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research-article

Adaptive Grinding Process (AGriPro) - Prevention of Thermal Damage using OPC UA Technique and in-Situ Metrology

[+] Author and Article Information
Steffan Matthias

Institute of Production Engineering, Graz University of Technology, Graz, Austria
matthias.steffan@tugraz.at

Haas Franz

Institute of Production Engineering, Graz University of Technology, Graz, Austria
franz.haas@tugraz.at

Pierer Alexander

Fraunhofer Institute for Machine Tools and Forming Technology, Chemnitz, Germany
alexander.pierer@iwu.fraunhofer.de

Jens Gentzen

Fraunhofer Institute for Machine Tools and Forming Technology, Chemnitz, Germany
jens.gentzen@iwu.fraunhofer.de

1Corresponding author.

ASME doi:10.1115/1.4038123 History: Received March 30, 2017; Revised October 02, 2017

Abstract

The production process grinding deals with finishing of hardened workpieces and is one of the last stages of the value-added production chain. Up to this process step, considerable costs and energy have been spent on the workpieces. In order to avoid production rejects, significant safety reserves are calculated according to the present state of the art. The authors introduce two approaches to minimize the safety margin thus optimize the process' economic efficiency. Both control concepts use the feed rate override of the machining operation as regulating variable to eliminate thermal damage of the edge zone. The first control concept is developed to avoid thermal damage in cylindrical plunge grinding by controlling the cutting forces. Therefore, the industrial standard OPC Unified Architecture (OPC UA) is used for the communication between a PID-controller and the SINUMERIK grinding machine tool control system. For non-circular workpieces, grinding conditions change over the circumference. Therefore, thermal damage cannot be ruled out at any time during the grinding process. The authors introduces a second novel control approach which uses a micro-magnetic measure that correlates with thermal damage as the main control variable. Hence, the cutting ability of the grinding wheel and thermal damage to the workpiece edge zone is quantified in the process. The result is a control concept for grinding of non-circular workpieces, which opens up fields for major efficiency enhancement. With these two approaches grinding processes are raised on higher economic level, independently of circular and non-circular workpiece geometries.

Copyright (c) 2017 by ASME
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