Wheel Regenerative Chatter of Surface Grinding

[+] 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), 393-403 (Sep 08, 2005) (11 pages) doi:10.1115/1.2137752 History: Received June 01, 2005; Revised September 08, 2005

In this paper we present a comprehensive dynamic model that simulates surface grinding processes and predict their regenerative chatter characteristics. The model considers special aspects in surface grinding processes, such as interrupted grinding on a series of surfaces and step-like wheel wear along the axial direction due to crossfeed. A new theory for the wheel regenerative chatter mechanism, which describes the regenerative force as a function of not only the instantaneous chip thickness but also the distributed uneven grit wear/dullness, is introduced and applied in the model. Using the model, explanations are provided for those unrevealed wheel regenerative chatter phenomena observed from the experimental results in literature. The model is validated by comparing the simulated chatter frequencies and thresholds with the experimental results.

Copyright © 2006 by American Society of Mechanical Engineers
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Figure 1

Three tests by Thompson (6) with different fixture setups under the chatter condition, which show that dominant chatter frequencies are very close to multiplications of an integer n and wheel rotational speeds: The spikes on the top show the marks per wheel revolution, and the waves on the bottom are the vibration signal

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Figure 2

Multiple chatter frequencies that are approximately multiplicities of the wheel rotational speed (13)

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Figure 3

The chatter frequencies and their second harmonics (11)

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Figure 4

Kinematics of surface grinding

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Figure 5

Geometrical interaction between wheel and workpiece

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Figure 6

Wheel wear in the axial direction

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Figure 7

Block diagram for the new theory of wheel regenerative chatter

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Figure 8

Test setup on a MAZAK CNC machine tool

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Figure 9

Instrumentation of grinding experiments

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Figure 10

Average grinding forces for three test cases. (a) Force in normal direction. (b) Force in traverse direction.

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Figure 11

The coefficients of the force in Eqs. 30 and 31. (a) Initial forces per unit width, Fx0′ and Fy0′. (b) Force growth rates, αx and αy.

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Figure 12

G ratio obtained from data of overcut fly milling tests for single grits in (19)

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Figure 13

Measured forces during the chatter development of test case #5. Spindle speed=2000rpm, workpiece speed=84.7mm∕s, depth of cut=30μm.

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Figure 14

Simulated forces and vibration of case #5 in frequency domain under a chatter condition. (a) Force. (b) Spindle vibration.

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Figure 15

Simulated wheel surface generation of case #5 under a chatter condition

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Figure 16

Simulated workpiece surface profile of case #5 under a chatter condition

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Figure 17

Chatter frequencies for different spindle speeds with workpiece speed=84.7mm∕s and depth of cut=30μm. (a) Predicted. (b) Measured.

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Figure 18

Chatter frequencies for different workpiece speeds with spindle speed=2500rpm and depth of cut=30μm. (a) Predicted. (b) Measured.

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Figure 19

Chatter frequencies for different depths of cut with spindle speed=2500rpm and workpiece speed=84.7mm∕s. (a) Predicted. (b) Measured.

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Figure 20

Simulated time history of normal force under a chatter condition

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Figure 21

Simulated peak-to-peak forces in the normal direction with various G ratios. (a) Before scaling. (b) After scaling with factor s.

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Figure 22

Chatter growth represented by peak-to-peak forces. Wheel speed=2000rpm, workpiece speed=200ipm(84.7mm∕s), depth of cut=0.0012 in (30μm).

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Figure 23

Chatter thresholds for different test conditions. (a) Depth of cut=0.0012in.(30μm), workpiece speed=200rpm(84.7mm∕s). (b) Wheel speed=2500rpm, workpiece speed=200ipm(84.7mm∕s). (c) Wheel speed=2500rpm, depth of cut=0.0012in.(30μm).



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