Numerical Calculation of Grinding Wheel Wear for Spiral Groove Grinding

Due to its good cutting performance in titanium alloy machining, integral end mills are more and more used in machining aero-engine impeller blades. The tool spiral groove plays the role of chip acceptor and chip removal, and the accuracy of its parameters has an important effect on the cutting performance. In the grinding process of the spiral groove, the grinding wheel's external grinding is mainly involved in the grinding task. The grinding wheel's wear degree is related to the grinding time and grinding times of the grinding wheel, and the wear of the grinding wheel will lead to the change of the parameters of the spiral groove. To achieve the accurate solution of the grinding wheel surface wear profile, image processing technology was used to extract the spiral groove end section contour coordinates of the grinding wheel and fit them. The worn sand profile was solved based on the contact line principle, and the grinding wheel wear amount was obtained. The traditional reconstruction method was used to verify the algorithm. The results show that the accuracy of the reverse algorithm for the wear profile of the grinding wheel is relatively high.

A compensation algorithm of tool path for grinding wheel wear in solid cutting tool flank grinding

In finishing machining, the quality of workpiece is significantly influenced by the performance of solid cutting tool. Solid cutting tool flank is ground by CNC tool grinder in accordance with the tool path of grinding wheel. In actual grinding process, the grinding area of wheel will be gradually worn down, resulting in the decrease of geometric accuracy of flank and even wrong profile. In order to compensate the error, a compensation algorithm of tool path for solid cutting tool flank based on grinding wheel wear is proposed. Firstly, the coordinate systems are defined for the grinding process of flank, and the orientation and location calculation model of ideal wheel with the grinding process parameters is derived. Secondly, based on the profile description of wheel wear, flank errors are analyzed. Then, the compensation algorithm for anastomosis of cutting edge and relief angle is proposed. Finally, series of experiments of simulation and actual grinding are carried out. The comparison of the results shows that the algorithm can reduce the influence of wheel wear effectively, which can also improve the grinding quality stability and prolong the service life of grinding wheel.

Wheel Wear Related Instability in Grinding of Quartz Glass

Grinding is a popular method for producing high-quality parts made of hard and brittle materials. A lot of researchers have focused on the impact of grinding parameters on surface quality. However, only a few studies discussed the surface quality instability caused by the grinding wheel wear during a long grinding process. In this paper, through wheel state monitoring and surface quality testing of ground samples, it is found that the relationship between ground surface roughness and theoretical undeformed chip thickness is significantly affected by the grinding wheel wear state, rather than maintain steady as described in most available models. By introducing the normal grinding force, a linearly relationship was found among normal grinding force, undeformed chip thickness and ground surface roughness. Besides, sensitivity analysis was conducted to guide the parameter adjustment to maintain the stability of ground surface roughness and grinding state. The mechanism of the effect of wheel wear on normal grinding force was also studied in detail. This study will help to further understand the mechanism of the influence of wheel wear on the grinding stability.

Prozessüberwachung beim Spitzenlosschleifen/Process monitoring during centerless grinding - Use of vibration sensor technology for detecting wear-related changes in contact conditions

Der konstruktive Aufbau von Spitzenlosschleifmaschinen erschwert die Implementierung von Sensorik zur Prozessüberwachung. Daher wird ein Sensorsystem zur Schwingungsmessung beim Spitzenlosschleifen vorgestellt, das auch zur Nachrüstung von Bestandsmaschinen geeignet ist. Die erfassten Daten während spitzenlosen Einstechschleifversuchen korrelierten in guter Näherung mit schleifscheibenverschleißbedingten Änderungen der Werkstückeigenschaften.   The design of centerless grinding machines makes it difficult to apply suitable sensors for process monitoring. This paper presents a sensor system for vibration monitoring during centerless grinding, which can also be used for retrofitting existing machines. The data recorded during centerless plunge grinding correlated in a good aproximation with changes in the workpiece properties related to grinding wheel wear.

A Study on Calculation of Optimum Exchanged Grinding Wheel Diameter when Surface Grinding Stainless Steel

This study aims to propose a method to calculate optimum exchanged grinding wheel diameter to minimize grinding cost in grinding surface process for stainless steel. The interactions of the grinding cost and optimum exchanged grinding wheel diameter have been analyzed and presented in mathematical formulae. To obtain the minimal grinding cost, the optimal exchanged grinding wheel diameter has been determined by investigating six two-level grinding process parameters including initial grinding wheel diameter, total dressing depth, radial grinding wheel wear per dress, wheel life, machine tool hour and grinding wheel cost. Based on 26 experiments conducted in computational program, the optimal exchanged grinding wheel diameter is presented as a function of these grinding parameters. This developed model has been verified and proven by experimental results. The proposed method of calculation of the optimum exchanged grinding wheel diameter can be applied in practice to reduce the grinding cost.