In this paper, a model is developed for computation of bore cylindricity of machined cylinder bores. The model takes into account the effect of cutting process variables and the bore design on bore cylindricity. Surface error, which is a measure of the lack of bore cylindricity, is caused by both the elastic deflection of the bore wall due to cutting forces and the thermal expansion of the bore during machining. The effect of both the cutting forces and the bore temperature is included in the model. Experiments have been conducted to measure the bore cylindricity using an Incometer device. Comparisons between the shape and magnitude of predicted and measured surface error show a good agreement.

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