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TECHNICAL PAPERS

A Time Domain Dynamic Simulation Model for Stability Prediction of Infeed Centerless Grinding Processes

[+] Author and Article Information
Hongqi Li

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

Yung C. Shin

School of Mechanical Engineering, Purdue University, West Lafayette, IN 47907shin@ecn.purdue.edu

J. Manuf. Sci. Eng 129(3), 539-550 (Oct 26, 2006) (12 pages) doi:10.1115/1.2716729 History: Received July 31, 2006; Revised October 26, 2006

This paper presents a comprehensive dynamic model that simulates infeed centerless grinding processes and predicts their instability-related characteristics. The new model has the unique ability of accurately predicting the coupled chatter and lobing process of a multi-degree of freedom and two-dimensional centerless grinding system by considering its critical issues. First, the model considers the complete two-dimensional kinematics, dynamics, surface profiles, and the geometrical interactions of the workpiece with the grinding wheel, regulating wheel, and supporting blade. Second, a two-dimensional distributed grinding force model along the contact length is adopted and modified for centerless grinding processes as a function of normalized uncut chip thickness. The forces of the work holding system are determined by balancing the grinding force and accordingly the work holding instability can be identified as well. Third, a two-dimensional contact deformation model under the condition of general surface profiles or pressure distributions is developed for the contacts of the workpiece with the grinding wheel, regulating wheel, and supporting blade. The new model is validated by comparing the predicted chatter and lobing occurrences with experimental results.

Copyright © 2007 by American Society of Mechanical Engineers
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References

Figures

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Figure 1

Geometric arrangement in centerless grinding

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Figure 2

Kinematics of centerless grinding

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Figure 3

Workpiece center position for ideal workpiece surface

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Figure 4

Workpiece center position for undulated workpiece surface

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Figure 5

Velocities and accelerations of workpiece

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Figure 6

Forces acting on the workpiece

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Figure 7

Geometrical interaction between grinding wheel and workpiece

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Figure 8

Measured E modulus of a wheel with vitrified bond and grit size of 60 (34)

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Figure 9

Grinding pressure (dash line) and wheel deformation (solid line)

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Figure 10

Wheel surface variation due to deformation

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Figure 11

Chip thickness variation due to wheel deformation

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Figure 12

Local deformation between workpiece, regulating wheel and supporting blade with consideration of undulated workpiece surface

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Figure 13

Iterative solution of local deformation between workpiece, regulating wheel and supporting blade with consideration of general contact surface profiles

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Figure 14

Comparison of chatter/stable conditions. The legend “Sim” represents the simulated results, while “Exp” represents experimental results in Ref. 18 and the solid lines represent the derived chatter boundary approximation in Ref. 18.

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Figure 15

Comparison of simulated chatter/stable conditions in Fig. 1 with the predicted chatter boundaries in Ref. 18. The regions bounded by solid lines are the predicted chatter regions in Ref. 18.

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Figure 16

Surface profiles for center height angle of 1.5deg(μm): (a) initial surface; (b) predicted finished surface; and (c) measured finished surface

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Figure 17

Surface profiles for center height angle of 2.5deg(μm): (a) initial surface; (b) predicted finished surface; and (c) measured finished surface

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Figure 18

Surface profiles for center height angle of 4deg(μm): (a) initial surface; (b) predicted finished surface; and (c) measured finished surface

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Figure 19

Surface profiles for center height angle of 6deg(μm): (a) initial surface; (b) predicted finished surface; and (c) measured finished surface

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Figure 20

Finished surface profiles (μm): (a) and (b): center height angle of 8deg, lobe number of 22; (c) and (d) center height angle of 10deg, lobe number of 16; and (e) and (f) center height angle of 12deg, lobe number of 16

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Figure 21

Elastic half-space with uniform pressure distribution

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