Optimization of Conditions for Non-rigid Workpieces Flat Grinding by Elastic Deformations Controlling

Abstract

The authors propose the technique for optimizing the conditions for non-rigid workpieces end surfaces flat grinding that guarantees obtaining the pre-defined quality requirements of the machined surface (surface roughness parameter Ra, absence of grinding burns, required flatness tolerance of end surface) while ensuring the maximum process efficiency.Mathematical models of the cutting force components, grinding ratio, and roughness of the machined surface (Ra parameter) are obtained by the full factorial experiment method. The input factors (grinding wheel hardness, depth of grinding, table feed speed and run) are considered as the grinding process optimization parameters. Mathematical models of the output factors are used to limit the range of optimization parameters allowable values. The resulted efficiency is an objective function. The optimization of parameters in the range of allowable values is carried out with the view of ensuring the maximum process efficiency.The required flatness admission is provided at the second optimization stage of the workpieces by controlling the elastic deformation extent.The varied parameters at controlling the maximum elastic deformation extent are cutting forces and attraction of the machine table magnetic field.The terms for providing of the required end surface flatness tolerance are determined for workpieces taking into account elastic deformation of the non-rigid workpieces under the magnetic field effect on the machine table and the radial component of the grinding force.