Modeling of the cylinder boring process for prediction of cutting force, temperature and surface error

In this thesis, models are developed for characterization of the cylinder boring process, a process used for machining cylinder bores in cast engine blocks. The models are used for predicting the lack of cylindricity of machined cylinder bores, also called surface error, which results in poor engine performance and excessive wear of cylinders and pistons. Surface error arises from two causes, namely, the elastic deflection of the bore wall due to cutting forces and the thermal expansion of the cylinder bore during machining. The prediction of cutting forces is achieved through the development of a mechanistic model which accounts for the effect of cutting condition and tool geometry variables on chip load and the magnitude and orientation of cutting forces. Since during machining there is an inherent coupling between the cutting process and the structural vibration of the machining system due to cutting forces, a procedure for computation of process dynamics, using finite element analysis, is developed which invokes this coupling. The predicted cutting forces are used along with an influence coefficient database of the engine block and fixturing to calculate the component of surface error resulting from elastic deflections of the bore wall during machining.

Name thesis:degree_name

Ph.D.

Level thesis:degree_level

Dissertation

Discipline thesis:degree_discipline

Mechanical Science and Engineering

Grantor

University of Illinois at Urbana-Champaign

Year dc:date

2011

Author dc:creator

• Subramani, Gnanasambandam

Contributors dc:contributor

• DeVor, Richard E.
• Kapoor, Shiv G.

• Engineering, Mechanical

Statement dc:rights

• Copyright 1991 Subramani, Gnanasambandam

Language dc:language

eng

Identifier

AAI9124494
(UMI)AAI9124494

OAI identifier oai:identifier

oai:www.ideals.illinois.edu:2142/22939