Abstract
This paper reports the spatial mathematical modeling of the process of dressing the working surface of grinding wheels for implementing the double-sided grinding of the ends of cylindrical components. Parts with high-precision end surfaces that are commonly used include bearing rollers, piston fingers, crosspieces of cardan shafts, and others. The geometric accuracy of surfaces is ensured by simultaneously grinding the ends at two-sided end-grinding machines with crossed axes of the part and wheels that operate under a self-blunting mode. Before starting the machining, the wheels are dressed in a working position. Moreover, the total orientation angle of the tools is selected subject to the condition of uniform distribution of allowance along the rough sections of wheels. Dressing involves a single-crystal diamond tool with a variable feed. That ensures different development of the surface of abrasive tools, which prolongs their operating time between dressings and improves overall stability. The constant size of micro irregularities at the calibration site enhances the quality of machining. The calibration site is made in the form of a straight line belonging to the plane that passes through the axis of rotation of the wheel and is perpendicular to the plane of the machined part. Based on the spatial mathematical models of the processes of removal of allowance and shape formation when dressing the wheel, the surface of the grinding wheel was investigated. Mathematical models for shaping the ends of parts when grinding with wheels with conical calibration sites have been proposed; it is shown that when applying the proposed machining scheme, there is no geometric error in the size of the part. In addition, due to the uniform distribution of the allowance along the rough area of the wheel, the quality of the surface layer of the ends of parts increases. The devised method for dressing the working surface of wheels could be used to grind the ends of non-circular components.
Highlights
The issue related to improving the accuracy of simulta neous grinding of two ends of round parts can be addressed by conducting spatial mathematical modeling of the processes of removal of allowance and shape formation when dressing grinding wheels while ensuring the straightness of the cone calibration site
We have proposed a scheme for dressing grinding wheels in order to form a straight-line conical calibration site located in a plane that passes through the axis of rotation of the wheel and belongs to the machined workpiece
The presence of such a site eliminates the geometric error in shape formation at the two-side end grinding of round parts
Summary
Trends in the development of the machine-building industry require constant improvement of technological and operational characteristics of various articles, as well as an increase in production performance while reducing its cost; this ensures the competitiveness of individual enterprises and the industry of the state as a whole [1]. Methods of high-quality sharpening are actively developing [3], which significantly reduces energy consumption for machining but the resulting accuracy and quality of the surface are traditionally ensured by finishing operations at grinding machines [4]. The process of control over machining in general and, in particular, the dressing of grinding wheels, is executed using CNC systems Their estimation and geometric basis are the mathematical and spatial models of all elements of the machined system and the model of the process of removal of allowance and shape formation. It is a relevant task to construct and investigate spatial mathematical models for dressing the grinding wheel, the process of removing the allowance, and the shape formation of a part’s ends at the simultaneous double-sided grinding with wheels with cone calibration sites
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