Effects of honing process parameters on residual stress fields of grey cast iron engine cylinder liners: Experimental and numerical study

Super polishing methods are widely employed to improve the surface integrity of machined parts. These methods not only improve the surface texture of the machined parts, but also modify the residual stresses induced at the outer layer of the machined surface. In this study, the effects of honing process parameters on the distribution of residual stresses at the surface of grey cast iron investigated numerically and experimentally. To this aim, a finite element (FE) model developed to evaluate the effects of process parameters, including cutting speed, grain size, and pressure of honing tools, on the residual stresses induced at the surface of samples. The friction coefficient introduced as an updating parameter in the model to get the best correlation between the results of FE and experiments. In addition, the X-ray diffraction method used to experimentally measuring the distribution of residual stresses at the honing surface of the samples. The experimental and numerical results showed that in majority of combinations of the process parameters, the maximum compressive residual stress occurs at a depth of approximately 0.03 mm from the cutting surface of the sample. Additionally, it was seen that decreasing the size of abrasive grains and cutting speed and increasing the pressure on the cutting tool result in higher levels of induced compressional stresses at the surface of samples. However, the depth at which the maximum residual stress occurs can proceed up to 0.06 mm by an increase in the diameter of abrasive grains and cutting speed.