The effect of wheel eccentricity and run-out on grinding forces, waviness, wheel wear and chatter

Badger, Jeffrey; Murphy, Stuart; O’Donnell, Garret E.

doi:10.1016/j.ijmachtools.2011.06.006

Cited by 34 publications

(15 citation statements)

References 9 publications

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“…All 5 tests were performed with good junction quality for the whole signal, so the 15-20 % differences between {T qs ,T le } and T jf for test A and B are probably due to the interactions between the junction and the grains. For small depths of cut, short arc contact length and high workpiece speed, Badger et al [32] have…”

Section: Experimental Results and Inverse Methods For Determining The mentioning

confidence: 99%

Measurement of grinding temperatures using a foil/workpiece thermocouple

Lefebvre

Lanzetta

Lipiński

et al. 2012

International Journal of Machine Tools and Manufacture

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The high temperature generated in abrasive processes is the main factor responsible for thermal damage to a ground surface. It can be predicted through the thermal balance of the heat fluxes in the process. Such predictions can be experimentally verified using a foil/workpiece thermocouple. To estimate the thermal behaviour of such a sensor, it was dynamically calibrated with a laser beam to measure its frequency response. It was found that the response of the sensor has a time constant dependant on the thermal load and cannot be modelled by a simple first order function. In the calibration conditions used, the sensor is fast enough to measure the surface temperature with a time constant less than 100 microseconds.A high frequency acquisition system allows the signal to be measured at the local grit scale so that the activity of grits and the contact stability between the foil and the workpiece during grinding can be studied. By using the peak temperature and the local cooling after a peak, suitably processed, a local background temperature can be defined. It is shown that this background temperature can be evaluated more accurately by matching the global cooling curve to a finite element solution. The temperatures obtained from the local minima of the local diffusive cooling curve agree better with measured results than a temperature obtained by low pass filtering, which can overestimate the background temperature and so the partition ratio.Keywords: grinding; temperature; thermocouple; dynamic calibration; heat transfer; signal processing Measurement of grinding temperatures using a foil/workpiece thermocouple AbstractThe high temperature generated in abrasive processes is the main factor responsible for thermal damage to a ground surface. It can be predicted through the thermal balance of the heat fluxes in the process. Such predictions can be experimentally verified using a foil/workpiece thermocouple. To estimate the thermal behaviour of such a sensor, it was dynamically calibrated with a laser beam to measure its frequency response. It was found that the response of the sensor has a time constant dependant on the thermal load and cannot be modelled by a simple first order function. In the calibration conditions used, the sensor is fast enough to measure the surface temperature with a time constant less than 100 microseconds.A high frequency acquisition system allows the signal to be measured at the local grit scale so that the activity of grits and the contact stability between the foil and the workpiece during grinding can be studied. By using the peak temperature and the local cooling after a peak, suitably processed, a local background temperature can be defined. It is shown that this background temperature can be evaluated more accurately by matching the global cooling curve to a finite element solution. The temperatures obtained from the local minima of the local diffusive cooling curve agree better with measured results than a temperature obtained by low pass filtering, which can overestimate...

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Section: Experimental Results and Inverse Methods For Determining The mentioning

confidence: 99%

Measurement of grinding temperatures using a foil/workpiece thermocouple

Lefebvre

Lanzetta

Lipiński

et al. 2012

International Journal of Machine Tools and Manufacture

View full text Add to dashboard Cite

show abstract

“…The complex influence mechanism on grinding dynamics is necessary to be studied deeply to improve applicability and accuracy of analytical models of grinding force and vibration. Badger et al analysed how grinding-wheel untruth or non-circular shape affects forces, wheel wear and temperatures and developed a model to predict final scallop-profile shape from grinding parameters and eccentricity [16]. Inasaki et al presented origin of chatter that is due to regenerative mechanism during cylindrical, surface and internal grinding process and discussed the effect of run-out on chatter as a function of material-removal rate along with an optical sensor to measure run-out [7].…”

Section: Introductionmentioning

confidence: 99%

Quantitative impacts of regenerative vibration and abrasive wheel eccentricity on surface grinding dynamic performance

Chen

et al. 2018

Int J Adv Manuf Technol

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In grinding, regenerative-vibration and forced-vibration due to grinding wheel eccentric rotation are main excited-vibration sources that interact with grinding material removal mechanism. In the paper, instantaneous undeformed chip thickness in down-grinding cutting phase may consist of two components, i.e. linear kinetic thickness and nonlinear dynamic thickness. Considering abrasive grit-workpiece interaction in the grinding contact zone, the grinding vibration system is presented by a new set of differential equations of two degrees of freedom (DOF) with a close-loop feedback control system models. Conventional grinding control parameters, including wheel spindle speed, work-speed in feed direction and radial cutting depth, are often regarded as linear constants in many existing simplified models. When considering time delay, they can be transferred to nonlinear variables, so the capability of prediction and the accuracy of solution of the grit-workpiece dynamics performance are improved. Based on quantitative comparison of force and vibration magnitudes, the influence of the eccentric rotation of abrasive wheel and the negative rake angle of working grit cutting edges on grinding performance are demonstrated in the paper.

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“…The mechanism of the wheel OOR was explained by a simple model proposed by Brommundt [12]. Badger et al [13] studied the evident degradation of the grinding force, wheel wear, and vibration caused by the wheel eccentricity, and some recommendations are given for detecting and determining the wheel eccentricity. Wu et al [14] studied the dynamic stresses of the wheel set axle based on a coupled vehicle/track dynamic model with the flexible wheelset; the results show that the resonance of wheel set axle could be excited by polygonal wear, which would increase the dynamic stress for the wheel set axle.…”

Section: Introductionmentioning

confidence: 99%

Influence of Wheel Eccentricity on Vertical Vibration of Suspended Monorail Vehicle: Experiment and Simulation

Wang

Chen

et al. 2017

Shock and Vibration

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This paper investigates the influence of wheel eccentricity on vertical vibration of suspended monorail vehicle based on experiment and simulation. Two sets of tests are conducted in the first Chinese suspended monorail, and the tested acceleration is analyzed and exhibited. A multibody dynamic model of the suspended monorail vehicle is established to simulate the vertical vibration of car body excited by wheel eccentricity. The results show that there are three factors which may cause an abnormal vibration considering the track and the vehicle system. The influence of wheel eccentricity on the car body vibration was firstly analyzed. Simulated acceleration of car body has a great accordance with test. The wheel eccentricity could excite the resonance of car body at the speed of 21 km/h, and the vertical acceleration would increase considerably. Decreasing the secondary stiffness can effectively reduce the vertical vibration caused by wheel eccentricity, especially at the resonant speed. In the secondary test, the peak of car body acceleration at speed of 20 km/h is not appearing when only renewing the wheels, and the acceleration is decreasing obviously at the domain frequency. It is further determined that the abnormal vibration is mainly caused by the wheel eccentricity.

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The effect of wheel eccentricity and run-out on grinding forces, waviness, wheel wear and chatter

Cited by 34 publications

References 9 publications

Measurement of grinding temperatures using a foil/workpiece thermocouple

Measurement of grinding temperatures using a foil/workpiece thermocouple

Quantitative impacts of regenerative vibration and abrasive wheel eccentricity on surface grinding dynamic performance

Influence of Wheel Eccentricity on Vertical Vibration of Suspended Monorail Vehicle: Experiment and Simulation

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