CYLINDRICAL GRINDING CYCLE DESIGN BASED ON FINAL PART QUALITY CONSTRAINTS

摘要

A grinding process model to predict the forces and power based on a probabilistic analysis of the chip thickness is presented. The model includes tool properties, material properties, kinematic conditions, and dynamic effects. A surface roughness model based on the predicted chip thickness is formulated and validated with empirical data. A grinding cycle is proposed by combining power control during the stock removal stage and feed control during the finishing stage. The grinding power model and the surface roughness model were used to simulate the process and to find the optimal settings for the cycle. The desired grinding power and the workpiece rotational velocity for stock removal were selected to not exceed the machine capabilities and to prevent workpiece burn. The feed and the workpiece tangential velocity of the finishing stage were found based on the final part requirements such as surface roughness and the theoretical out-of-roundness. This grinding cycle was implemented and tested in an open architecture machine.