Modeling the Processing Accuracy Restrictions During the Developing of the Optimal Cycles of the Internal Grinding
Keywords:
internal grinding, process optimization, processing accuracy restriction, tolerance, errorAbstract
Inefficient using of CNC machine tools in the internal grinding operations due to lack of standards and methods of calculating the optimum cycles for operations led to the fact that in modern automated production cycle parameters selection is performed manually based on the experience and the adjuster by choosing cutting conditions experimentally, with a significant understating their level. To solve this problem, the method of calculation of optimal internal grinding cycle, which includes a model of the grinding process, a mathematical optimization method, the objective function and model constraints. The requirement to ensure the accuracy of the treated surface is a must for any internal grinding operations. Therefore, the restriction on the machining accuracy is one of the most important and obligatory in the optimization of operating parameters of internal grinding cycle.Due to the fact that the internal processing is used for grinding precise holes 6–7 quality class, the operating tolerances on the cards are set for not only the diametral dimensions, but also to shape deviations and location, the implementation of which requires substantial adjustment cycle. Therefore, restrictions on the model developed for the operation of precision internal grinding allows you to calculate all the main types of errors on the entire length of treatment, resulting in internal grinding: error diametrical size deviation from roundness, radial run-out; deviation from cylindricity, roughness and longitudinal section of a complete radial runout. All kinds of errors in the model restrictions are determined through the actual values of the radii of the treated surface, which is calculated by modeling the process of metal removal with each radius. Moreover, the actual calculation is carried out taking into account the radius of the original beats radius of the hole blanks and elastic deformation characteristics of the technological system.
The developed model limitations precision machining is designed for use in the optimization
of automatic internal grinding cycles in order to select the optimal combination of value and
removes software innings of the allowance by steps cycle to ensure the prescribed accuracy of
the machined surface.
References
Oliveira J.F.G., Silva E.J., Guo C., Hashimoto F. Industrial Challenges in Grinding. CIRP Annals – Manufacturing Technology. 2009, vol. 58, pp. 633–680. DOI: 10.1016/j.cirp.2009.09.006
Rowe, W.B. Principles of Modern Grinding Technology: Second Edition.Elsevier Inc, 2013. 437 p.
Yashcheritsyn P.I. [Influence of Structure of a Working Cycle of Intra Grinders on Quality of Processed Surfaces]. Stanki i instrument, 1965, no. 10, pp. 13–15. (in Russ.)
Kazakov N.V., Avtonomov V.A. [Analysis of Working Cycles of Intra Grinding Automated Machines]. Stanki i instrument, 1974, no. 6, pp. 9–11. (in Russ.)
Inasaki, I. Monitoring and Optimization of Internal Grinding Process. CIRP Annals – Manufacturing Technology, 1991, vol. 400, pp. 359–363. DOI: 10.1016/S0007-8506(07)62006-X
Nishimura T., Inasaki I., Yamamoto N. Study on Optimization of Internal Grinding Cycle. Nippon Kikai Gakkai Ronbunshu, C Hen/Transactions of the Japan Society of Mechanical Engineers, Part C, 1989, vol. 55, pp. 1808–1813.
D’yakonov A.A. Capabilities of Internal-Grinding Wheels. Russian Engineering Research, 2015, vol. 34, pp. 781–784. DOI: 10.3103/S1068798X14120107
Ardashev D.V. Standardization of Grinding Wheels. Russian Engineering Research, 2011, vol. 31, pp. 910–912. DOI: 10.3103/S1068798X11090048
Ardashev D.V. Physicochemical Wear of Abrasive Grains During Grinding Processes. Journal of Friction and Wear, 2014, no. 4, pp. 284–289. DOI: 10.3103/S1068366614040023
Ardashev D.V. [The Technique of Group Technology Operations Abrasion Conditions for Modern Multiproduct Manufacturing]. STIN, 2014, no. 10. pp. 31–33. (in Russ.)
Mikhel'kevich V.N. Avtomaticheskoe upravlenie shlifovaniem [Automatic Control of Grinding]. Moscow, Mashinostroenie Publ., 1975. 304 p.
