Cylindricity of engine cylinder bore is identified as one of the crucial factors to exert great influence on engine performance including piston friction and wear, energy consumption, and gas emission. Cylindricity at macroscopic level as well as surface roughness at microscopic level such as peak roughness, core roughness, and valley roughness of engine cylinder bore is typically generated by honing operations. However, the selection of the process parameters of honing is currently based on empirical methods since honing is mechanically complex process. It thus makes a significance to analytically investigate honing operation to effectively improve the cylindricity of engine cylinder bore based on its functional 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 cylinder bore honing with its previous boring operation, and optimizing honing parameters such as honing velocity, stroke speed, and overrunning distance. The research presents a systematical thinking to achieve macrogeometrical features in the honing of engine cylinder bore and a theoretical approach for the successful selection and optimization of honing process parameters.

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