Scientific and methodological support for designing grinding operations using an acoustic indicator.
Authors
A. S. Zhukov
South Ural State University, Chelyabinsk
D. V. Ardashev
South Ural State University, Chelyabinsk
V. L. Kulygin
South Ural State University, Chelyabinsk
V. V. Batuev
South Ural State University, Chelyabinsk
V. G. Shalamov
South Ural State University, Chelyabinsk
A. V. Morozov
Vladimir State University named after A. and N. Stoletovs, Vladimir
Keywords:
grinding, grinding process design, acoustic monitoring of grinding, acoustic criterion for grinding wheel performance
Abstract
This article describes a methodology for designing grinding operations that employs an acoustic indicator and outlines the main stages of its development. The methodology was developed to enhance the productivity of grinding operations. The efficiency criteria are defined as the minimization of: operational
time, setup and teardown time, the residual service life of the grinding wheel, and the consumption of the wheel's useful volume and mass.
The methodology is implemented at the grinding process design stage and is based on a computer simulation model of the sound pressure parameters generated by the grinding process, developed in specialized software. This model enables the calculation of sound pressure amplitude values at an informative frequency
for specified technological conditions.
A crucial element of the methodology is the application of an integrated model. This comprehensive modeling approach allows for the formation of a data cell containing values for the grinding sound pressure amplitude and the topographical quality parameters of the machined surface for specific technological conditions. The development of the integrated model involves coupling data from three sources: the described model of the grinding acoustic signal parameters, and existing models for determining the values of surface roughness (Ra) and deviation from cylindricity (Δ) of the ground surface.
Based on the integrated model, prediction maps for the defect-free operation zone of the grinding wheel have been developed within the coordinates of processing regime and time. These maps facilitate the determination of rational processing regimes and grinding wheel characteristics.
The main industrial scenarios where the application of this methodology yields the most significant effect are also considered. The intended area of application for the methodology is high-variety manufacturing, which holds a leading position in the modern machine-building industry.
