AI-Integrated Thermal Prediction and Multi-Criteria Optimization in Cylindrical Grinding Using Machine Learning and Genetic Algorithms

To explore the effects of support stiffness and grinding media shape on the superfine grinding performance of wheat bran, a vibration grinding platform with adjustable support stiffness (25 to 55 kN/m) was used for tests with stainless steel spherical grinding media (SGM) and cylindrical grinding media (CGM), respectively. The results showed that both factors significantly affected the grinding effect. When stiffness exceeded 35 kN/m, micro powder quality and yield improved for both media. Below 35 kN/m, SGM’s micro powder quality deteriorated, while CGM’s micro powder quality peaked at 30 kN/m. At 30 kN/m, fine powder, micro powder, and superfine powder yields reached their maximum for both media. The mass fraction of superfine powder was 52.9% for CGM, and that of SGM was 29.3% higher than at 35 kN/m. SGM consistently produced better particle size distribution than CGM, with the smallest median particle size (D50) difference (21.5%) at 30 kN/m. The superfine yield of CGM was not always higher than that of SGM. Their mass fraction difference showed a quadratic nonlinear relationship. A coupling effect between media shape and stiffness was found to determine grinding performance. Overall, this work provides a basis for optimizing the superfine grinding performance of wheat bran in vibration mills.

Effects of ultrasonic vibration on the machining mechanism of internal cylindrical ultrasonic-assisted electrochemical hybridized grinding of bearing ring: Experimental study

The grinding wheel wear condition monitoring method based on multi-sensor information hierarchical fusion for high-speed cylindrical grinding

Abstract There is a need to develop new chemical protection concepts for water-based cooling lubricants (CL) against microbial infestation. To this end, research was carried out into potential active substances that can be obtained or produced from renewable raw materials. In this project, seven substance groups with more than 70 compounds were identified and subjected to a literature-based suitability assessment. The substances with good expected suitability could be assigned to two groups according to their antimicrobial effect: minimum inhibitory concentration (MIC) 0.25–1% (e.g. terpenes, coumarins) and MIC 5–30% (e.g. divalent and trivalent alcohols). The former should be incorporated into the CL as additives, the latter should rather be classified as base fluid components. Chemical-physical, tribological and biological tests were carried out in the laboratory. Interestingly, in the microbiological tests with a test duration of 20 d, a complete biostatic but no biocidal inhibitory effect was found for all the active ingredients considered. In a CL reference formulation, glycerol was replaced by the newly identified active ingredient 1,6-hexanediol as an example. This formulation was successfully tested in an industrial machine for cylindrical grinding of steel, demonstrating the immediate applicability for machining. Thus, a comprehensive research and development strategy for novel CL additives is presented which can be used for all identified antimicrobial compounds. Furthermore, it is certainly applicable to novel additives with other performance spectra, as well.

The paper studies the dynamics features of form shaping in external cylindrical grinding taking into account the speed ratio of the grinding wheel and the feed movement of the abrasive tool; assesses the resulting errors on the processed surface of the part. The work develops mathematical dependencies for calculating the main parameters of form shaping; analyses the influence of speed ratios on the dynamics of the grinding process. The obtained results allow predicting the quality of the machined surface and optimizing cutting modes during cylindrical grinding.

The finishing operation (grinding) is a complex task of the field of spiroid worm manufacturing. I am investigating the grinding process of spiroid worm using lathe center displacement on a classical cylindrical grinding machine. The lathe center displacement means the adjustment of the spiroid worm according to the half taper angle to get a horizontal position of the generatix of the taper of the spiroid worm in comparison with the center line of the grinding wheel. In this case the center distance between the spiroid worm and the grinding wheel is permanent during the whole grinding process. This adjustment causes changing angular velocity for the rotation of the spiroid worm that affects to the error of the lead of thread and the error of the position of the pitch circle diameter that can influence the profile accuracy during the whole grinding process.

