HONING PROCESS OPTIMIZATION IN ENGINE COMPONENT REMANUFACTURING: A SYSTEMATIC REVIEW OF METHODS, PARAMETERS, FUNCTIONAL PERFORMANCE METRICS AND CAM INTEGRATION

Abstract

Honing is the most precise abrasive finishing process used to achieve the dimensional accuracy, surface integrity and functional cross-hatch surface texture of the internal cylindrical surfaces of an engine. In engine remanufacturing it has an extra weight as a worn cylinder bore or relining sleeve will require a cylinder bore that is both back to standard and capable of sealing pistons, lubricating the engine and maintaining good piston ring performance. The present systematic review, which follows the PRISMA 2020 reporting guideline, gathers and summarizes 39 studies related to honing optimisation of cylinder sleeves, liners and similar bores, as well as contextual studies on design of experiments (DOE), condition monitoring and Industry 4.0 in a developing-economy context. It reviews conventional, multi-stage plateau, slide, variable-kinematics and non-conventional (electrochemical and magnetorheological) honing as well as the main variables that can be controlled (abrasive grain size and density, honing pressure, rotational and reciprocating speed, stroke, cross-hatch angle, time and tool expansion), and the performance criteria used to evaluate them (roughness, material-ratio and areal parameters, cylindricity, material removal rate, tool wear, energy and productivity). The results demonstrate that the influences of the parameters are related to the honing stages, the abrasive system, the material of the workpiece, and the texture of the object to be honed; so honing should be considered as a multi-response problem. The resolution of conflicting optima is a common feature of the Taguchi, ANOVA, grey relational analysis, desirability and neuro-fuzzy models, which is evident across the authors' experience in DOE in milling, injection moulding, additive manufacturing and wood machining. The Rk-family and the ISO 25178-2 parameters are more suitable to describe the function of cylinder-liners than the Ra alone. The review highlights eight research gaps, such as core-condition-aware parameter selection, functional-metrology-based objectives, energy and carbon accounting, stone-wear evolution and skills and proposes a CAM-integrated, data-driven framework for repeatable remanufacturing.