Full-scale cutting force measurement for the design and control of honing processes with a sensor integrated tool for machining cylinder liner surfaces to reduce friction and wear during engine operation

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The main objective of this research project is the transfer of the knowledge gained in the preceding project "resource efficient piston ring / cylinder mating" of the DFG Priority Programm SPP 1551 to complete the in-process measurement of the cutting forces and the development of a deformation simulation during longitudinal stroke honing of cylinder running surfaces. An in-situ measurement system of all cutting forces during honing in the industrial environment will be realized, which can be used for path- and force controlled infeed mechanisms at all honing steps. The evaluation of the project's success can be based on the following criteria:1. Construction and integration of the sensor in a honing tool under spatial limits,2. Functioning of the sensor integrated honing tool for in-process measurement of the normal force,3. Deformation simulation using the measured data and4. Identification of relationships and interactions to define a valid process model and integration into a control loop.