Improvement of form accuracy in cylindrical traverse grinding with steady rest by controlling traverse speed

Fujii, Hidetaka; Onishi, Takashi; Lin, Chinhu; Sakakura, Moriaki; Ohashi, Kazuhito

doi:10.1299/jamdsm.2021jamdsm0049

Cited by 3 publications

(4 citation statements)

References 10 publications

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“…The results are shown in Table 7. The improvement percentage of around 77% is near the value of 82% obtained by Fujii et al [14] for a workpiece with a similar slenderness of around 18, but without the need of using a steady rest and with variation in the traverse feed rate.…”

Section: Conflicts Of Interestsupporting

confidence: 70%

“…Automation for this solution is complicated, particularly as with a different transversal speed, topography and geometric parameters will change throughout the length of the workpiece. The same approach was presented by Fujii et al [14], but also took into consideration the use of steady rest, which leads to a more expensive-and difficult-to-set-up solution.…”

Section: Introductionmentioning

confidence: 99%

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Improvement of Shape Error for Slender Parts in Cylindrical Traverse Grinding by Part-Deformation Modelling and Compensation

Mendez¹,

Alvarez²,

Barrenetxea³

et al. 2021

Metals

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Achieving geometrical accuracy in cylindrical traverse grinding for high-aspect slender parts is still a challenge due to the flexibility of the workpiece and, therefore, the resulting shape error. This causes a bottleneck in production due to the number of spark-out strokes that must be programmed to achieve the expected dimensional and geometrical tolerances. This study presents an experimental validation of a shape-error prediction model in which a distributed load, corresponding to the grinding wheel width, is included, and allows inclusion of the effect of steady rests. Headstock and tailstock stiffness must be considered and a procedure to obtain their values is presented. Validation of the model was performed both theoretically (by comparing with FEM results) and experimentally (by comparing with the deformation profile of the real workpiece shape), obtaining differences below 5%. Having determined the shape error by monitoring the normal grinding force, a solution was presented to correct it, based on a cross-motion of the grinding wheel during traverse strokes, thus decreasing non-productive spark-out strokes. Due to its simplicity (based on the shape-error prediction model and normal grinding force monitoring), this was easily automatable. The corrective compensation cycle gave promising results with a decrease of 77% in the shape error of the ground part, and improvement in geometrically measured parameters, such as cylindricity and straightness.

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Section: Conflicts Of Interestsupporting

confidence: 70%

Section: Introductionmentioning

confidence: 99%

Improvement of Shape Error for Slender Parts in Cylindrical Traverse Grinding by Part-Deformation Modelling and Compensation

Mendez¹,

Alvarez²,

Barrenetxea³

et al. 2021

Metals

View full text Add to dashboard Cite

show abstract

“…The accuracy of grinding of low-stiffness shafts can, therefore, be significantly increased by using technological machining methods that allow for the control of the compliance of the technological system, while the efficiency of the process can be significantly increased by using higher machining parameters [ 35 , 36 , 37 ].…”

Section: Introductionmentioning

confidence: 99%

Influence of the Compliance of a Technological System on the Machining Accuracy of Low-Stiffness Shafts in the Grinding Process

Świć

Gola

2023

Materials

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This paper reports the results of research on the influence of the compliance of the technological system used in grinding low-stiffness shafts on the shape accuracy of the workpieces. The level of accuracy achieved using passive compliance compensation was assessed, and technological assumptions were formulated to further increase the shape accuracy of the low-stiffness shafts obtained in the grinding process. Taking into account the limitations of passive compliance compensation, a method for the active compensation of the compliance of the elastic technological system during the machining process was developed. The experiments showed that the accuracy of grinding was most effectively increased by adjusting the compliance and controlling the bending moments, depending on the position of the cutting force (grinding wheel) along the part. The experimental results were largely consistent with the results of the theoretical study and confirmed the assumptions made. Adjusting the compliance in the proposed way allows for the significant improvement in the accuracy and productivity of machining of low-stiffness shafts.

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“…Such specialization of machine tools requires the development of specific optimization and control criteria suitable for the individual classes of those tools [ 33 , 34 ]. The point of departure for controlling all the classes of machine tools is the stabilization of the cutting forces and the associated elastic deformations [ 35 , 36 ].…”

Section: Introductionmentioning

confidence: 99%

Technological Methods for Controlling the Elastic-Deformable State in Turning and Grinding Shafts of Low Stiffness

et al. 2022

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The article presents original technological methods that allow the improvement of the accuracy of the turning and grinding of elastic-deformable shafts by increasing their stiffness by controlling the state of elastic deformations. In particular, the adaptive control algorithm of the machining process that allows the elimination of the influence of the cutting force vibration and compensates for the bending vibrations is proposed. Moreover, a novel technological system, equipped with the mechanism enabling the regulation of the stiffness and dedicated software, is presented. The conducted experimental studies of the proposed methods show that, in comparison with the passive compliance equalization, the linearization control ensures a two-fold increase in the shape accuracy. Compared to the uncontrolled grinding process of shafts with low stiffness, the programmable compliance control increases the accuracy of the shape by four times. A further increase in the accuracy of the shape while automating the processes of abrasive machining is associated with the proposed adaptive control algorithm. Moreover, the initial experiments with the adaptive devices prove that it is possible to reduce the longitudinal shape inaccuracy even by seven times.

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Improvement of form accuracy in cylindrical traverse grinding with steady rest by controlling traverse speed

Cited by 3 publications

References 10 publications

Improvement of Shape Error for Slender Parts in Cylindrical Traverse Grinding by Part-Deformation Modelling and Compensation

Improvement of Shape Error for Slender Parts in Cylindrical Traverse Grinding by Part-Deformation Modelling and Compensation

Influence of the Compliance of a Technological System on the Machining Accuracy of Low-Stiffness Shafts in the Grinding Process

Technological Methods for Controlling the Elastic-Deformable State in Turning and Grinding Shafts of Low Stiffness

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