TAILIEUCHUNG - Intelligent Centerless Grinding: Global Solution for Process Instabilities and Optimal Cycle Design

In this paper, new simulation techniques are described to determine instability-free configurations, making it possible to guarantee that the final workpiece profile is round. With this information and taking into account other process restrictions, like system static stiffness and workpiece tolerance, the optimal grinding cycle is designed. These results have been implemented into an intelligent tool to assist the application of this research in industrial environments. | ELSEVIER Intelligent Centerless Grinding Global Solution for Process Instabilities and Optimal Cycle Design I. Gallego 3 Manufacturing Department Faculty of Engineering - Mondragon University Mondragon Spain Submitted by R. Bueno 1 San Sebastian Spain Abstract Centerless grinding productivity is largely limited by three types of instabilities chatter geometric lobing and workpiece rotation problems. Regardless of its negative effect in manufacturing plants no functional tool has been developed to set up the process because it involves the simultaneous resolution of several coupled problems. In this paper new simulation techniques are described to determine instability-free configurations making it possible to guarantee that the final workpiece profile is round. With this information and taking into account other process restrictions like system static stiffness and workpiece tolerance the optimal grinding cycle is designed. These results have been implemented into an intelligent tool to assist the application of this research in industrial environments. Keywords Centerless Grinding Productivity Simulation 1 INTRODUCTION In centerless grinding the workpiece is not clamped but simply supported between the grinding wheel the blade and the regulating wheel figure 1 reducing the machine idle time and avoiding the necessity of centring holes on the workpiece. Due to the enormous manipulating time and manufacturing cost saving that this implies centerless grinding is extensively used in the mass production of components in automotive and bearing industries for example. Nevertheless the process suffers from three kinds of instabilities that may limit its precision and productivity. 1 Chatter whose growing is much more pronounced than in conventional grinding. 2 Geometric lobing which appears when the workpiece does not self-centre and begins to oscillate between the wheels. 3 Work-holding instability which appears when the regulating wheel is not able to make the workpiece

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