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DeVor, Richard E. Kapoor, Shiv G. Subramani, Gnanasambandam 2011-05-07T13:56:34Z 2011-05-07T13:56:34Z 10000-01-01 1991 In this thesis, models are developed for characterization of the cylinder boring process, a process used for machining cylinder bores in cast engine blocks. The models are used for predicting the lack of cylindricity of machined cylinder bores, also called surface error, which results in poor engine performance and excessive wear of cylinders and pistons. Surface error arises from two causes, namely, the elastic deflection of the bore wall due to cutting forces and the thermal expansion of the cylinder bore during machining. The prediction of cutting forces is achieved through the development of a mechanistic model which accounts for the effect of cutting condition and tool geometry variables on chip load and the magnitude and orientation of cutting forces. Since during machining there is an inherent coupling between the cutting process and the structural vibration of the machining system due to cutting forces, a procedure for computation of process dynamics, using finite element analysis, is developed which invokes this coupling. The predicted cutting forces are used along with an influence coefficient database of the engine block and fixturing to calculate the component of surface error resulting from elastic deflections of the bore wall during machining. The temperature field in the cylinder bore during machining is computed through the development of analytical solutions using the method of integral transforms. In this derivation, the tool-work interface is modeled as a helically moving volumetric heat source. The derived temperature field is used to compute the magnitude of surface error resulting from thermal expansion of the cylinder bore during machining. Experiments have been conducted on a cylinder boring test set-up to study the effect of cutting condition and tool geometry variables on cutting forces, bore temperatures, and surface error. The measured cutting force and temperature data have been used to calibrate and verify the developed models. Comparisons between measured and predicted cutting forces, bore temperatures, and surface error show very good agreement. Simulations performed to study the effect of cutting speed, feed, depth of cut, and tool rake angles on surface error show that feed and depth of cut significantly affect surface error. The use of the developed models for designing the process through sensitivity calculations is discussed. Made available in DSpace on 2011-05-07T13:56:34Z (GMT). No. of bitstreams: 2 license.txt: 4922 bytes, checksum: 910b249b4beec47e7ab768910c8f966f (MD5) 9124494.pdf: 8068673 bytes, checksum: 6c3b005b3fb4031eb5620baac11e5844 (MD5) Previous issue date: 1991 Item marked as restricted to the 'UIUC Users [automated]' Group (id=2) by Howard Ding (hding2@illinois.edu) on 2011-05-07T15:01:03Z Item is restricted indefinitely. Restriction data tranferred 2014-07-01T11:28:57-05:00 Original Data Group with Access UIUC Users [automated] Release Date: none Reason: ETDs are only available to UIUC Users without author permission Open Restriction set for Item 23074 on 2021-04-28T13:50:38Z with date null by madinag@illinois.edu. Open Restriction set for Item 23074 on 2021-04-28T13:50:43Z with date null by madinag@illinois.edu. U of I Only Restriction set for Item 23074 on 2021-04-28T13:59:20Z with date by madinag@illinois.edu. Legacy item U of I Only AAI9124494 (UMI)AAI9124494 http://hdl.handle.net/2142/22939 eng Copyright 1991 Subramani, Gnanasambandam Engineering, Mechanical Modeling of the cylinder boring process for prediction of cutting force, temperature and surface error text Mechanical Science and Engineering Mechanical Science and Engineering University of Illinois at Urbana-Champaign Dissertation Ph.D.