Form Honing

At present, the most important

objective when developing internal
combustion engines for vehicles is
the reduction of fuel consumption
and pollutant emissions. The focus
is currently on the CO2 value (g/km).
The reduction of internal engine
friction is considered a contribution
to the targeted limits.

Principle of form honing

The ideal cylindrical bore distorts
during operating conditions. By
means of form honing, this deformation is reproduced during manufacturing which results in an almost
cylindrical shape during operation.
Objective of form honing

The earlier production of internal

combustion engines required cylinder
bores with high cylindric form and
surface qualities. During operating
conditions there are complex distortion mechanisms which deform the
cylinder bore.
We have therefore developed a process
which does not have the cylindrical
bore shape as a target but the deformation in the manufacturing process.

By honing non-cylindrical free

forms, the component deformation
in operating mode is taken into
consideration. The deformation in
the operating condition depends on:

--------------- actual form --------------- target form

Form honing result:
form-honed free form in processing
on eight gauging levels with target and
achieved geometry
high degree of approximation to the
target form within 2 to 3 m

static assembly distortions

dynamic distortion
thermal cylinder distortions
The cylindrical free form is
determined either by FEM calculation or simulations using torque
plates and tempering.

45

315

225
9,00 mm
26,29 mm
43,57 mm
60,86 mm
78,14 mm

10 0m -10
Conventional
Honing, cylindrical
after honing

Problem:
deformtion
in function

Solution:
form honing,
machining with
negative form

Operating mode:
cylindrical form
arises in operating
mode

135

-10 0m 10

Cylinder bore was machined with form

honing. The desired free form serves as
allowance for a cylindrical functional
geometry.

Your benefits

Form honing components

In order to implement form honing
from a manufacturing point of view,
a number of innovations to control
the work surfaces of the diamond
honing stones are required. For
this reason, a tooling concept was
developed featuring four expandable
honing stones.

The form data of the negative cylinder

shape are converted into honing tool
feeding parameters for each cylinder
of a block using the form honing
control. The feeding system and
the form honing tool dynamically
transfer this feeding profile to the
form honing stones during honing.
In the next step, a pneumatic shape
gauging system measures the actual
free form geometry.

The main advantages of form

honing are:
reduced blow-by
reduced piston ring tension
lower friction
This has a positive effect on the
overall engine performance such as
exhaust emission quality, oil and
fuel consumption as well as engine
output and wear.

Static assembly
distortion

Thermal
cylinder distortion
Dynamic
distortion

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