Grinding Machine Tool Research Articles

New Development of Supersonic Surface Grinding Machine Tool with a Linear-Motor-Driven Table System

New Development of Supersonic Surface Grinding Machine Tool with a Linear-Motor-Driven Table System

Error Correction of Radial Displacement in Grinding Machine Tool Spindle by Optimizing Shape and Bearing Tuning

Error Correction of Radial Displacement in Grinding Machine Tool Spindle by Optimizing Shape and Bearing Tuning

Development of a novel supersonic grinding machine tool

Ultra-high speed grinding (UHSG) is a significant and promising machining technology for grinding hard-to-cut materials. To study the aerodynamics of the grinding wheel body when the airflow field has subsonic, transonic, and supersonic speed characteristics and to clarify the corresponding influence on the grinding mechanism, this study is carried out to develop a supersonic grinding machine tool capable of high-speed operations at wheel speeds up to 450 m/s while also maintaining high grinding capability. In accordance with main design objectives, a high-performance grinding motorized spindle with a maximum rotational speed of 36,000 r/min and a maximum power of 28 kW is developed. A linear motor feed-driven system is also exploited to satisfy the requirement of maximum reciprocating speed up to 2 m/s. In particular, carbon fiber-reinforced plastic (CFRP) grinding wheel with ceramic-bond cubic boron nitride (CBN) abrasives is manufactured for the UHSG process. Furthermore, some analyses on the developed whole grinding machine tool are also conducted to verify and further improve the performance. Finally, following specific design and performance analysis, a prototype of supersonic grinding machine tool is finally developed.

Influence of the machining conditions when preparing cutting edges with elastic bonded grinding wheels

An appropriated cutting edge geometry can highly contribute to the cutting tools performance and lifetime. But although today many technologies for cutting edge preparation are known each one requires extra equipment and extensive experience in application. The presented technology of manufacturing rounded cutting edges with elastic bonded grinding wheels inside the tool grinding machine deals with those disadvantages. In this context the influence of machining conditions such as cutting speed, feed rate and depth of cut when manufacturing rounded cutting edges with elastic bonded grinding wheels on the size of the resulting cutting edge will be investigated. Additionally the effects of changing the grinding wheel contact condition as well as the grinding strategy on the shape of the resulting cutting edge were analyzed. It will be shown that the machining conditions are suitable to adjust the properties of the rounded cutting edge regarding size and shape.

Energy efficiency assessment of grinding strategy

Purpose – This paper aims to set the framework for measuring the energy performance of a manufacturing process. The availability and affordability of energy is becoming a critical parameter nowadays, affecting the whole lifecycle of the product, and hence the production phase as well. The energy efficiency of the grinding process, as a widely used manufacturing process in the industry, is assessed with regard to the selected process strategies. Design/methodology/approach – To assess the grinding machine tool energy performance, a measuring framework is designed, implemented and validated. The process strategy effect on the energy consumption is experimentally assessed through energy audits of the grinding machine tool. Such energy audits provide better insights into the way subsystems composing a machine tool affect the energy consumption. Findings – It is revealed that the proper selection of process strategy can significantly reduce the energy consumption. The amount of energy consumed for the actual process is less than the energy required for maintaining the processing environment (e.g. for the coolant pump delivering coolant fluid in the processing area). The key finding is that the measuring framework can be used for the understanding and analysis of the energy consumption of the various machine tool components. Additionally, for the grinding process itself, the energy audits indicate that reducing the processing duration can significantly reduce the overall energy. Originality/value – The main novel contribution of the present paper is the development of a measurement framework for assessing the energy consumption of subsystems running simultaneously when processing a workpiece. Grinding process energy demand is analysed in detail, allowing for the first time to consider energy consumption as a manufacturing decision criterion.

Kinematic analysis and feedrate optimization in six-axis NC abrasive belt grinding of blades

The purpose of this paper is to propose a kinematic analysis and optimization method for a kind of six-axis numerical control (NC) belt grinding machine tools when grinding blades. Six-axis NC abrasive belt grinding machine tools have been widely used for grinding blades in the aero engine manufacturing enterprises. Kinematic analysis and feedrate optimization play an important role in efficient machining with NC machine tools. After analyzing the basic kinematic relation of the six-axis NC abrasive belt grinding machine tool, coordinate systems are established to calculate the generalized kinematics model. The formulas of the rotary angles and the motion coordinates are provided by simultaneously transforming the three vectors which control the motions of the abrasive belt contact disk. An efficient strategy for feedrate optimization is developed to meet the accuracy requirements of blade abrasive belt grinding process. Both the load capacity of process system and the servo drive capability of machine tools are considered. The validity is demonstrated with simulations and experiments on a TX6-1000HV computer numerical control (CNC) machine tool.

