Effect of Energy Consumption in the Contact Zone on Machining Condition Optimization in Precision Surface Grinding

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CHEN, Yong ;CHEN, Xun ;XU, Xipeng ;YU, Ge .
Effect of Energy Consumption in the Contact Zone on Machining Condition Optimization in Precision Surface Grinding. 
Strojniški vestnik - Journal of Mechanical Engineering, [S.l.], v. 64, n.4, p. 233-244, june 2018. 
ISSN 0039-2480.
Available at: <https://www.sv-jme.eu/article/effect-of-energy-consumption-in-the-contact-zone-on-machining-condition-optimization-in-precision-surface-grinding/>. Date accessed: 01 dec. 2021. 
doi:http://dx.doi.org/10.5545/sv-jme.2017.4995.
Chen, Y., Chen, X., Xu, X., & Yu, G.
(2018).
Effect of Energy Consumption in the Contact Zone on Machining Condition Optimization in Precision Surface Grinding.
Strojniški vestnik - Journal of Mechanical Engineering, 64(4), 233-244.
doi:http://dx.doi.org/10.5545/sv-jme.2017.4995
@article{sv-jmesv-jme.2017.4995,
	author = {Yong  Chen and Xun  Chen and Xipeng  Xu and Ge  Yu},
	title = {Effect of Energy Consumption in the Contact Zone on Machining Condition Optimization in Precision Surface Grinding},
	journal = {Strojniški vestnik - Journal of Mechanical Engineering},
	volume = {64},
	number = {4},
	year = {2018},
	keywords = {precision grinding; energy consumption; eccentrical vibration; machining stability; condition optimization},
	abstract = {The instantaneous energy consumption in the grit-material interaction zone is an important indicator to represent the efficiency of grinding. In contrast to methods based on chip crack and formation or energy consumption from experimental measurement, this paper presents an improved differential model of energy consumption that takes account of dynamic grinding force, forced-vibration induced by the eccentrically grinding wheel rotation, and the phase difference between adjacent regenerative surface waviness. Furthermore, the vibratory amplitude and relevant frequency elements of a wheel-workpiece coupled system are analysed to optimize the key machining conditions involved in spindle speed, pack density of abrasive wheel and effective cutting space of adjacent contour grits in discrete transverse plane. It demonstrates that machining stability is the best when the phase difference value is π/2 between continuously formed adjacent waviness generated by grit-workpiece interaction, i.e. the calculated value of instantaneous grinding energy consumption reaches its maximum value. In comparison to stable situations, an unstable grinding process is excited when the phase difference value is 3π/2, i.e. micro-grinding force and vibration reinforce each other. It proves that a satisfied and stable grinding process can be controlled in real-time or in-situ by means of utilizing combination of optimal parameters, such as spindle speed, effective pack density, and the cutting space of abrasive grits. The presented mechanism is practical and can provide good guidance for further studies on machine-tool dynamics, time-domain or frequency-domain analysis of grinding vibration, and then on depth distribution of cut and ground surface accuracy.},
	issn = {0039-2480},	pages = {233-244},	doi = {10.5545/sv-jme.2017.4995},
	url = {https://www.sv-jme.eu/article/effect-of-energy-consumption-in-the-contact-zone-on-machining-condition-optimization-in-precision-surface-grinding/}
}
Chen, Y.,Chen, X.,Xu, X.,Yu, G.
2018 June 64. Effect of Energy Consumption in the Contact Zone on Machining Condition Optimization in Precision Surface Grinding. Strojniški vestnik - Journal of Mechanical Engineering. [Online] 64:4
%A Chen, Yong 
%A Chen, Xun 
%A Xu, Xipeng 
%A Yu, Ge 
%D 2018
%T Effect of Energy Consumption in the Contact Zone on Machining Condition Optimization in Precision Surface Grinding
%B 2018
%9 precision grinding; energy consumption; eccentrical vibration; machining stability; condition optimization
%! Effect of Energy Consumption in the Contact Zone on Machining Condition Optimization in Precision Surface Grinding
%K precision grinding; energy consumption; eccentrical vibration; machining stability; condition optimization
%X The instantaneous energy consumption in the grit-material interaction zone is an important indicator to represent the efficiency of grinding. In contrast to methods based on chip crack and formation or energy consumption from experimental measurement, this paper presents an improved differential model of energy consumption that takes account of dynamic grinding force, forced-vibration induced by the eccentrically grinding wheel rotation, and the phase difference between adjacent regenerative surface waviness. Furthermore, the vibratory amplitude and relevant frequency elements of a wheel-workpiece coupled system are analysed to optimize the key machining conditions involved in spindle speed, pack density of abrasive wheel and effective cutting space of adjacent contour grits in discrete transverse plane. It demonstrates that machining stability is the best when the phase difference value is π/2 between continuously formed adjacent waviness generated by grit-workpiece interaction, i.e. the calculated value of instantaneous grinding energy consumption reaches its maximum value. In comparison to stable situations, an unstable grinding process is excited when the phase difference value is 3π/2, i.e. micro-grinding force and vibration reinforce each other. It proves that a satisfied and stable grinding process can be controlled in real-time or in-situ by means of utilizing combination of optimal parameters, such as spindle speed, effective pack density, and the cutting space of abrasive grits. The presented mechanism is practical and can provide good guidance for further studies on machine-tool dynamics, time-domain or frequency-domain analysis of grinding vibration, and then on depth distribution of cut and ground surface accuracy.
%U https://www.sv-jme.eu/article/effect-of-energy-consumption-in-the-contact-zone-on-machining-condition-optimization-in-precision-surface-grinding/
