Simulation of Cylinder Deformations during Honing of Thermally Coated Running Surfaces in Crankcases

The internal combustion engine of the future has to cope with increasing high requirements. A large potential is seen in reducing friction in the piston group. For this purpose a coating technology for cylinder running surfaces, including mechanical machining processes was developed. By substituting the compact cast iron liners (4 mm wall thickness) for the thin coating layer (0.1 mm) the normal forces become more important in the honing process. Due to the different stiffness of the crankcase roundness deviations occur caused by the machining forces as a result of elastic deformation. Content of this paper is the calculation of the elastic deformations using the finite element method. Based on a honing tool model, the effective normal forces are calculated, which afterwards are used as input variables for the crankcase model.