STUDER has further developed its globally successful CNC universal cylindrical grinding machine with the introduction of its latest favoritCNC model

Grinding, as the most crucial finishing process for bearing rings, influences the surface integrity of bearings through the roughness of the ground surface. In order to improve the surface roughness of bearing ring grinding under multiple working conditions, a prediction model of bearing ring surface roughness based on feature extraction was proposed. Firstly, the signal was decomposed using the Complete Ensemble Empirical Mode Decomposition with Adaptive Noise (CEEMDAN) algorithm, and the sensitive components were selected based on the correlation coefficient between Intrinsic Mode Functions (IMFs) and the original signal. The time-domain, frequency-domain, and entropy-domain features of the selected IMF components were extracted. Then, Principal Component Analysis (PCA) was employed for signal feature fusion, and a feature set was constructed in combination with grinding parameters. A prediction model based on Support Vector Regression (SVR) was established to achieve regression prediction of the grinding surface roughness. The proposed method for predicting the surface roughness of precision cylindrical grinding of bearings demonstrated that the determination coefficient (R2), mean absolute error (MAE), root mean square error (RMSE), and mean absolute percentage error (MAPE) were 0.9953, 0.0020, 0.0050, and 0.0187, respectively. The results indicate that the incorporation of entropy features and grinding parameters in the model provide more information pertinent to grinding surface roughness, thereby effectively enhancing the predictive accuracy.

Explanation of micro lead generation in external cylindrical plunge grinding of radial shaft sealing counterfaces

The study reports an important research gap, as identified from literature surveys revealed, where minimal studies about dry cylindrical grinding processes which require excessive specific energy. The present investigation intends to explore the effect of grinding variables on D3 tool steel in two diverse settings: dry condition and ideas of wet condition. Experimental research has evaluated heat generation levels in dry workpiece grinding compared to the wet grinding process. The Taguchi method has contributed to deriving optimal parameters for achieving favorable tool steel responses during dry and wet grinding processes. Scanning electron microscope evaluation has shown the ground surface of D3 tool steel displays a well-maintained topography. Investigative outcomes demonstrate dry grinding can produce precise surface finishes while maintaining the integrity of workpiece surfaces. The method minimizes adverse effects on the working environment by reducing the need for grinding fluids. When performing dry grinding operations proper feed rates vary from 5 mm/min to 25 mm/min. A feed rate lower than 25 mm/min protects the workpiece surface from thermal harm. Dry grinding with optimal parameters achieved a surface roughness of 0.25 µm, comparable to wet grinding, whereas in the case of roundness error wet grinding yield least value of 0.001 mm and returning a maximum material removal rate of 154.95 g/min. Wet grinding operation requires a coolant flow rate between 5 l/min and 7.5 l/min for optimal results. Wet grinding operations using lower coolant levels or adopting dry grinding methods both allow companies to decrease chemical waste exposure to the working environment, which will reduce the environmental impact.

Evolution mechanisms in cylindrical grinding of ceramic materials: from cylindrical transverse grinding to cup wheel grinding

A novel laser-assisted cylindrical grinding process has been developed to enhance the machining of silicon-carbide-bonded diamond composites (DSiCs), critical for improving the performance and durability of components in subsea pump applications. DSiCs, containing approximately 50% diamond by volume, exhibit excellent mechanical and thermal properties. The conventional grinding of these superhard materials presents challenges such as high grinding forces, elevated temperatures, and significant tool wear. To overcome these difficulties, a laser-assisted cylindrical grinding process has been developed, utilizing ultra-short-pulse laser radiation to induce material ablation with controlled structural damages, thereby reducing grinding forces, temperatures, and tool wear. This research investigates the influence of grinding wheel specifications and grinding parameters on surface quality and tool life. The results indicate modest enhancements in surface integrity, achieving damage-free ground surfaces, and notable improvements in grinding ratio (G-ratio) by up to 247% and actual removal depth by up to 99% compared to conventional grinding. The laser-assisted cylindrical grinding process using vitrified-bonded diamond wheels holds significant promise for advancing subsea pump technology by enabling the use of DSiCs and achieving plateau ground surfaces.

