Kinetostatic Analysis of the Interaction between the Cutting Rolls and the Machined Surface in Rotary Honing

Conventional honing methods employ three types of basic movements: rotational — around the axis of the machined hole, reciprocating — along the axis of the machined hole, and radial movement of the honing stones as the surface layer of the metal is removed. Unlike in the existing honing methods, in rotary honing the diamond cutting rolls perform additional movements, those of self-rotation around their axes. The self-rotation is due to the angle of installation of the diamond rolls in relation to the honing head axis. The main advantage of rotational tools is their high durability due to the periodic sharpening of the cutting area of the diamond barrel-shaped rolls during the machining process. Rotary honing also guarantees high quality of the machined surface, and increases the machining speed by offering the possibility to adjust the cutting mode parameters in a wide range. The article presents an equation that describes the trajectory of the relative movement of a single grain of the cutting barrel-shaped roll, coordinates of the vector and modulus of the actual cutting speed, rotational speed of the roll, and roll setting angle. Based on the conditions of the linear contact with the workpiece surface, the authors have obtained the parameters of the elliptic curves that form generating lines of the barrel-shaped rolls.

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