%0 Journal Article
%R 10.5545/sv-jme.2017.4995
%& 233
%P 12
%J Strojniški vestnik - Journal of Mechanical Engineering
%V 64
%N 4
%@ 0039-2480
%8 2018-06-26
%7 2018-06-26
Chen, Yong, Xun  Chen, Xipeng  Xu, & Ge  Yu.
"Effect of Energy Consumption in the Contact Zone on Machining Condition Optimization in Precision Surface Grinding." Strojniški vestnik - Journal of Mechanical Engineering [Online], 64.4 (2018): 233-244. Web.  01 Dec. 2021
TY  - JOUR
AU  - Chen, Yong 
AU  - Chen, Xun 
AU  - Xu, Xipeng 
AU  - Yu, Ge 
PY  - 2018
TI  - Effect of Energy Consumption in the Contact Zone on Machining Condition Optimization in Precision Surface Grinding
JF  - Strojniški vestnik - Journal of Mechanical Engineering
DO  - 10.5545/sv-jme.2017.4995
KW  - precision grinding; energy consumption; eccentrical vibration; machining stability; condition optimization
N2  - The instantaneous energy consumption in the grit-material interaction zone is an important indicator to represent the efficiency of grinding. In contrast to methods based on chip crack and formation or energy consumption from experimental measurement, this paper presents an improved differential model of energy consumption that takes account of dynamic grinding force, forced-vibration induced by the eccentrically grinding wheel rotation, and the phase difference between adjacent regenerative surface waviness. Furthermore, the vibratory amplitude and relevant frequency elements of a wheel-workpiece coupled system are analysed to optimize the key machining conditions involved in spindle speed, pack density of abrasive wheel and effective cutting space of adjacent contour grits in discrete transverse plane. It demonstrates that machining stability is the best when the phase difference value is π/2 between continuously formed adjacent waviness generated by grit-workpiece interaction, i.e. the calculated value of instantaneous grinding energy consumption reaches its maximum value. In comparison to stable situations, an unstable grinding process is excited when the phase difference value is 3π/2, i.e. micro-grinding force and vibration reinforce each other. It proves that a satisfied and stable grinding process can be controlled in real-time or in-situ by means of utilizing combination of optimal parameters, such as spindle speed, effective pack density, and the cutting space of abrasive grits. The presented mechanism is practical and can provide good guidance for further studies on machine-tool dynamics, time-domain or frequency-domain analysis of grinding vibration, and then on depth distribution of cut and ground surface accuracy.
UR  - https://www.sv-jme.eu/article/effect-of-energy-consumption-in-the-contact-zone-on-machining-condition-optimization-in-precision-surface-grinding/
@article{{sv-jme}{sv-jme.2017.4995},
	author = {Chen, Y., Chen, X., Xu, X., Yu, G.},
	title = {Effect of Energy Consumption in the Contact Zone on Machining Condition Optimization in Precision Surface Grinding},
	journal = {Strojniški vestnik - Journal of Mechanical Engineering},
	volume = {64},
	number = {4},
	year = {2018},
	doi = {10.5545/sv-jme.2017.4995},
	url = {https://www.sv-jme.eu/article/effect-of-energy-consumption-in-the-contact-zone-on-machining-condition-optimization-in-precision-surface-grinding/}
}
TY  - JOUR
AU  - Chen, Yong 
AU  - Chen, Xun 
AU  - Xu, Xipeng 
AU  - Yu, Ge 
PY  - 2018/06/26
TI  - Effect of Energy Consumption in the Contact Zone on Machining Condition Optimization in Precision Surface Grinding
JF  - Strojniški vestnik - Journal of Mechanical Engineering; Vol 64, No 4 (2018): Strojniški vestnik - Journal of Mechanical Engineering
DO  - 10.5545/sv-jme.2017.4995
KW  - precision grinding, energy consumption, eccentrical vibration, machining stability, condition optimization
N2  - The instantaneous energy consumption in the grit-material interaction zone is an important indicator to represent the efficiency of grinding. In contrast to methods based on chip crack and formation or energy consumption from experimental measurement, this paper presents an improved differential model of energy consumption that takes account of dynamic grinding force, forced-vibration induced by the eccentrically grinding wheel rotation, and the phase difference between adjacent regenerative surface waviness. Furthermore, the vibratory amplitude and relevant frequency elements of a wheel-workpiece coupled system are analysed to optimize the key machining conditions involved in spindle speed, pack density of abrasive wheel and effective cutting space of adjacent contour grits in discrete transverse plane. It demonstrates that machining stability is the best when the phase difference value is π/2 between continuously formed adjacent waviness generated by grit-workpiece interaction, i.e. the calculated value of instantaneous grinding energy consumption reaches its maximum value. In comparison to stable situations, an unstable grinding process is excited when the phase difference value is 3π/2, i.e. micro-grinding force and vibration reinforce each other. It proves that a satisfied and stable grinding process can be controlled in real-time or in-situ by means of utilizing combination of optimal parameters, such as spindle speed, effective pack density, and the cutting space of abrasive grits. The presented mechanism is practical and can provide good guidance for further studies on machine-tool dynamics, time-domain or frequency-domain analysis of grinding vibration, and then on depth distribution of cut and ground surface accuracy.
UR  - https://www.sv-jme.eu/article/effect-of-energy-consumption-in-the-contact-zone-on-machining-condition-optimization-in-precision-surface-grinding/
Chen, Yong, Chen, Xun, Xu, Xipeng, AND Yu, Ge.
"Effect of Energy Consumption in the Contact Zone on Machining Condition Optimization in Precision Surface Grinding" Strojniški vestnik - Journal of Mechanical Engineering [Online], Volume 64 Number 4 (26 June 2018)

