Cylindricity of engine cylinder bore is identified as one of crucial factors to exert great influence on engine performance such as piston friction and wear, energy consumption and emission. Cylindricity at macroscopic level as well as surface roughness at micro-level such as peak roughness, core roughness and valley roughness for engine cylinder bore is typically generated by honing operation. However, the selection of the process parameters of honing is currently based on empirical methods since honing is mechanically complex. It thus makes a significance to analytically investigate honing operation to significantly improve the cylindricity of engine cylinder bore based on its function requirements. This research aims to explore the methodology on achieving the desired cylindricity for engine cylinder bore through several approaches including simulating honing motion trajectory, improving honing head structure, coordinating honing with its previous boring operation, and optimizing honing parameters including honing speed, feed rate, overrunning distance. This research aims to provide a systematical thinking to achieve macro-geometrical features in honing engine cylinder bore and a theoretical approach for the selection and optimization of honing process parameters.

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