According to the structure of a machine tool, the mathematical model of face gear grinding with a disc grinding wheel is established. The face gear tooth surface equation that contains the machine tool parameter errors is derived, and the influence of the parameter errors on the topological deviation of the tooth surface is analyzed. The experiments on face gear grinding are completed with the cylindrical internal gear grinding machine and detected in the gleason gear detection center. The maximum tooth surface deviation is -24.6 μm, verifying the feasibility of the proposed grinding method and the correctness of the machine tool parameter adjustment method. The use of the general cylindrical internal gear grinding machine to grind face gears without special face gear machine tool is of great significance for the promotion of face gears and the reduction of manufacturing cost.

This paper focuses on the MKE1620A CNC cylindrical grinder, using an equivalent analysis of the joint spring-damping characteristics to investigate the overall performance of the grinder and propose directions for design optimization. A total of 168 spring-damper elements were established to model the fixed, movable, and bearing joints. These elements were classified and calculated to determine their parameters, which were then incorporated into a finite element analysis model to examine the impact of joint stiffness on the static and dynamic performance of the machine tool, with results showing less than a 10% error compared to actual measured data. Additionally, the paper investigates how the quality of six common structural materials influences the first-order natural frequency of components and explores the relationship between variations in joint stiffness and changes in the machine tool’s natural frequency. The findings provide theoretical and data-driven insights for the design and optimization of CNC cylindrical grinding machines, serving as a valuable reference for enhancing machine tool performance and machining quality.

The article conducts a research study on the use of Multi-Criteria Decision-Making (MCDM) in the internal grinding process of SKD11 tool steel. The aim is to identify the optimal input process parameters for the dressing process in order to minimize surface roughness (SR) and maximize wheel life (Lw). The EAMR strategy was employed to address the MCDM task, whereas the Entropy method was utilized to determine the weights of the criterion. The experiment also included the analysis of six input process parameters: coarse dressing depth, coarse dressing passes, fine dressing depth, fine dressing passes, non-feeding dressing, and dressing feed rate. The experiment was performed using an L16 orthogonal array and the Taguchi method. The wheel's durability and the roughness of the sample's surface were quantified and recorded for analysis in the MCDM problem. The research findings have identified the optimal dressing solutions for internal cylindrical grinding.).

Simultaneous cutting and grinding of micropins using cylindrical microtools

Grinding is a material removal procedure used at the end of manufacturing to obtain high dimensional precision and a desirable surface polish. External cylindrical grinding is a type of grinding procedure that used to grind cylindrical things such as engine shafts, connecting rods, spindles, and axles. This study examines how control settings affect response parameters using EN24 alloy steel on a cylindrical grinding machine. Response parameters are material removal rate (MRR) and surface roughness (Ra), whereas control parameters are workpiece speed (v), feed rate (f), and depth of cut (d). Taguchi DOE is employed with L16 orthogonal array to optimize control parameter levels, followed by cylindrical grinding tests.An artificial neural network (ANN) model was created to validate and predict cylindrical grinding reaction parameters. To train the network, experimental data was used, and ANN predictions were compared to real data. Data collection has also completed.In the purposed work minimum Ra is 0.52 µm and maximum MRR is 0.6588 g/sec found and results indicate that feed rate and workpiece speed are the most dominating parameters of cylindrical grinding. The experimental results can be employed by various manufacturing and industrial firms and they can select suitable combinations of input parameters for desired Ra and MRR

Modeling and experimental study of the force and surface topography in cylindrical grinding of GH4169

A machine overhaul by cylindrical grinding machine manufacturer Studer is helping to breath new life into old machines by upgrading their efficiency, performance and precision