Abstract
Wheel-sided chatter vibration is a limiting factor in terms of productivity and surface finish regarding the application of conventional grinding wheels. Due to the formation of waviness on the grinding wheel during the process, many expensive trueing cycles are necessary. Therefore, a system for chatter detection and elimination for external cylindrical grinding machines was presented in previous work. It was demonstrated that an electromagnetic actuator reduces the generation of the grinding wheel waviness. The control of this actuator requires precise knowledge about frequency, amplitude, and phase of the chatter vibration. This information is extracted from two eddy-current sensors, which measure the workpiece displacement. However, a direct measurement of the workpiece displacement restricts the working area and is inflexible. Hence, this paper explores the qualification of sensors integrated into the grinding machine for extracting the aforementioned information with high accuracy of phase. For this purpose, two acceleration sensors mounted on the workpiece spindle and the tailstock, an acoustic emission (AE) sensor applied to the grinding wheel, and the motor current of the directly driven headstock spindle are considered. To determine the suitability of these sensors, the frequency response function (FRF) for each sensor is calculated under three conditions: no contact between the workpiece and the grinding wheel, the grinding wheel tensed to the workpiece without a grinding process, and during the process. The method for the in-process measurement of the sensor FRFs and the influence of the contact conditions on these FRFs is shown in this paper.
Similar content being viewed by others
References
Wegener K, Hoffmeister H-W, Karpuschewski B, Kuster F, Hahmann W-C, Rabiey M (2011) Conditioning and monitoring of grinding wheels. CIRP Ann Manuf Technol 60(2):757–777
Altintas Y, Weck M (2004) Chatter stability of metal cutting and grinding. CIRP Ann Manuf Technol 53(/2):619–642
Aurich J, Linke B, Hauschild M, Carrella M, Kirsch B (2013) Sustainability of abrasive processes. CIRP Ann Manuf Technol 62(/2):653–672
Badger J, Murphy S, O’Donnell G (2011) The effect of wheel eccentricity and run-out on grinding forces, waviness, wheel wear and chatter. Int J Mach Tools Manuf 51(10–11):766–774
Tönshoff HK, Kemmerling M, Tellbüscher E (1985) Quick actuators: new possibilities and applications. CIRP Ann Manuf Technol 34(/1):515–518
Hoshi T, Matsumoto S, Mitsui S (1986) Suppression of wheel regenerative grinding vibration by alternating wheel speed. Ann CIRP 35(12):231–234
Spur G, Rogel E (1984) Optimierung des dynamischen Schleifprozesses durch Periodische Drehzahlvariation. Zeitschrift für wirtschaftliche Fertigung 79(/7):337–343
Cuntze, E.O. (1966) Entstehung und Minderung von Ratterschwingungen beim Schleifen, Dr.-Ing. Dissertation, TH Braunschweig
Gosebruch H (1987) Active damping of dynamic interactions in grinding machines. In: Inman, D. J. (ed.) Vibration control and active vibration suppression: presented at the 1987 ASME Design Technology Conferences-11th Biennial Conference on Mechanical Vibration and Noise, Boston, Mass., Sep 27-30, 4:147–152
Michels, F (1999) Stabilisierung des Schleifprozesses mit aktiven Systemen, Dr.-Ing. Dissertation, RWTH Aachen
Ahrens M, Fischer R, Dagen M, Denkena B, Ortmaier T (2014) Active chatter damping in plunge grinding using magnetic actuators, Proceedings of the ASME 2014 International Manufacturing Science and Engineering Conference, MSEC2014, June 9-13, Detroit, Michigan, USA
Ahrens M, Fischer R, Dagen M, Denkena B, Ortmaier T (2013) Abrasion monitoring and automatic chatter detection in cylindrical plunge grinding. Procedia CIRP 8:374–378
Funding
The authors would like to thank the German Research Foundation (DFG) for their support and funding of the associated project within the Project DE447/89.
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher’s note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Denkena, B., Ortmaier, T., Bergmann, B. et al. Suitability of integrated sensors for the determination of chatter characteristics in a cylindrical grinding machine. Int J Adv Manuf Technol 102, 2339–2344 (2019). https://doi.org/10.1007/s00170-019-03323-y
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-019-03323-y