An Intelligent System for Online Optimization of the Cylindrical Traverse Grinding Operation

2006 ◽  
Vol 220 (3) ◽  
pp. 355-363 ◽  
Author(s):  
B W Kruszyński ◽  
P Lajmert
Keyword(s):  
Material Removal ◽  
Intelligent System ◽  
Removal Rate ◽  
Feedforward Neural Network ◽  
Grinding Process ◽  
Grinding Temperature ◽  
Optimization Scheme ◽  
Wheel Wear ◽  
Simulation Research ◽  
Traverse Grinding

This paper presents an intelligent system for optimization of the cylindrical traverse grinding process whose objective is to maximize the material removal rate with constraints on workpiece out-of-roundness and waviness errors, on surface finish, and on grinding temperature. A theoretical analysis of wheel wear development in the traverse grinding process is presented. Next, the results of an experimental test are discussed to establish the most efficient strategy for grinding allowance removal. In the optimization scheme a feedforward neural network is employed to obtain a model which describes relations between the process input parameters and the grinding results. Then this model is used to optimize adaptively the traverse grinding process. The performance of the proposed optimization system is evaluated by simulation research.

scholarly journals Study on the Effect of Grinding Pressure on Material Removal Behavior Performed on a Self-Designed Passive Grinding Simulator

2021 ◽  
Vol 11 (9) ◽  
pp. 4128
Author(s):  
Peng-Zhan Liu ◽  
Wen-Jun Zou ◽  
Jin Peng ◽  
Xu-Dong Song ◽  
Fu-Ren Xiao
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Service Life ◽  
Material Removal ◽  
Removal Rate ◽  
Grinding Force ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Grinding Temperature ◽  
Grinding Efficiency

Passive grinding is a new rail grinding strategy. In this work, the influence of grinding pressure on the removal behaviors of rail material in passive grinding was investigated by using a self-designed passive grinding simulator. Meanwhile, the surface morphology of the rail and grinding wheel were observed, and the grinding force and temperature were measured during the experiment. Results show that the increase of grinding pressure leads to the rise of rail removal rate, i.e., grinding efficiency, surface roughness, residual stress, grinding force and grinding temperature. Inversely, the enhancement of grinding pressure and grinding force will reduce the grinding ratio, which indicates that service life of grinding wheel decreases. The debris presents dissimilar morphology under different grinding pressure, which reflects the distinction in grinding process. Therefore, for rail passive grinding, the appropriate grinding pressure should be selected to balance the grinding quality and the use of grinding wheel.

Analysis of the Tribological Conditions in Grinding of Polycrystalline Diamond Based on Single Grain Friction Tests Using the Pin-Disk Principle

2018 ◽  
Vol 767 ◽  
pp. 259-267 ◽  
Author(s):  
Frederik Vits ◽  
Daniel Trauth ◽  
Patrick Mattfeld ◽  
Rudolf Vits ◽  
Fritz Klocke
Keyword(s):  
Contact Zone ◽  
Material Removal ◽  
Polycrystalline Diamond ◽  
Grinding Wheel ◽  
Grinding Process ◽  
State Variables ◽  
Wheel Wear ◽  
Grinding Wheel Wear ◽  
Single Grain ◽  
Zone Temperature

Cutting tools made of polycrystalline diamond (PCD) are used for machining of aluminum alloys, fiber-reinforced plastic composites and wood. Compared to cemented carbide tools with geometrically defined cutting edges, PCD tools offer significant advantages with respect to tool life. High demands regarding the cutting edge roughness and the quality of the rake and the flank face usually require a grinding process with diamond grinding wheels. The PCD grinding process, however, is characterized by low material removal rates and high grinding wheel wear. The material removal rate and the grinding wheel wear, in turn, highly depend on the process state variables process force and process temperature. However, the relationship between these process state variables and the process input variables is largely unknown. This work provides a contribution to the closure of this knowledge gap by means of an adapted friction law. A single grain friction test stand using the pin-disk principle was developed, which enables a measurement of the friction force and the contact zone temperature for normal forces and relative speeds that are common in PCD grinding. During the experiments, the specification of the PCD disc, the cross-sectional area of the friction sample made of monocrystalline diamond as well as the process parameters normal force and relative speed were varied. In addition, the tests were carried out without lubrication as well as with a minimum lubrication. A high correlation between the contact force and the coefficient of friction was determined. This relationship was mathematically formulated in a friction law. In addition, a direct influence of the contact force and the relative velocity on the contact zone temperature was identified. The knowledge gained leads to an improved understanding of the PCD grinding process and thus enables a more efficient grinding process design.

