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Research Papers

Avoiding Chatter in Traverse Cylindrical Grinding by Continuous Workpiece Speed Variation

[+] Author and Article Information
J. Alvarez

e-mail: jalvarez@ideko.es

J. I. Marquinez

IK4-IDEKO S.COOP.,
Pol. Industrial de Arriaga, 2.
Elgoibar 20870, Spain

N. Ortega

Faculty of Engineering of Bilbao,
Alda. Urquijo s/n,
Bilbao 48013, Spain

I. Gallego

Faculty of Engineering,
Mondragon University,
Loramendi 4,
Mondragon 20500, Spain

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received March 15, 2013; final manuscript received June 4, 2013; published online September 11, 2013. Assoc. Editor: Tony Schmitz.

J. Manuf. Sci. Eng 135(5), 051011 (Sep 11, 2013) (5 pages) Paper No: MANU-13-1094; doi: 10.1115/1.4024820 History: Received March 15, 2013; Revised June 04, 2013

Regenerative chatter is one of the main limiting factors in traverse cylindrical grinding since it involves loss of productivity, geometric inaccuracies, superficial marks, and increase of roughness. Continuous workpiece speed variation is demonstrated to be an efficient method among chatter suppression techniques but variation parameters (amplitude and frequency) are normally selected based on trial-and-errors. Therefore, a dynamic stability approach is proposed in which optimal combination of these parameters is defined based on semidiscretization technique, which consists of obtaining the eigenvalues of the transition matrix between consecutive workpiece rotations. Validation is carried out experimentally and good correlation between simulated and experimental results is achieved. Best combinations of variation parameters are achieved with amplitudes higher than 10% of the nominal workpiece speed and frequencies lower than 1 Hz. Then, the optimal parameters of continuous workpiece speed variation for chatter suppression can be predicted theoretically via semidiscretization. The application of this suppression technique has been successfully assessed for traverse cylindrical grinding.

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Copyright © 2013 by ASME
Topics: Grinding , Chatter
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Figures

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Fig. 1

Cylindrical traverse grinding model

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Fig. 2

Instability reduction map for combination of CWSV parameters: amplitude and frequency

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Fig. 3

Stability map for cylindrical traverse grinding via semidiscretization. Comparison between theoretical and experimental results.

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Fig. 4

Map of instability degree reduction ratio. Comparison of theoretical and experimental results.

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Fig. 5

Accelerometer signal FFTs for different combinations of CWSV parameters

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Fig. 6

Roundness for each CWSV combination: (a) without CWSV; (b) A = 5%, f = 2 Hz; (c) A = 25%, f = 2 Hz; (d) A = 25%, f = 0.5 Hz

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