Modelling and Optimization of Cycles of Internal Grinding in the Conditions of the Automated Machine-Building Productions
DOI:
https://doi.org/10.14529/engin160306Keywords:
internal grinding, optimization of process, method of dynamic programming, the conditions of cutting, cycle, a set of technological limitationsAbstract
Despite emergence of new high-productive metal working machines with CNC in the national engineering industry, the problem connected with the existing low-productivity of the operations carried out on these machines isn’t solved yet. The reason for that is the lack of normative and reference literature, CAD and the engineering techniques allowing to design cycles for CNC machine tools which would satisfy the requirements of modern automated production. In practice, this problem is solved in two ways: 1) purchasing of the cutting modes from equipment manufacturers; 2) using the method of cutting modes choice by processing of a number of test billets. Both ways require considerable additional expenses which are imposed on the final cost of the products and don't solve a problem of increasing the productivity of operations carried out on CNC machine tools in general, throughout the domestic engineering industry.The solution of this problem is the methodology of designing of optimal internal grinding cycles considered in this article which is based on two fundamental models: the model of the cutting force components and the model of metal removal. The power model of internal grinding process connects the cutting forces with processing regimes and covers most of the basic technological parameters. The model of metal removal reflects interrelation of the program and the actual values of the radial feed with elastic deformations of the technological system, and also allows calculating the value of the actually removed allowance, the current values of radiuses of
the treated holes, cutting force, removal time for the specified grinding cycle, etc. As a mathematical optimization method of grinding cycles the dynamic programming method is used. Application of this method is caused by the fact that it doesn't require pre-construction of the boundaries of acceptable restrictions and isn't sensitive to properties of model controls and limitations.
The methodology of designing of optimal internal grinding cycles allows calculating mathematically optimal values of radial and axial feeds at all steps of a cycle, optimal allocation of removal allowance on cycle steps for radial and axial feeds in case of which the minimal cycle time considering the specified technological limitations of criterion function is provided.
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
Obshchemashinostroitel'nye normativy vremeni i rezhimov rezaniya dlya normirovaniya ra-bot, vypolnyaemykh na universal'nykh i mnogotselevykh stankakh s chislovym programmnym upravleniem. Chast' II. Normativy rezhimov rezaniya [Engineering Industry Standards of Time and the Cutting Modes for Rationing of the Works Carried Out on the Universal and Multi-Purpose Machines with Numerical Program Control. Part II. Standards of the Cutting Modes]. Moscow, Ekonomika Publ., 1990. 311 p.
Rezhimy rezan'ya na raboty, vypolnyaemye na shlifoval'nykh i dovodochnykh stankakh s ruchnym upravleniem i poluavtomatakh: spravochnik [The Cutting Modes for the Works Carried Out on Grinding and Hand-Operated Lapping Machines and Semiautomatic Machines: Reference Book]. Chelyabinsk,
ATKOSO Publ., 2007. 384 p.
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
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.
Pimenov D.Yu. Mathematical Modeling of Power Spent in Face Milling Taking into Consideration Tool Wear. Journal of Friction and Wear, 2015, vol. 36, no. 1, pp. 45–48. DOI: 10.3103/S1068366615010110
Novoselov Yu.K. Dinamika formoobrazovaniya poverkhnostey pri abrazivnoy obrabotke [Dynamics of Surfaces Formation at 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.)
Salov P.M., Vinogradova T.G., Salova D.P. [Managing of a Circle Rerun at Internal Grinding]. High technologies in Mashinostroenie, 2009, no. 1, pp. 61–63. (in Russ.)
Guzeev V.I., Nurkenov A.K. Researching the CNC-Machine Stiffness Impact on the Grinding Cycle Design. Procedia Engineering, 2016, vol. 150, pp. 815–820. DOI: 10.1016/j.proeng.2016.07.118
Pereverzev P.P., Akintseva A.V. Mathematical Model for the Internal Grinding Process of a Non-Circular Hole Machining. Procedia Engineering, 2016, vol. 150. pp. 1118–1123. DOI: 10.1016/j.proeng.2016.07.223
Pereverzev P.P., Akintseva A.V. Model of Cutting Force While Managing Two Regime Parameters in the Process of Internal Grinding. Procedia Engineering, 2016, vol. 150. pp. 1113–1117. DOI: 10.1016/j.proeng.2016.07.222
Pereverzev P.P., Akintseva A.V. [Modeling of Metal Removal During an Internal Grinding in View of Kinematics Cutting Features]. STIN, 2016, vol. 4, pp. 23–28. (in Russ.)
Pereverzev P.P., Akintseva A.V. [Model of Formation of Processing Errors Intragrinding]. STIN, 2016, vol. 6, pp. 25–30. (in Russ.)
Bellman R. Dinamicheskoe programmirovanie [Dynamic Programming]. Moscow, Foreign Literature Publishing House, 1960. 400 p.
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
Dong S., Danai K., Malkin S., Deshmukh A. Continuous Voptimal 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
Pereverzev P.P., Pimenov D.Yu. Optimization of Control Programs for Numerically Controlled Machine Tools by Dynamic Programming. Russian Engineering Research, 2015, vol. 35. no. 2, pp. 135–142. DOI: 10.3103/S1068798X15020197
Mikhel'kevich V.N. Avtomaticheskoe upravlenie shlifovaniem [Automatic Control of Grinding]. Moscow, Mashinostroenie Publ., 1975. 304 p.
