing industries consume significant amounts of electrical energy, to power the several modules constituting the machine tool, with low levels of efficiency. Honing operations, are vital machining manufacturing operations, utilised in the motor vehicles engine block cylinders internal surfaces super-finishing process, for improving many functional attributes of the machined cylinders. In an environment of diminished energy generation, bulk electrical energy users, like the machining industry, encounter many pressures to reduce consumption. Electrical energy consumption is a production driver of the ozone layer depleting carbon emissions, from the manufacturing sector. Governments’ environmental legislation directives, in collaboration with environmental protection lobbyist groups, added to the ever soaring energy market prices, all exert mounting pressure on the machining industries, such as engine block manufacturers and repairers. Thus, compelling them to consider reducing energy consumption from their operations processes as well as increasing the efficiency of their machining processes. Machining productivity improvement and operation efficiency are influenced by the selection and setting of cutting parameters, during practical operation. In this present experimental study, honing parameters were investigated and optimised with focus on energy use conservation and surface quality enhancement during the machining operation. The L16 experiments were planned using Minitab 19. The three cutting parameters investigated were varied at four levels each. The study results showed the optimum honing parameters combination conditions, respectively, determined for surface roughness, power and total machining energy. The study results confirms that significant Energy could be saved by optimising process parameters at the machining planning stage.