Estimation of Grinding Cycle Time Taking into Account Specific Grinding Force

2014 ◽  
Vol 1017 ◽  
pp. 72-77
Author(s):  
Takazo Yamada ◽  
Hwa Soo Lee ◽  
Kohichi Miura
Keyword(s):  
Cycle Time ◽  
Grinding Force ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Elastic Deformations ◽  
The Real ◽  
Calculating Method ◽  
Grinding Machine ◽  
Specific Grinding Force

In the grinding process, due to the elastic deformations of grinding machine and grinding wheel, the ground depth of cut is smaller than the applied depth of cut. Consequently, the ground depth of cut has to be controlled in spark-out grinding process. However, the cycle time in spark-out grinding process is not easy to be estimated. From such a viewpoint, in this study, using specific grinding force obtained by measured grinding force in the first spark-out pass, a calculating method of the real ground depth in continuous pass process is proposed. And, this method is experimentally evaluated.

Calculation of Effective Ground Depth of Cut by Means of Grinding Process Model

2011 ◽  
Vol 496 ◽  
pp. 7-12 ◽  
Author(s):  
Takazo Yamada ◽  
Michael N. Morgan ◽  
Hwa Soo Lee ◽  
Kohichi Miura
Keyword(s):  
Process Model ◽  
Ground Surface ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Wheel Wear ◽  
Elastic Deformations ◽  
Proposed Model ◽  
Effective Depth ◽  
Grinding Machine

In order to obtain the effective depth of cut on the ground surface, a new grinding process model taking into account thermal expansions of the grinding wheel and the workpiece, elastic deformations of the grinding machine, the grinding wheel and the workpiece and the wheel wear was proposed. Using proposed model, the effective depth of cut was calculated using measured results of the applied depth of cut and the normal grinding force.

Estimation of the Grinding Time by Means of the Grinding Process Model

2012 ◽  
Vol 565 ◽  
pp. 52-57 ◽  
Author(s):  
Takazo Yamada ◽  
Hwa Soo Lee ◽  
Kohichi Miura
Keyword(s):  
Process Model ◽  
The Other ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Elastic Deformations ◽  
Residual Stock ◽  
Grinding Machine ◽  
Stock Removal ◽  
Grinding Time

In grinding operation, elastic deformations of the grinding machine and the grinding wheel induce a residual stock removal of workpiece. On the other hand, thermal expansions of the workpiece and the grinding wheel increase the depth of cut. Therefore, calculation of a ground depth of cut and/or the grinding time has to be considered by the elastic deformations and the thermal expansions. From such a viewpoint, in this study, grinding process model taking into account the elastic deformations and the thermal expansions was proposed. This paper aims to estimate the grinding time by means of the proposed grinding process model.

Control of Cutting Force for Creep-Feed Grinding Processes Using a Multi-Level Fuzzy Controller

2006 ◽  
Vol 129 (4) ◽  
pp. 480-492 ◽  
Author(s):  
Chengying Xu ◽  
Yung C. Shin
Keyword(s):  
Real Time ◽  
Grinding Force ◽  
Open Architecture ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Stable Range ◽  
Creep Feed Grinding ◽  
Creep Feed ◽  
Multi Level

In this paper, a multi-level fuzzy control (MLFC) technique is developed and implemented for a creep-feed grinding process. The grinding force is maintained at the maximum allowable level under varying depth of cut, so that the highest metal removal rate is achieved with a good workpiece surface quality. The control rules are generated heuristically without any analytical model of the grinding process. Based on the real-time force measurement, the control parameters are adapted automatically within a stable range. A National Instrument real-time control computer is implemented in an open architecture control system for the grinding machine. Experimental results show that the cycle time has been reduced by up to 25% over those without force control and by 10–20% compared with the conventional fuzzy logic controller, which indicates its effectiveness in improving the productivity of actual manufacturing processes. The effect of grinding wheel wear is also considered in the creep-feed grinding process, where the grinding force/power can be maintained around the specified value by the proposed MLFC controller as the wheel dulls gradually.

Research on Grinding Model of Roller for Manufacturing Involute Spline

2009 ◽  
Vol 416 ◽  
pp. 524-528 ◽  
Author(s):  
Feng Shou Zhang ◽  
Feng Kui Cui ◽  
Chun Mei Li ◽  
Xiao Qiang Wang
Keyword(s):  
Mathematical Model ◽  
Theoretical Basis ◽  
Grinding Force ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Motion Trajectory ◽  
Rolling Experiment ◽  
Grinding Machine ◽  
The Mathematical Model ◽  
Involute Spline

The paper studies the grinding process of cold roller. The shape of grinding wheel, the arc radius of grinding wheel, the motion trajectory of wheel center and the grinding force are analyzed. The mathematical model is established. The cold rolling experiment shows that the analyses and formula deduced in this paper are correct. It provides theoretical basis for designing and manufacturing roller and provides the mathematical guidance for making process parameter and designing grinding machine.