scholarly journals Model Based on an Effective Material-Removal Rate to Evaluate Specific Energy Consumption in Grinding

Materials ◽  
2019 ◽  
Vol 12 (6) ◽  
pp. 939 ◽  
Author(s):  
Amelia Nápoles Alberro ◽  
Hernán González Rojas ◽  
Antonio Sánchez Egea ◽  
Saqib Hameed ◽  
Reyna Peña Aguilar
Keyword(s):  
Energy Consumption ◽  
Material Removal Rate ◽  
Specific Energy ◽  
Chip Formation ◽  
Material Removal ◽  
Removal Rate ◽  
Specific Energy Consumption ◽  
Industrial Scale ◽  
Depth Of Cut ◽  
Grinding Process

Grinding energy efficiency depends on the appropriate selection of cutting conditions, grinding wheel, and workpiece material. Additionally, the estimation of specific energy consumption is a good indicator to control the consumed energy during the grinding process. Consequently, this study develops a model of material-removal rate to estimate specific energy consumption based on the measurement of active power consumed in a plane surface grinding of C45K with different thermal treatments and AISI 304. This model identifies and evaluates the dissipated power by sliding, ploughing, and chip formation in an industrial-scale grinding process. Furthermore, the instantaneous positions of abrasive grains during cutting are described to study the material-removal rate. The estimation of specific chip-formation energy is similar to that described by other authors on a laboratory scale, which allows to validate the model and experiments. Finally, the results show that the energy consumed by sliding is the main mechanism of energy dissipation in an industrial-scale grinding process, where it is denoted that sliding energy by volume unity decreases as the depth of cut and the speed of the workpiece increase.

Influence of granularity of grinding stone on grinding force and material removal in the rail grinding process

2018 ◽  
Vol 233 (2) ◽  
pp. 355-365 ◽  
Author(s):  
Wen-jian Wang ◽  
Kai-kai Gu ◽  
Kun Zhou ◽  
Zhen-bing Cai ◽  
Jun Guo ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Friction Coefficient ◽  
Material Removal ◽  
Grinding Force ◽  
Grinding Process ◽  
Grinding Temperature ◽  
Material Removal Mechanisms ◽  
Rail Grinding ◽  
Grinding Efficiency ◽  
Grinding Stone

The objective of this study is to explore the influence of grinding stone granularity on the grinding force and rail material removal behaviors using a rail grinding friction machine. The results indicate that with the increase in granularity, the grinding force, and friction coefficient in the grinding interface obviously increase, which brings about a rise in the hardness and grinding temperature-rise of rail specimens. The increase in the grinding stone granularity causes a fall in the grinding volume and surface roughness of rail materials and brings about stronger vibration in the grinding interface owing to different material removal mechanisms. In view of the experimental results, the optimization of grinding stone granularity is significant for improving the rail grinding efficiency and surface quality.

Determination of a Dynamic Grinding Model

1997 ◽  
Vol 119 (2) ◽  
pp. 289-293 ◽  
Author(s):  
H. E. Jenkins ◽  
T. R. Kurfess ◽  
S. J. Ludwick
Keyword(s):  
Material Removal ◽  
Process Model ◽  
Normal Force ◽  
Removal Rate ◽  
Control Process ◽  
Power Input ◽  
Grinding Process ◽  
Abrasive Machining ◽  
Dimensional Precision

In precision abrasive machining, it is important to control process variables such as the material removal rate, normal force and power input, as these factors influence surface finish, dimensional precision, and material damage. In this research, a linear grinding process model, with enhancements over past models, is developed relating normal force to material removal rates. Two experimental procedures for the determination of the grinding model’s parameters are presented. Simulations are performed to validate the grinding model. The determined model is found to be a valid representation of the grinding process that should prove useful in adaptive control with real-time parameter estimation.

