Hybrid tool for high performance structuring and honing of cylinder liners

Micro-structuring of cylinder liners reduces friction of combustion engines. However, the process time of known fly-cutting and even laser micro machining is too long. This paper presents a hybrid tool for high performance structuring and finish-honing. The structuring tool is driven by a piezo actuator. A positioning system and control algorithms were developed to overcome the limited travelling range of the piezo and to deal with workpiece errors. Furthermore, the entire process chain and machined surfaces of the liners are examined. It is shown that the structuring of common grooves is up to 6 times faster compared to laser machining.