Novoselov Yu.K. Dinamika formoobrazovaniya poverkhnostey pri abrazivnoy obrabotke [Dynamics of a Shaping of Surfaces in Case of Abrasive Processing]. Sevastopol', SevNTU Publ., 2012. 304 p.
D'yakonov A.A., Shipulin L.V. [Complex Process Modeling of Plane Grinding by the Periphery of a Circle]. Science Intensive Technologies in Mechanical Engineering, 2013, no. 6 (24), pp. 14–18. (in Russ.)
Nathan R.D., Vijayaraghavan L., Krishnamurthy R. Intelligent Estimation of Burning Limits to Aid in Cylindrical Grinding Cycle Planning. Heavy Vehicle Systems, 2001, vol. 80, pp. 48–59.
Horiuchi O., Shibata T. Computer simulations of cylindrical plunge grinding – Influence of work stiffness on grinding accuracy. Key Engineering Materials, 2007, vol. 329, pp. 51–56. DOI: 10.4028/0-87849-416-2.51
Pereverzev P.P., Popov A.V., Pimenov D.J. [Analytical Simulation of Correlation of Force of Cutting in Case of Internal Grinding with Elastic Deformations of Technological System]. STIN, 2014, iss. 9, pp. 23–27. (in Russ.)
Pereverzev P.P., Popov A.V. [Analytical Modeling of Interrelation of Force of Cutting at Internal Grinding with the Key Technological Parameters]. Metalloobrabotka, 2013, iss. 3, pp. 24–30. (in Russ.)
Bellman R. Dinamicheskoe programmirovanie [Dynamic Programming]. Moscow, Foreign Literature Publishing House Publ., 1960. 400 p.
Pereverzev P. P. [Simulation and Optimization of the Controlling Programs in Automated Machine-Building Production]. Bulletin of the South Ural State University. Ser. Mechanical Engineering Industry, 2012, iss. 12, no. 271, pp. 152–157. (in Russ.)
Lee C.W. Dynamic optimization of the grinding process in batch production. Journal of Manufacturing Science and Engineering, Transactions of the ASME, 2009, vol. 131, pp. 61–66. DOI: 10.1115/1.3090880
Krajinik P., Drazumeric R., Badger J., Hashimito F. Cycle Optimization in Cam-Lobe Grinding for High Productivity. CIRP Annals – Manufacturing Technology, 2014, vol. 630, pp. 333–336. DOI: 10.1016/j.cirp.2014.03.036
Alvarez J., Barrenetxea D., Marquinez J.I., Begiaga I., Gallego I. Continuous Variable Feed Rate: A Novel Method for Improving Infeed Grinding Processes. International Journal of Advanced Manufacturing Technology, 2014, vol. 73, pp. 53–61. DOI: 10.1007/s00170-014-5771-1
Dong S., Danai K., Malkin S., Deshmukh A. Continuousvoptimal Infeed Control for Cylindrical Plunge Grinding. Part 1: Methodology. Journal of Manufacturing Science and Engineering, Transactions of the ASME, 2004, vol. 126, pp. 327–333. DOI: 10.1115/1.1751423
Naerman M.S., Naerman Ya.M., Isakov. A.E Spravochnik molodogo shlifovshchika [Reference Manual of the Young Grinder: Reference Manual]. Moscow, Vysshaya shkola, 1991. 232 p.
GOST R 53442-2009. Osnovnye normy vzaimozamenyaemosti. Kharakteristiki izdeliy geometricheskie. Dopuski formy, orientatsii, mestoraspolozheniya i bieniya [Main Norms of Interchangeability.
Characteristics of Products the Geometrical. Tolerances of the Form, Orientation, Site and Beat]. Moscow, Standartionform Publ., 2010. 45 p.
Dunin-Barkovskiy I.V., Kartasheva A.N. Izmerenie i analiz sherokhovatosti, volnistosti i nekruglosti poverkhnosti [Measurement and Analysis of a Roughness, Sinuosity and not Roundness of a Surface]. Moscow, Mashinostroenie Publ., 1978. 232 p.
