The effective width of the moving heat source is presented and the shape of the grinding block is simplified in order to use the traditional heat source model in modelling flat grinding with a cup wheel. Both triangular and rectangular heat source models are presented and compared with experimental results. The heat transfer process, the end-face temperature of a single wear particle, and the one-dimensional heat transfer model are integrated to study the heat flux into the workpiece. The energy partition ratio is obtained under conditions of different grinding parameters in order to make the temperature model precise. The feasibility of the temperature model is validated by experimental results, and the influence of grinding parameters on the grinding temperature is also analysed.
A smooth spherical surface has been obtained by grinding using a precise spherical grinder and a cup-type resin-bonded diamond wheel without any polishing. Two methods were used in machining: cup-wheel spherical grinding with swing (CSGS) and cup-wheel spherical grinding with no swing (CSGNS). In this paper we propose, for the first time, a trajectories analysis approach (TAA) based on the above two methods to optimize the machining parameters in the spherical grinding process. The cup-wheel rotation speed and swing speed, spindle rotation speed, number of grinding blocks and size of the cup wheel were considered as the process variables. The surface roughness and production rate were evaluated for the optimal grinding conditions, subject to the constraints of the density of trajectories, compatible parameters, and the size of the workpiece. A mathematical model was developed and an optimization strategy was proposed for the process parameters, and verified by two experiments. The experimental results show that the TAA is valid for selecting the optimal process parameters for the two methods of spherical grinding.
Kinematics theory for a multi-body system is used to analyse translational joint error, rotational joint error, and quadrature error in a spherical grinding system. A virtual grinding point method is proposed that is based on process features, and the feasibility as well as effectiveness of this method is demonstrated. A volumetric error model of the grinding system is created and the compensation method is coded into a control computer program. A laser interferometer is used to experimentally measure the error both with and without the proposed error compensation scheme. The experimental results validate the proposed approach in that they show that the spherical surface grinding precision is significantly improved.
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