Modelling of surface finish and material removal rate in rough honing

• We obtain mathematical models for roughness and material rate in rough honing operations.
• We analyze most significant parameters for roughness and material rate.
• We take into account process conditions and abrasive stone characteristics.
• Within the range studied, the higher material rate the higher roughness.

In the present work influence of different parameters of the rough honing process on surface roughness and material removal rate were studied. Specifically, second order mathematical models are presented for mean average roughness Ra (μm), maximum peak-to-valley roughness Rt (μm) and material removal rate Qm (cm min−1), obtained by means of regression analysis.For doing this a central composite design was defined, with a full two-level five variables design of experiments, 5 centre points and 10 face-centred points. Steel cylinders were employed. Abrasive chosen was cubic boron nitride. Considered factors were grain size, density of abrasive, tangential speed of cylinders, linear speed of honing head and pressure of abrasive stones on internal surface of cylinders.From the models most influential factors on process quality as well as on productivity were determined. Within the range studied, roughness depends mainly on grain size, pressure and density of abrasive. Material removal rate depends on grain size and pressure, followed by tangential speed. Optimization by means of the desirability function technique allowed determining most appropriate conditions to minimize roughness (surface quality) and/or maximize material removal rate (productivity).