Fast on-machine profile characterization for grinding wheels and error compensation of wheel dressing

Abstract

Fast on-machine measurement of grinding wheel profiles is imperative for monitoring grinding wheel wear and wheel dressing accuracy. However, directly measurement of wheel profiles is considerably challenging due to harsh machining conditions. In this study, a novel method for fast vision based on-machine characterization of a grinding wheel profile was investigated based on a self-developed profile grinding machine. A new vision system was developed for the on-machine measurement of grinding wheel profiles and a calibration method for the vision system was introduced. A methodology for precisely measuring wheel profiles and for quantifying wheel wear was developed. The reliability and measurement accuracy were testified. Finally, segmented representation and compensation method were developed for wheel dressing. The experimental results revealed that the proposed method can achieve fast on-machine characterization of profile errors of the grinding wheel, and the wheel dressing accuracy was effectively improved based on the in-situ monitoring of the wheel dressing error.