Online force control of large optical grinding machine for brittle materials assisted by force prediction

2019 ◽  
Vol 234 (1-2) ◽  
pp. 14-26
Author(s):  
Shuo Lin ◽  
QianRen Wang ◽  
ZhenHua Jiang ◽  
YueHong Yin
Keyword(s):  
Cutting Parameters ◽  
Grinding Force ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Force Model ◽  
Orthogonal Experiments ◽  
Grinding Conditions ◽  
Carbide Ceramics ◽  
Grinding Machine ◽  
Silicon Carbide Ceramics

Trajectory planning of aspherical surfaces with appropriate cutting parameters is always a tedious task, especially on difficult-to-grind materials. Orthogonal experiments are usually designed and conducted first to get a full estimation of forces under different sets of grinding conditions (e.g. depth of cut and feeding velocity). However, all these data will change, as the grinding wheel becomes blunt. To reduce the work on the selection of grinding parameters and keep the grinding process stable, a new force-controlled grinding strategy for large optical grinding machine on brittle material is proposed. The grinding force is controlled by adjusting feeding velocity along the trajectories in real time. The grinding force model is established by analyzing the complex contact area between the arc-shaped wheel and the workpiece. The co-existing of brittle and ductile removal is also considered. For the longtime delay of the system, the controller foresees the grinding force in 0.4 s later based on the model proposed, to prevent the large overshoot of the force (up to 87.5%). The verification of the controller was conducted on silicon carbide ceramics. The force overshoot was reduced to 22.5%, and the motion accuracy was guaranteed by position servo within 5 µm. The subsurface damage along the trajectory was further analyzed and discussed.

Study on Edge Contact Area and Surface Integrity of Workpiece in Point Grinding Process

2009 ◽  
Vol 407-408 ◽  
pp. 577-581
Author(s):  
Shi Chao Xiu ◽  
Zhi Jie Geng ◽  
Guang Qi Cai
Keyword(s):  
Surface Integrity ◽  
Contact Area ◽  
High Speed ◽  
Ground Surface ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Edge Contact ◽  
Cylindrical Grinding ◽  
Theoretic Foundations

During cylindrical grinding process, the geometric configuration and size of the edge contact area between the grinding wheel and workpiece have the heavy effects on the workpiece surface integrity. In consideration of the differences between the point grinding and the conventional high speed cylindrical grinding, the geometric and mathematic models of the edge contact area in point grinding were established. Based on the models, the numerical simulation for the edge contact area was performed. By means of the point grinding experiment, the effect mechanism of the edge contact area on the ground surface integrity was investigated. These will offer the applied theoretic foundations for optimizing the point grinding angles, depth of cut, wheel and workpiece speed, geometrical configuration and size of CBN wheel and some other grinding parameters in point grinding process.

scholarly journals Study on the Effect of Grinding Pressure on Material Removal Behavior Performed on a Self-Designed Passive Grinding Simulator

2021 ◽  
Vol 11 (9) ◽  
pp. 4128
Author(s):  
Peng-Zhan Liu ◽  
Wen-Jun Zou ◽  
Jin Peng ◽  
Xu-Dong Song ◽  
Fu-Ren Xiao
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Service Life ◽  
Material Removal ◽  
Removal Rate ◽  
Grinding Force ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Grinding Temperature ◽  
Grinding Efficiency

Passive grinding is a new rail grinding strategy. In this work, the influence of grinding pressure on the removal behaviors of rail material in passive grinding was investigated by using a self-designed passive grinding simulator. Meanwhile, the surface morphology of the rail and grinding wheel were observed, and the grinding force and temperature were measured during the experiment. Results show that the increase of grinding pressure leads to the rise of rail removal rate, i.e., grinding efficiency, surface roughness, residual stress, grinding force and grinding temperature. Inversely, the enhancement of grinding pressure and grinding force will reduce the grinding ratio, which indicates that service life of grinding wheel decreases. The debris presents dissimilar morphology under different grinding pressure, which reflects the distinction in grinding process. Therefore, for rail passive grinding, the appropriate grinding pressure should be selected to balance the grinding quality and the use of grinding wheel.

scholarly journals Grinding of AISI 4340 steel with interrupted cutting by aluminum oxide grinding wheel

