Abstract
The grinding normal force is one of the main factors that affect grinding quality. We report on the development of a compact grinding tool which not only can rotate the grind wheel but also can actively control the wheel in the fore/aft direction to modulate the contact force. The two motion degrees of freedom are coupled in the sense of mechanism yet their motions are independent. The designed grinding tool was modeled and its parameters were systemically identified. A repetitive controller was designed to suppress periodic force variation, which was mainly caused by the rotational motion of the grinding wheel, and the results were compared with other control methods. The selection of the grinding parameters was conducted using the Taguchi method. Finally, the grinding tool and the repetitive controller were experimentally evaluated, and the experimental results confirm that the proposed control strategy can reduce the force disturbance and improve the surface quality of the flat and curvy workpieces.
Highlights
The grinding process is regarded as an essential part of machining in the metal manufacturing industry
To make the simulation as realistic as possible, a periodic disturbance which consisted of a base frequency and a resonance frequency was added at the output of the plant to simulate the force vibration caused by the interaction between the grinding wheel and the workpiece
The peak filter can suppress the base frequency, the resonance frequency still variated the tracking performance while the repetitive controller reduced the magnitude of the oscillation caused by the disturbance with different frequency
Summary
The grinding process is regarded as an essential part of machining in the metal manufacturing industry. While the grinding wheel spins, the grinding tool is capable of a highly dynamic and actively controlled fore/aft motion to adjust the normal contact force in real time. A simple yet rigid structure is desired Based on these criteria, a hollow voice coil motor (HVCM) was utilized for fore/aft motion of the grinding wheel, where the motor could perform large and rapid force output compared with other linear actuators. To reduce the payload of the HVCM, the BLDC should be mounted at the fixed end, and only the grinding wheel should be moved by the HVCM for fore/aft motion. The moving tool frame was designed to mount the grinding wheel (No 11), which can simultaneously rotate and move in the fore/aft direction for position and force adjustment. The overall length of the grinding tool is only about 20 cm, and its weight is only 4 kg, so it can be mounted and operated on the end of the mainstream manipulator
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