A Time-Domain Dynamic Model for Chatter Prediction of Cylindrical Plunge Grinding Processes

[+] Author and Article Information
Hongqi Li, Yung C. Shin

School of Mechanical Engineering, Purdue University, West Lafayette, IN 47907

J. Manuf. Sci. Eng 128(2), 404-415 (Feb 20, 2005) (12 pages) doi:10.1115/1.2118748 History: Received November 30, 2004; Revised February 20, 2005

This paper presents a time-domain dynamic model, which simulates cylindrical plunge grinding processes under general grinding conditions. The model focuses on the prediction of grinding chatter boundaries and growth rates. Critical issues are considered in the model including: the distributed nonlinear force along the contact length, the geometrical interaction between the wheel and workpiece based on their surface profiles, the structure dynamics with multiple degrees of freedom for both the wheel and workpiece, the response delay due to spindle nonlinearities and other effects, and the effect of the motion perpendicular to the normal direction. A simulation program has been developed using the model to predict regenerative forces, dynamic responses, surface profiles, stability regions, and chatter growth rates. The model is validated using existing numerical and experimental results.

Copyright © 2006 by American Society of Mechanical Engineers
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Figure 4

Uncut chip thickness variation due to vibration

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Figure 5

Flow chart for simulation of cylindrical plunge grinding processes

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Figure 6

Stability region obtained using the analytical method in Ref. 20

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Figure 7

Contours of growth rate exponents

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Figure 8

Contours of decay rate exponent

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Figure 9

Peak-to-peak force for various grinding width

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Figure 10

Stability region obtained from growth of peak-to-peak force

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Figure 11

Stability region obtained from growth of peak-to-peak force

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Figure 12

Contours of growth rate exponents with consideration of speed ratios

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Figure 13

Contours of the growth rate exponents in a lower workpiece speed range

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Figure 14

Chatter generation process on the surface of wheel and workpiece

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Figure 15

Relative chatter amplitude

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Figure 18

Geometry relationship between the depth of cut and immersion angle

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Figure 3

Geometrical interaction between wheel and workpiece

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Figure 2

Kinematics of internal plunge grinding

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Figure 1

Kinematics of external plunge grinding

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Figure 17

Comparison of chatter boundary

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Figure 16

Comparison of chatter boundary




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