The Design of NC Spherical Turning and Grinding Machine Tool

With the requirements of machining develop towards high precision, high efficiency, intelligentization, combination and greenization, in this paper we develop a NC spherical turning and grinding machine tool with high precision and combination to meet the brisk demand of market for spherical workpieces with large diameter and high precision. According to the enterprises’ practice results ,our machine tool can finish machining of large diameter and high precision sphere quickly, with high quality and low cost, and it has a high practical value.

Degradation analysis of grinding machine spindle systems based on complexity

In order to monitor the degradation statuses of the spindle systems of machine tool during use, a degradation analysis method based on the complexity is proposed. In this article, the workpiece spindle systems of the grinding machine tool are taken as research object. First, the vibration signals of the workpiece spindle systems in X2 direction are monthly measured from April to October. The complexity values per month of the filtered vibration signals in X2 direction are calculated by Lempel–Ziv algorithm and are used as the index to monitor the degradation statuses of the workpiece spindle systems during 6 months running. The results show that the complexity values of the measured vibration signals from April to October gradually increase, and the status of the workpiece spindle systems of the grinding machine tool has a slight degradation. Finally, in order to verify the validity of the proposed method, the degradation bearing data published by Case Western Reserve University are used to verify the feasibility, and the result shows that the complexity is effective to the degradation analysis of the spindle systems of machine tool.

Modal Analysis of Artificial Granite Grinding Machine Tool Bed

Machine tool bed, which supports headstock, tailstock and other functional components, is one of the important structure parts of machine tools. Precision grinding machine tool beds are designed by the authors with artificial granite and cast iron respectively for research. Their three-dimensional models were established via software SOLIDWORKS and then imported into the finite element software (ANSYS) to simulate for the first eight modal frequencies and the corresponding vibration modes. Simulation results show that the first eight order natural frequencies of artificial granite bed are better and the corresponding maximum amplitude of vibration modes are decreased significantly than cast iron bed. The dynamical properties of artificial granite bed are obviously better than grey cast iron bed.

Research on the Evaluation of Small Sample Reliability for CNC Grinding Machine Tools Based on Bayes Theory

Aiming at the limitation by the high cost of test and length cycle process of the CNC grinding machine reliability evaluation, this article adopted small sample technology which needs less data while getting higher evaluation accuracy, by using the theory of Bayes theorem and failure rate as of the random variables, the experiment data of tracking CNC grinding machine for a year is analyzed. Results indicate that results acquired by this mean are consistent with the actual; meanwhile, it shortens test cycle and reduces cost, which is a very effective way to analysis CNC grinding machine. Therefore, it’s very essential that the small sample technology research is applied in the CNC grinding machine evaluation.

볼 엔드밀 헬릭스 각에 따른 절삭 특성

Development of five axis tool grinding machine and CAD/CAM systems increase tool design flexibility. In this research, investigated are cutting characteristics of ball-end mill with different helix angle. Special WC ball-end mills with 0o, 10o, 20o, 30o helix angles are designed and used in various cutting tests. Machining performance according to helix angle variation is evaluated from cutting forces, surface roughness, tool wear, produced chip shape, and vibration characteristics. The ball-end mill with 10o helix angle shows the best cutting performance due to appropriate chip load distribution and smooth chip flow. This research can be used for cutting edge geometry optimization and novel design of ball-end mill.

Error Modeling Analysis of Face-Gear NC Grinding Machine

Based on the multi-body system theories and used the homogeneous coordinate transform. Systematically analyzed the geometric error and thermal error of face gear NC grinding machine. Established the face gear NC grinding machine of grinding mathematical model of comprehensive error according with the mechanism grinding errors,To provide a theoretical basis of the error modeling analysis and the error compensation on NC grinding Machine Tool of face-gear.

A new design and grinding algorithm for ball-end milling cutter with tooth offset center

Ball-end milling cutter with tooth offset center is widely used in machining industry, because it has higher machining efficiency and better stability compared with the ball-end milling cutter without tooth offset center. In addition, the tooth offset center has lower wear rate of the tool tip so the life of the milling cutter is improved. However, up to present, there is no mature and effective theory for the design and manufacture of this kind of milling cutters. This article presents a new mathematical model for S-shaped edge curve of the ball end taking the tooth offset center into account, which can construct accurate S-shaped edge curve for the ball-end cutting tools with tooth offset center as well as without tooth offset center. This model overcomes the complex computation and bad adaptability of the traditional modeling method. At the same time, a five-axis grinding algorithm for rake face of the ball end is also presented in this article. Finally, based on the application programming interface of CATIA™, a three-dimensional computer-aided design and computer-aided manufacturing system is developed. The accuracy and effectiveness of the grinding algorithm are verified by simulation in VERICUT™ and machining experiment in tool grinding machine.

Finite Element Analysis for Static Stiffness of a Crankshaft Grinding Machine Tool

Taking a grinding machine tool as an example, this paper obtained the static stiffness of the machine tool by finite element analysis method. The structure and technical parameters of the machine tool were introduced at first.Then, the finite element model of the machine tool was established. The static stiffness of the machine tool in x-, y-, and z-directions were simulated at last. The results show that, the static stiffness in x-direction is 2.0062×107 N/m, the static stiffness in y-direction is 0.821×107 N/m, and the static stiffness in z-direction is 0.2992×107 N/m. This paper provides advices for structure optimization of the machine tool which is convenient for improving the machining accuracy.

