Measuring the bore straightness during reaming with sensoric tools
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PRODUCTION PROCESS
Measuring the bore straightness during reaming with sensoric tools Andreas Bretz1 · Eberhard Abele1 · Matthias Weigold1 Received: 29 April 2020 / Accepted: 4 August 2020 / Published online: 2 September 2020 © The Author(s) 2020
Abstract Reaming plays a crucial role in production to meet the high quality requirements of precision bore machining. It is either directly responsible for the final component quality or influences subsequent processes such as honing. The narrow tolerances are usually monitored by measuring random samples in mass production due to cost efficiency. Having a closer look at an exemplary process chain for the production of hydraulic valves shows the possibility to adapt the honing parameters which reduces processing time and costs. However, the bore straightness after the reaming process has to be known. In this paper an approach is presented which allows to record the bore straightness within the productive time. For this purpose, a sensory reaming system is developed. It can be used without additional components in the machine tool and thus integrated into existing machining processes. Cutting tests show that the system is able to measure the bore straightness as good as sensing probes used in machine tools. Keywords Reaming · Sensoric tools · Process monitoring
1 Introduction
2 State of the art
The production of precision bores by reaming is an essential part of many manufacturing processes. Parts with strict tolerances can be found in combustion engines, hydraulic components, the dental technology as well as in the mechanical and plant engineering. However, high requirements on the reaming process to ensure component quality are in conflict with the parameters time and costs. The bore quality can be monitored by measuring the parts on coordinate measuring machines (CMM). To do this, the components must first be cleaned to remove residues of chips and cooling lubricants. The non-value-adding time required for cleaning and measuring leads to higher costs. Therefore, a 100% inspection of the parts is only carried out if it is absolutely necessary for safety-relevant components.
Reaming as a manufacturing process for the production of precision bores is characterized by low cutting depths and resulting low process forces. In the past, mostly singlebladed reamers were used because higher cutting speeds and better hole quality could be achieved. On the one hand more and more multi-bladed reamers are used as they can compensate for the lower cutting speed by a larger feed per revolution. On the other hand, they have even overtaken single-bladed reamers in the cutting speeds, as a research in the product range of different manufacturers shows [10]. In contrast to turning and milling, reaming is receiving less attention in science, as shown in various review publications [4, 17]. Scientific work is mainly concerned with the simulation of the process for optimizing the reamer design or the determination of ideal cutting parameters to improve the quality of the bore. A compre
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