2015 ◽  
Vol 68 (2) ◽  
pp. 229-238
Author(s):  
Hamilton Jose de Mello ◽  
Diego Rafael de Mello ◽  
Eduardo Carlos Bianchi ◽  
Paulo Roberto de Aguiar ◽  
Doriana M. D'Addona
Keyword(s):  
Aluminum Oxide ◽  
Rotation Speed ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Wheel Wear ◽  
Machined Surface ◽  
Aisi 4340 Steel ◽  
4340 Steel ◽  
Grinding Machine ◽  
Aisi 4340

AbstractThere has been a great advance in the grinding process by the development of dressing, lubri-refrigeration and other methods. Nevertheless, all of these advances were gained only for continuous cutting; in other words, the ground workpiece profile remains unchanged. Hence, it becomes necessary to study grinding process using intermittent cutting (grooved workpiece – discontinuous cutting), as little or no knowledge and studies have been developed for this purpose, since there is nothing found in formal literature, except for grooved grinding wheels. During the grinding process, heat generated in the cutting zone is extremely high. Therefore, plenty of cutting fluids are essential to cool not only the workpiece but also the grinding wheel, improving the grinding process. In this paper, grinding trials were performed using a conventional aluminum oxide grinding wheel, testing samples made of AISI 4340 steel quenched and tempered with 2, 6, and 12 grooves. The cylindrical plunge grinding was performed by rotating the workpiece on the grinding wheel. This plunge movement was made at three different speeds. From the obtained results, it can be observed that roughness tended to increase for testing sample with the same number of grooves, as rotation speed increased. Roundness error also tended to increase as the speed rotation process got higher for testing the sample with the same number of grooves. Grinding wheel wear enhanced as rotation speed and number of grooves increased. Power consumed by the grinding machine was inversely proportional to the number of grooves. Subsuperficial microhardness had no significant change. Micrographs reveal an optimal machining operation as there was no significant damage on the machined surface.

scholarly journals Modeling of Vibration Condition in Flat Surface Grinding Process

2020 ◽  
Vol 2020 ◽  
pp. 1-12
Author(s):  
Amon Gasagara ◽  
Wuyin Jin ◽  
Angelique Uwimbabazi
Keyword(s):  
Process Model ◽  
Flat Surface ◽  
Normal Component ◽  
Cutting Speed ◽  
Surface Grinding ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Grinding Forces ◽  
Vibration Condition

This article presents a new model of the flat surface grinding process vibration conditions. The study establishes a particular analysis and comparison between the influence of the normal and tangential components of grinding forces on the vibration conditions of the process. The bifurcation diagrams are used to examine the process vibration conditions for the depth of cut and the cutting speed as the bifurcation parameters. The workpiece is considered to be rigid and the grinding wheel is modeled as a nonlinear two-degrees-of-freedom mass-spring-damper oscillator. To verify the model, experiments are carried out to analyze in the frequency domain the normal and tangential dynamic grinding forces. The results of the process model simulation show that the vibration condition is more affected by the normal component than the tangential component of the grinding forces. The results of the tested experimental conditions indicate that the cutting speed of 30 m/s can permit grinding at the depth of cut up to 0.02 mm without sacrificing the process of vibration behavior.

Development of Three-Dimensional Dynamometer for Wafer Grinder

2010 ◽  
Vol 126-128 ◽  
pp. 361-366 ◽  
Author(s):  
Xiang Long Zhu ◽  
Ren Ke Kang ◽  
Yong Qing Wang ◽  
Dong Ming Guo
Keyword(s):  
Three Dimensional ◽  
High Sensitivity ◽  
Grinding Force ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Performance Parameters ◽  
Grinding Forces ◽  
Grinding Method ◽  
Static Performance ◽  
Good Repeatability

Grinding forces during grinding silicon wafer have great influences on the accuracy, surface quality and grinding yield of the wafer. It is necessary to develop an accurate and reliable grinding dynamometer for measuring and monitoring the grinding process of the large and thin wafer. In this work, a new 3D (three-dimensional) grinding dynamometer using piezoelectric sensors is designed and developed, which is used for a wafer grinder based on wafer rotating grinding method. The calibrating experiments of the 3D grinding dynamometer are carried out. The FEA and modal analysis are made and compared with the results of mode testing. Furthermore, the static performance parameters of the dynamometer are obtained from the loading experiment. The experiment results indicate that the 3D grinding dynamometer can measure axial, radial and tangential grinding force of grinding wheel with high sensitivity, good linearity, good repeatability and high natural frequency, and fully satisfied requirement for measuring and monitoring of the grinding force in wafer grinding process.

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