Authors

Affiliations

  • Huaqiao University, College of Mechanical Engineering and Automation, China 1
  • Liverpool John Moores University, Faculty of Engineering and Technology, UK 2
  • Huaqiao University, Ministry of Education Engineering Research Center for Brittle Materials Machining, China 3
  • Jilin University, Roll forging institute, China 4

Paper's information

Strojniški vestnik - Journal of Mechanical Engineering 64(2018)4, 233-244

https://doi.org/10.5545/sv-jme.2017.4995

The instantaneous energy consumption in the grit-material interaction zone is an important indicator to represent the efficiency of grinding. In contrast to methods based on chip crack and formation or energy consumption from experimental measurement, this paper presents an improved differential model of energy consumption that takes account of dynamic grinding force, forced-vibration induced by the eccentrically grinding wheel rotation, and the phase difference between adjacent regenerative surface waviness. Furthermore, the vibratory amplitude and relevant frequency elements of a wheel-workpiece coupled system are analysed to optimize the key machining conditions involved in spindle speed, pack density of abrasive wheel and effective cutting space of adjacent contour grits in discrete transverse plane. It demonstrates that machining stability is the best when the phase difference value is π/2 between continuously formed adjacent waviness generated by grit-workpiece interaction, i.e. the calculated value of instantaneous grinding energy consumption reaches its maximum value. In comparison to stable situations, an unstable grinding process is excited when the phase difference value is 3π/2, i.e. micro-grinding force and vibration reinforce each other. It proves that a satisfied and stable grinding process can be controlled in real-time or in-situ by means of utilizing combination of optimal parameters, such as spindle speed, effective pack density, and the cutting space of abrasive grits. The presented mechanism is practical and can provide good guidance for further studies on machine-tool dynamics, time-domain or frequency-domain analysis of grinding vibration, and then on depth distribution of cut and ground surface accuracy.

precision grinding; energy consumption; eccentrical vibration; machining stability; condition optimization