PNEUMATIC CIRCIT FOR CYLINDER II

COMPLETE ELECTRO- PNEUMATIC DIAGRAM

P+

L2 L1 L1 L2 C1 C2

C1 C2

C1 S S
C2
1 2

N N

Main Stem

External sleeve
Forcing Spring

Tool bit Arms

Honing tool bit

The dimensional and geometrical accuracies obtained by normal methods of

machining like turning, milling, etc. are limited. The geometrical errors include

circularity, cylindricity, flatness and parallelism of frictional surfaces. Also, the

surface finish has a vital influence on most important properties such as wear

resistance and power losses due to a friction. Poor surface finish on the peaks of

mirco irregularities, which lead to a state approaching dry friction, and result in

excessive wear of the rubbing surfaces.

Therefore, fine finishing processes are employed in machining the surface of

many critical components to be obtain a very high surface finish or high dimensional

and geometrical accuracies. The better finish may be desired for looks

accuracy, wearing qualities or for any other reason. Such processes include lapping,

super finishing, burnishing, polishing, buffing and HONING. It is very difficult

today downspecific rules regarding the choice of any of these methods because of the

many variables involved, the most important being the particular piece to be

machined.

Basically honing finishing process and not metal removing process but

during our industrial visit it was noticed that when the length/diameter ratio exceeds

by 15 times, it becomes very difficult to maintain straightness of the length of bores,

hence it was observed that in industrial honing is done to remove metal to extent of

1mm (depending upon the length of job). Although this takes larger time it avoids
rejections due to tool marks which might occur during the process of boring.

When cylindrical holes or bores require a high degree of surface finish and accuracy

of the honing process is certain to be adopted. The ever increasing use of hydrical

power as a motivator of mechanical equipment has held led to the need for cylindrical

bores to be machined to close degrees of both accuracy and surface finish.

For example : Consider a system in which a piston is acting i.e. reciprocating

inside a cylinder. There is hydraulic oil inside the cylinder (It is forced under pressure

from another cylinder to drive the piston) and so to ensure a leak free system a plastic

oil resistant washer is used which is fitted with the piston. It serves as an effective oil

seal for the oil. Clearly the surface finish of the bore needs to be of a high order if a

reliable and trouble free life is expected from the assembly a poor surface finish on

the bore will result in repaid fraying or damage to the bearing face of the washer and

hence in oil leaks, loss of pressure and malfunctioning of the assembly.

It is in precisely such conditions as these that the honing process is applied,

the object being to achieve an acceptable and geometrical accuracy. Several types of

both horizontal and vertical honing machines are now available, capable of high

production honing of both through and blind holes.

Honing should no longer be regarded as just finishing process for

cylindrical surface (internal and external). The process has been developed to the
stage where it can frequently provide a cost effective alternative to grinding and fine

boring. Modern honing machines are capable of removing hard or soft materials at
economical machining rates, whilst giving a product accurately to size, at good

geometric shape(roundness and taper) and a controlled finish. Machines currently

available range from manually operated machines to fully automated multi spindle

machines with microprocessor control.

SELECTION AND SCOPE OF PROJECT

Our college, have various types of machines and equipments. The

‘HONING MACHINE can be made in college successfully. It is special

purpose equipment and requires more skill. These parts can be made in college.

Its sub-Components price is also moderate. This project gives us knowledge,

experience and skill along with new ideas of manufacturing. It is working project and

have guarantee of success. Also , some of the material is available from our college.

This project we could manufacture in less time. So we have selected this machine.

Also by working on this project it have fulfilled following objectives laid by

curriculum of Maharashtra state board of technical education.

1. We become able to have market survey of raw material and finished

product.

2. We can actually implement practical procedure for manufacturing

different components.

3. We became known with the concept of alignment, which is part of

metrology.
 4. We became able to specify the machine.

