An Enhanced Computer-Based Process Simulation Model for the Cylinder Boring Process

This paper discusses an advanced computer-based process simulation model to predict cutting forces and surface error (also referred to as the lack of cylindricity) for the cylinder boring process. The model takes into consideration several enhanced features including dual and multiple-cylinder boring, back-boring, boring in the presence of windows/cavities, etc.. The model makes use of a Finite Element product model and the cutting force process model to generate a surface error profile at any axial level in the cylinder bore. A design of experiment approach is employed to study the influence of various process variables on bore surface error. The enhanced process simulation model may be used as a valuable tool in enhancing the simultaneous engineering of products and manufacturing processes.