Analysis of Residual Stress Induced by Hand Grinding Process

2011 ◽  
Vol 681 ◽  
pp. 327-331 ◽  
Author(s):  
Sawsen Youssef ◽  
O. Calonne ◽  
Eric Feulvarch ◽  
P. Gilles ◽  
Hédi Hamdi
Keyword(s):  
Residual Stress ◽  
Experimental Study ◽  
Crack Initiation ◽  
Residual Stresses ◽  
Material Removal Rate ◽  
Surface Integrity ◽  
Material Removal ◽  
Removal Rate ◽  
Grinding Process ◽  
Cup Wheel

Grinding cup wheel is often used in the case of hand grinding which allows an important material removal rate but with secondary concern of surface integrity. Integrity is strongly affected by the process and consequently influences the surface behaviour in terms of resistivity to stress corrosion and crack initiation. This operation is difficult to master in terms of results on the surface and subsurface due to its manual nature. The paper presents results of an experimental study to investigate the residual stresses induced by this hand grinding process.

Experimental Study on Grinding of a Nickel-Based Alloy Using Vitrified CBN Wheels

2011 ◽  
Vol 325 ◽  
pp. 134-139 ◽  
Author(s):  
Zhong De Shi ◽  
Amr Elfizy ◽  
Benoit St-Pierre ◽  
Helmi Attia
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Material Removal ◽  
Removal Rate ◽  
Wheel Wear ◽  
Creep Feed ◽  
Nickel Based Alloy ◽  
Specific Material ◽  
Grinding Power ◽  
Vitrified Cbn

An experimental study is reported on the grinding of a nickel-based alloy using vitrified CBN wheels. This work was motivated by switching the grinding of fir-tree root forms of jet engine blades from creep-feed grinding with conventional abrasive wheels to vitrified CBN wheels. The objective is to explore process limits and practical grinding parameters for judging the switch in terms of overall costs and productivity. Straight surface grinding experiments were conducted with water-based fluid on rectangular blocks at a fixed wheel speed vs = 45 m/s, various depths of cut a = 0.05 - 1.0 mm, and workspeeds vw = 2 - 40 mm/s. Grinding power, forces, surface roughness, and radial wheel wear were measured. Specific material removal rate of 8 mm3/(mm.s) was reached in rough grinding using a wheel dressed for achieving surface roughness Ra = 0.8 µm in finish grinding. It was found that shallow depths of cut combined with fast workspeeds, or less creep-feed modes, are more suitable for achieving high material removal rates with vitrified CBN grinding. Rough grinding is restricted by high grinding temperatures with newly dressed wheels and by chatters with worn wheels.

A Preliminary Study of Surface Integrity and Wheel Wear in the Grinding of Multilayered Thin Film Structures

2014 ◽  
Vol 1017 ◽  
pp. 88-91
Author(s):  
Cheng Wei Kang ◽  
Bing Jun Hao ◽  
Han Huang
Keyword(s):  
Thin Film ◽  
Surface Finish ◽  
Material Removal ◽  
Removal Rate ◽  
Ground Surface ◽  
Depth Of Cut ◽  
Wheel Wear ◽  
Multilayered Thin Film ◽  
Pull Out ◽  
Grinding Conditions

This study aimed to investigate the effect of grinding conditions, including depth of cut and grinding direction, on the material removal and surface finish of multilayered thin film structures. It was found that the increase in depth of cut improved the material removal rate, but worsened the ground surface finish. The grinding perpendicular to the thin films caused less damage and produced better surface than that parallel to the films. The characteristics of wheel wear were also studied. Grit pull-out and micro-fracture should be attributed to the wheel wear.

Genetic Programming for Grinding Surface Roughness Modelling

2012 ◽  
Vol 565 ◽  
pp. 183-189
Author(s):  
Xun Chen ◽  
Asma Alabed
Keyword(s):  
Surface Roughness ◽  
Genetic Programming ◽  
Material Removal Rate ◽  
Surface Finish ◽  
Material Removal ◽  
Removal Rate ◽  
High Accuracy ◽  
Grinding Process ◽  
Reliable Prediction ◽  
Modelling Process

Grinding process is commonly selected for finishing operation because grinding has high accuracy and surface finish with a relatively high material removal rate. One of the most common issues in grinding process planning is to determine grinding condition for required surface roughness. This paper presents a feasibility study on grinding surface roughness modelling using genetic programming (GP) method. It has successfully demonstrated that GP could provide reliable prediction and has advantages over other established methods in terms of dealing with missing data during modelling process.

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