A study on the grinding of the major flank face of error-free spur slice cutter

A grinding method for the major flank face of error-free spur slice cutter is proposed according to urgent demand for the slice cutter in practical production. The geometrical characteristic of the major flank face is analyzed based on the surface Gaussian curvature. On this basis, the grinding motion model based on B-type CNC five-axis tool grinding machine is built. The grinding point path planning method according to the accuracy requirement of the major flank face is proposed. The interference checking and avoiding method is also found. The major flank face of a slice cutter is grinded based on the above study result. As a result, the machining error of the major flank face is less than 0.01 mm and the surface roughness is Ra0.3. This result meets the accuracy requirement that the machining error and surface roughness of the major flank face need to be respectively less than 0.01 mm and Ra0.4. The machining example shows that the study result in this paper is valid for the major flank face grinding. This paper provides a technical support for the manufacturing of error-free spur slice cutter.

Ultra-High-Speed Grinding — Theoretical Basis and Development of a Grinding Machine Tool

This study describes the theoretical basis of ultra-high-speed grinding. In addition, a new grinding machine tool whose maximum grinding speed can reach 450m/s has been recently developed, particularly, some of main components are basically discussed. Finally, this paper concludes with a presentation of current work and some future desirable plans in the area of ultra-high-speed grinding by means of the developed grinding machine tool.

Finite Element Analysis for Critical Components of Ultra-Precision Grinding Machine Tool

The ensemble static stiffness of machine tool is its ability to maintain smooth working condition and resist a variety of loads. As the dispensable part of ensemble static stiffness, critical components stiffness plays a significant role in the performance of the ultra-precision grinding machine tool. In this paper, a three-axis CNC grinding machine tool for the ultra-precision mirror surface grinding of advanced materials such as ceramics and other hard and brittle materials has been designed. And the stiffness and modal parameters of the grinding machine tool are discussed using finite element software. The results are presented and discussed thoroughly. This in turn can help to revise design defects and reduce research and develop costs.

Fuzzy Reliability Allocation of CNC Grinding Machine Tools

Reliability allocation influence factors of CNC grinding machine tools are mostly uncertain and the fuzzy method is one powerful tool for uncertain question. The reliability allocation influence factors were analyzed and the subsystems were divided of CNC grinding machine tools. Reliability allocation weight calculation method by fuzzy mathematics is proposed and the reliability is allocated to subsystem of CNC grinding machine tools by given condition. Fuzzy reliability allocation method considering various factors is practical, accurate and it can be used in concept design of CNC grinding machine tools.

Research on CNC Grinding Program of Overall End Milling Cutter

With high precision special rotary tool is widely used in automotive, mold, aerospace, machinery, electronics and other fields, the demand of manufacturing for such type and quantity of cutting tool is more and more big, lead to the demand for multi-axis CNC tool grinder which provides efficient, high quality production support for it also increasing. In terms of hardware and software multi-axis CNC tool grinder in developed countries are relatively mature, but domestic did not have enough for this research, especially for development of CNC tool grinding machine operation software system, and rarely reference data. In view of the domestic manufacturer in urgent need of independent research and development of CNC tool grinder, this article will research tool grinding automatic programming and simulation technology of CNC tool grinding machine operation software system, through analyzing the four main steps of NC grinding four-blade overall end milling cutter, parametric programming with MATLAB, and grinding trajectory data in the form of mixed programming of MATLAB and VC+ + will be post processed into NC programs, then simulation in VERICUT virtual machine tool, finally the actual grinding out overall end milling cutter.

A New Method for the Preparation of Cutting Edges via Grinding

In this paper, a new method for the preparation of cutting edges via grinding is presented. This method enables the manufacturing of the tool macro and micro geometry in one setup without reclamping, allowing improved flexibility, repeatability and accuracy at reduced processing times. This new method is path controlled using a special elastic bond for the grinding wheels. By using elastic bond, a rounded cutting edge instead of undesired chamfers can be achieved, as the bond nestles around the cutting edge and elastically deforms. The elastic bond is specified by the grain concentration and its basic hardness. Besides the specifications of the bond, the process kinematics highly influences the properties of the cutting edge. The kinematics is a combination of the tool path (machining strategy) and the grinding wheel geometry. The presented experiments include the examination of three different kinematics using three different grinding wheel geometries, FEPA 1A1, 1V1 and 4A2. For each kinematics, three different grain concentrations and three degrees of basic bond hardness were tested, resulting in a complete amount of 27 parameter combinations. The outer diameter cutting edges of cemented carbide milling tools (end mills) were prepared in a 5-axis tool grinding machine. The shape and quality of the achieved cutting edge rounding was qualitatively evaluated by means of scanning electron microscopy (SEM).