Investigation of the Influence of Different Process Setting Parameters on the Surface Formation at Honing of Thermally Sprayed Layers

In the development of modern combustion engines, light metal alloys combined with cylinder bore coatings are increasingly used to reduce total car mass. These coatings require an adaption of the honing process to achieve the coating's full technological potential. In this study, the influence of different process setting parameters on the surface formation of thermally sprayed layers was investigated using two different coating materials. Emphasis of this study was on the investigation of the pore opening process and the formation of burr extending into the pore cavity. The mechanism of pore opening was simulated using an FEM-Model in Abaqus/explicit. In order to gain an improved fundamental understanding of the mechanism of pore opening, a single abrasive grain and exemplary pore geometry were used.