Cylindrical Surface Profile Cutting Tool and Process

Abstract

A method of cutting a profile in a cylinder surface. The method includes simultaneously interpolating an axial portion of the cylindrical surface using a cutting tool to form a profile having a plurality of annular grooves and a pocket having a radius larger than the cylindrical surface prior to the interpolating step.

What is claimed: 
     
         1 . A method of cutting a profile in a cylinder surface, the method comprising:
 simultaneously interpolating an axial portion of the cylindrical surface using a cutting tool to form a profile having a plurality of annular grooves and a pocket having a radius larger than the cylindrical surface prior to the interpolating step.   
     
     
         2 . The method of  claim 1 , wherein flat peaks are formed between adjacent grooves, and further comprising deforming each flat peak to form an undercut region. 
     
     
         3 . The method of  claim 1 , further comprising forming the cylindrical surface by pre-boring an unhoned cylindrical surface. 
     
     
         4 . The method of  claim 1 , wherein the cylindrical surface is an aluminum or magnesium alloy. 
     
     
         5 . The method of  claim 1 , wherein the cutting tool includes a cylindrical cutting body having cutting elements and mounted in a spindle. 
     
     
         6 . The method of  claim 5 , wherein the simultaneously interpolating step includes rotating the cylindrical cutting body relative to the spindle at a rotation speed. 
     
     
         7 . The method of  claim 6 , wherein the rotation speed is at least 4,500 rpm. 
     
     
         8 . The method of  claim 5 , wherein the simultaneously interpolating step includes rotating the spindle about cylindrical surface axis. 
     
     
         9 . The method of  claim 8 , wherein the rotation speed is at least 0.15 millimeters per revolution. 
     
     
         10 . The method of  claim 2 , wherein the deforming step is carried out using a swiping tool having multiple deforming surfaces. 
     
     
         11 . The method of  claim 10 , wherein the deforming step includes rotating the swiping tool at a rotational speed. 
     
     
         12 . The method of  claim 10 , wherein the swiping tool deforming edges having nonzero axial helix to reduce tool deflection. 
     
     
         13 . The method of  claim 10 , wherein the swiping tool deforming edges are ground with radially staggered axial relief grooves to reduce tool deflection. 
     
     
         14 . The method of  claim 5 , wherein the cutting elements include two or more axial rows of cutting elements. 
     
     
         15 . A method of cutting a profile in an inner surface of a cylindrical bore, the inner surface including an axial travel area and an axial non-travel area, the method comprising:
 interpolating the axial non-travel area using a cutting tool to form a profile having a plurality of annular grooves.   
     
     
         16 . The cylindrical bore of  claim 15 , wherein the nominal diameter of the axial travel area is greater than that of the axial non-travel area. 
     
     
         17 . The cylindrical bore of  claim 15 , wherein the axial non-travel area includes two discontinuous axial widths of the cylindrical bore, and the axial travel area extends therebetween. 
     
     
         18 . The cylindrical bore of  claim 15 , wherein the aspect ratio of the depth of the annular grooves to the width of the annual grooves is 0.5 or less. 
     
     
         19 . The method of  claim 15 , wherein the plurality of annular grooves are a plurality of rectangular annular grooves. 
     
     
         20 . A method of cutting a profile in a cylinder bore surface, the method comprising:
 forming a profile having a plurality of annular grooves and a plurality of peaks therebetween; and   cutting an upper portion of the plurality of annular peaks to reduce the height of the annular peaks.