11PROHIPP-FIRST YEAR TERM- GENERAL MEETING – 12TH Sept 2005 BrusselsPage : 1PROHIPP-THIRD YEAR TERM- GENERAL MEETING – ROMA 07-06-07 Page : 1
PROHIPPPROHIPPNEW DESIGN AND MANUFACTURING PROCESSES NEW DESIGN AND MANUFACTURING PROCESSES FOR HIGH PRESSURE FLUID POWER PRODUCTSFOR HIGH PRESSURE FLUID POWER PRODUCTS
HONINGTECHONINGTEC
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MAIN TASKS
Preparation of a new MAA head to try to use Preparation of a new MAA head to try to use ultrasonic honing device. ultrasonic honing device. A.R. 05-037v001
Realisation of ultrasonic honing trials in M.A.A. Realisation of ultrasonic honing trials in M.A.A. A.R. 05-045v001Study of honing oil contamination. Study of honing oil contamination. A.R. 05-050v001Handicaps on the application of plateau honing in Handicaps on the application of plateau honing in industrial processes. industrial processes. A.R. 05-049v001Explanation activities done in BIEMH Bilbao on Explanation activities done in BIEMH Bilbao on March 08. March 08. A.R. 05-048v001Documentation and guidelines for Honing chapter on Documentation and guidelines for Honing chapter on PROHIPP global video. PROHIPP global video. A.R. 05-046v001
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EXTRA B46/B91/B181 TRIALS
Not for honing at more pressure the operation will be faster.Not for honing at more pressure the operation will be faster.Bigger grit size faster is the honing operation. (with remarks)Bigger grit size faster is the honing operation. (with remarks)Bigger grit concentration, faster honing operation. (with remarkBigger grit concentration, faster honing operation. (with remarks)s)Details reflected in A.R. 05Details reflected in A.R. 05--038V001038V001
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MAA Honing tests
Done 252 experiences of DOE V and DOE IV.Done 252 experiences of DOE V and DOE IV.300/600 N/cm300/600 N/cm2 2 abrasive pressureabrasive pressureDetailed in A.R. 05Detailed in A.R. 05--34/35/39/4034/35/39/40
Ra DOE V and DOE VI comparisonRa DOE V and DOE VI comparison
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MAA Honing tests
VaVa DOE V and DOE VI comparisonDOE V and DOE VI comparison
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EXTRA B46/B91/B181 TRIALS
Due to unexpected values on DOE V and DOE VI we must to Due to unexpected values on DOE V and DOE VI we must to repeat 67 honing trials.repeat 67 honing trials.New results are in accordance to the expected values.New results are in accordance to the expected values.Possible causes (will not be finished in PROHIPP PROJECT):Possible causes (will not be finished in PROHIPP PROJECT):
Different chemical composition in the height of abrasive bars.Different chemical composition in the height of abrasive bars.Differences in the tube composition or physical properties.Differences in the tube composition or physical properties.Uncontrolled machine parameters.Uncontrolled machine parameters.
DoE-5 and DoE-6 Qm results comparison (Linear models)Real Results DoE-5 and DoE-6
0,0
0,1
0,1
0,2
0,2
0,3
0,3
0,4
18 22 26 30 20 24 28 32 2 6 10 14 4 8 12 16 17 21 25 29 19 23 27 31 1 5 9 13 3 7 11 15 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47
Experiment
Qm
(cm
/min
)
Qm (cm/min) DOE-5 Real
Qm (cm/min) DOE-6 Real
DoE-5 and DoE-6 Qm proposed results
0,00
0,05
0,10
0,15
0,20
0,25
0,30
0,35
18 22 26 30 20 24 28 32 2 6 10 14 4 8 12 16 17 21 25 29 19 23 27 31 1 5 9 13 3 7 11 15 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47
Experiment
Qm
(cm
/min
)
Qm (cm/min) DOE-5 Real
Qm (cm/min) DOE-6 Real
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REAL MACHINE TEST TUBES
Done 83 tubes of diam. 45x576 Ref Done 83 tubes of diam. 45x576 Ref DinacilDinacil N2812.N2812.15 done with B18115 done with B18115 done with B9115 done with B9115 done with B4615 done with B4638 done with B6438 done with B64
Serve to confirm industrial application of mathematic Serve to confirm industrial application of mathematic model.model.Detailed in A.R. 05Detailed in A.R. 05--036V001036V001
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44ThThPERIODIC ACTIVITYPERIODIC ACTIVITY REPORTREPORT
Real machine for test tubesMachine adapted for data acquisition.Machine adapted for data acquisition.
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4Th4Th PERIODIC ACTIVITY REPORTPERIODIC ACTIVITY REPORTReal machine for test tubes
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44ThThPERIODIC ACTIVITYPERIODIC ACTIVITY REPORTREPORT
FINISHING OF FINISHING OF REAL MACHINE TEST TUBES
Finished 46 tubes of diam. 45x576 Ref N2812.Finished 46 tubes of diam. 45x576 Ref N2812.23 done with B2023 done with B2029 done with B529 done with B5
Serve to confirm fine grit sizes industrial application of Serve to confirm fine grit sizes industrial application of mathematic model.mathematic model.Serve to confirm PlateauServe to confirm Plateau--honing mathematic model.honing mathematic model.Detailed in A.R. 05Detailed in A.R. 05--047v001047v001
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44ThThPERIODIC ACTIVITYPERIODIC ACTIVITY REPORTREPORT
ULTRASONIC HONING DEVICEULTRASONIC HONING DEVICEInitial and final head for MAA to apply ultrasonic waves to the abrasive. A.R. 05-037v001
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44ThThPERIODIC ACTIVITYPERIODIC ACTIVITY REPORTREPORT
MAA ultrasonic honing tests
Done 7 experiences to detect the ultrasonic effect on Done 7 experiences to detect the ultrasonic effect on the honing process.the honing process.The results shows significant improvements. The results shows significant improvements. Detailed in A.R. 05Detailed in A.R. 05--045V001045V001
OUTBURST SPEED (cm3/min.cm2) WITH AND WITHOUT ULTRASONIC EFFECT
0,0000
0,0200
0,0400
0,0600
0,0800
0,1000
1034 246 1022 1078 1019 1083
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44ThThPERIODIC ACTIVITYPERIODIC ACTIVITY REPORTREPORT
MAA ultrasonic honing tests
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44ThThPERIODIC ACTIVITYPERIODIC ACTIVITY REPORTREPORT
HANDICAPS ON THE INDUSTRIAL PLATEAU HONING HANDICAPS ON THE INDUSTRIAL PLATEAU HONING APLICATIONAPLICATION
Use of plateau honing on hydraulic cylinders Use of plateau honing on hydraulic cylinders give more life expected on its and it is faster to give more life expected on its and it is faster to produce (cheaper).produce (cheaper).It is difficult to apply in industrial production.It is difficult to apply in industrial production.We must to work on to facilitate the easy We must to work on to facilitate the easy industrial application.industrial application.Best rules reflected on AR 05Best rules reflected on AR 05--049v001049v001
