抄録
During the boring process of the engine cylinder liner in automotive manufacturing, the heat at the cutting point flows into the cylinder liner and causes it to thermally expand, which is an inescapable machining issue. This affects the machining accuracy of the machined liner. However, the thermal expansion can be minimized under suitable cutting conditions and boring operations. The boring operation of an engine cylinder liner usually has two stages, semi-finishing boring and finishing. Different from the conventional boring operation, a new boring operation which can perform semi-finishing boring and finishing boring in one stage is explored in this paper. By this boring operation, the influence of the thermal expansion of the machined liner can be minimized. This boring operation is called a “simultaneous boring operation” in this paper. To prove the validity of the simultaneous boring operation, a finite element method (FEM) model was developed to predict the thermal behavior in the cylinder liner during the simultaneous boring operation/conventional boring operation. The results show that the machining errors caused by the thermal expansion of the cylinder liner during the simultaneous boring operation are smaller than those of the cylinder liner during the conventional boring operation. To investigate the influence of the cutting conditions on temperature distribution in the cylinder liner during simultaneous boring operation, FEM analysis of the temperature and thermal expansion on the cylinder liner under three levels of cutting speeds (300,600, and 900m/min) combined with two types of cutting fluid (dry, wet) during simultaneous boring was performed. The results showed that the temperature rise of the cylinder liner during a high-speed, wet simultaneous boring operation is small.