5. We became able to calculate the quantity of the material required.

6. We could plan a manufacturing process.

7. We became known with process chart.

8. We can design the hydraulic cylinder and linkages.

9. We became able to co-ordinate the activities.

10. We could have time study.

11. We could implement the drawings for manufacturing processes.

We could do the following different manufacturing process:-

1. Turning

2. Drilling

3. Casting

4. Tapping

5. Grinding

6. Heat treatment

7. Welding

8. Milling

9. Assembly

CHAPTER-2

BASIC HONING PRINCIPLE

WHAT IS HONING ?
 Honing is a low velocity abrading process in which stock is removed from

metallic of non metallic surface by the shearing action of the bonded abrasive grains

of a honing stone or stick and produces highly characteristic surface having a

particular texture, which exhibits a cross hatched pattern.

The honing tool, consists of a holder carrying three to six abrasive sticks

which fit in slots arranged radialy around the body of the hone. It has provision by

taper bushes or other means, to force the sticks outwards against the side of bore to be

honed and expansion ceasing when the desired size has been attained. Both

mechanical and hydraulic methods are used to bring about expansion of the abrasive

sticks; in the production honing of large numbers of components, expansion and

retraction of the sticks is completely under automatic control.

Honing stones- It have a relatively large area of abrasive in contact with the work at

relatively show speeds and low pressure surface Grinding, on the other hand, has

relatively high pressure and a line contact between abrasive and bore, and runs at

high speeds. Extremely high surface temperature is developed and the surface

structure of the bore may be permanently finer surface finish than grinding, and

provides a sets-free base metal surface in the bore.

Typically, the honing process would involve machining a bore using specialist

cooling of individual design which forces the grinding blocks or strips against the

work piece. The tooling is subject to a complex motion consisting of both rotation
and reciprocation of the stone simultaneously resulting in a characteristic cross

hatched lay pattern.

BORE PROBLEMS

CAUSES OF COMMON BORE PROBLEMS :-

1) OUT OF ROUND

1) Improper tool set up on tool holder.

2) Improper holding of job in fixture.

2) TAPER

1) Loose fitting tool in tool holder.

2) Faulty guide ways of machine.

3) BELLMOUNTH

1) Oscillation of tool when enters or exists from bore.

4) BORING MARKS

1) Worn out tool applied for operation.

2) Due to excessive vibrations.

3) Scratches on tool.

5) WAVINESS

1) Vibration in tool or job due to high speed.

2) Improper application of force on tool.

6) REAMER CHATTER

1) Effect of improper reamer operation.

 Misalignment of axis of tool & job.

 Asymmetry of tool.

8) RAINBOW

1) Bending of boring bar in boring machine.

9) BARREL

1) Deflection at middle of boring bar due to long length.

10) MISALINGNMENT

1) Improper support to tool for boring long length job.

2) Fluctuation in tool axis.

3) Improper fixture of job.

ADVANTAGES OF HONING

HONING Vs OTHER PROCESS

1) It is possible to created dimensions i.e. the desired size thought honing while

super finishing is employed only for obtaining a high quality surface finish with

no appreciable amount of stock removed.

2) The honing process needs only two motions, whereas super finishing may

involve many. With the result, the path of an abrasive grain never repeated.

3) The process is mostly employed for finishing internal surface, whereas super
finishing is largely used for outside surface.

4) Super finishing is done at much lower operating seeds than honing.

5) The total pressure on the work is too in super finishing as compared to honing

enabling finishing of even the very delicate parts.

6) The length of stroke in super finishing is very short, usually 1.5 mm to 6 mm,

as compared to honing. With the result, there is an appreciable accumulation of

chips and therefore, no scratches are produced on the job surface.

7) Lapping is the process for improving the surface finished by reducing

reoughness, waviness and other irregularities on the surface, while super finishing

is employed only for obtaining a high quality surface finish.

Sr. no. HONING Sr. no. GRINDING

1. Honing is a slow speed operation. 1. Grinding is a fast speed operation.

2. In Honing there is a surface contact. 2. In Grinding there is a line contact.

3. It is self dressing operation. 3. Dressing is required.

4. Kerosene type coolant is used. 4. Water soluble coolant oil is used as

5. No new axis is generated. 5. New axis is produced.

6. Tool is floating. 6. Tool is rigid.

7. Perfect cylinder is produced. 7. No perfect cylinder is produced.

8. All geometrical accuracies are 8. Only the size control is possible & very
controlled. few geometrical accuracies are
controlled.

9. A surface produced by honing operation 9. Surface produced in grinding does not