Process monitoring in high efficiency deep grinding- HEDG

Abstract

High Efficiency Deep Grinding (HEDG) is an emerging technology that allows grinding to be undertaken at high wheelspeeds (up to 250 m/s), relatively large depth of cut (1 to 25 mm or more) and extremely high workspeeds up to 1000 mm/s. However, this new technology is not fully understood, thus it needs further investigation into machining requirements in order to develop adequate strategies to control the process. Various sensors are used to monitor the process performance in grinding. Thermocouple technique is commonly used and has advantages of low-cost, ease of use and direct surface temperature measurement. Temperature measurement is particularly challenging in deep grinding with cuts that may exceed 5 mm and high workspeeds approaching 1 m/s. Grinding coolant and electrical noise cause further challenges for achieving accurate and reliable temperature measurement. A single-pole thermocouple technique that provides reliable measurements is presented. This paper presents various grinding force measurement techniques and the thermal modelling that has been used to predict temperature in the HEDG process as a function of cutting parameters. Results obtained for in-process monitoring of the high efficiency deep grinding using the power and temperature measurements are presents.