Abstract
The automobile industry was one of the sectors most affected by the economic collapse in 2008. It suffered a backlash in terms of demand, which obliged automobile manufacturing companies to rationalize their investments and workforce. Even more seriously affected was the supply chain of this sector since, firstly, they suffered cut in orders (quantity and product value) and secondly, they were facing considerable challenges due to competition from emerging markets with their frugal innovation technologies and low-cost products. For those who could decode the encoded message at that time, a world of new opportunities was opening up and now, with the economic recovery, we can see the first production technology platform “species” which were able to survive the evolutionary process of the economic market and fulfill the requirements of the new production systems for motor blocks, which include high productivity, high quality, flexibility, versatility (capacity to change), availability and energy efficiency. The new honing technology platform of the Nagel Company VARIOLINE has opened up a new avenue of possibilities for motor block production lines. While maintaining all of its prior quality characteristics for mass production (optimized surface quality and integrity, and generation of tight cylinder bore geometry and dimensions) new features have been added, such as High Performance Honing (HPH) and Perpendicularity Angularity Technology Honing (PATH-Honing), technology boosters which replace the fine boring machining operation and guarantee the required bore position in a modular machine concept. Those innovations have increased the degree of flexibility and reduced the production chain, the investment in machinery, and the set-up, transport and processing times. Another advantage of this platform is its new ball bearing spindle technology, which is highly energy efficient and environmentally friendly in comparison to hydraulic or linear motor spindles. Furthermore, the use of such technology makes it possible to develop helical slide and stratum honing (the generation of different surface structures (different honing angles and roughness) in a specified stroke position in the cylinder 2 bore, considering the piston position and speed). Thus, it offers new opportunities to reduce the friction, wear, oil consumption and emissions of the new generation of motors, as verified by Deutz AG and AUDI for grey cast iron and for application with aluminum alloys like ALUSIL and DISPAL®.