Grinding Tool Perpendicular Feed for Uniform Load Distribution
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Solution Overview
Problem
Existing grinding methods, such as deep grinding and creep feed grinding, suffer from slow feed rates due to high grinding tool engagement, leading to increased cycle times, heat input, and potential material deterioration. Additionally, plunge grinding is limited by the fixed diameter of the grinding tool, resulting in workpieces with varying dimensions.
Innovation Solution
A method for grinding a workpiece with a grinding tool where the axis of rotation is oriented perpendicular to the feed plane, allowing for divided removal volumes through two distinct traverse velocities. This approach enables high traverse velocities, short cycle times, and uniform load distribution on the grinding tool and workpiece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If deep grinding or creep feed grinding method is used with high grinding tool engagement, then material removal efficiency is improved, but feed rate becomes very slow and heat input increases leading to potential material deterioration
Solution Approach 1:
The grinding process is segmented into multiple passes with different engagement depths. Instead of removing the entire volume in one pass, the method divides the material removal into sequential steps, allowing higher overall productivity while maintaining acceptable feed rates in each individual pass.
Solution Approach 2:
The grinding tool engagement is made dynamic by adjusting the depth of engagement between passes. The method employs variable engagement depths where initial passes remove larger volumes and subsequent passes refine the geometry, optimizing both productivity and feed rate throughout the machining sequence.
2Loss of time
If plunge grinding method is used, then cycle time is reduced, but workpiece width is limited by the fixed diameter of the grinding tool
Solution Approach 1:
The method transitions from single-dimension plunge grinding to multi-dimensional processing by combining axial and radial movements. This allows the grinding tool to effectively handle workpieces with widths exceeding the tool diameter by engaging the workpiece at different positions and angles throughout the machining sequence.
Solution Approach 2:
The workpiece width capability is extended by segmenting the grinding operation into multiple passes at different lateral positions. Each pass handles a portion of the total width, and the combination of passes achieves the complete machining of wide workpieces that would be impossible in a single plunge pass.
3Productivity
If high traverse velocity is used to reduce cycle time, then productivity improves, but load peaks may occur causing damage to workpiece and grinding tool
Solution Approach 1:
The method applies preliminary actions by performing initial grinding passes that prepare the workpiece geometry and reduce peaks or irregularities before subsequent passes. This preliminary shaping prevents load peaks in later passes by ensuring more uniform contact between the grinding tool and workpiece throughout the machining sequence.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method achieves efficient and cost-effective grinding with the shortest possible cycle times, ensuring uniform material removal rates and minimizing the risk of structural changes or damage to the workpiece and grinding tool.
Implementation Method 1
the grinding tool is brought on one occasion to the total vertical engagement setting external to the workpiece, and this is removed from the workpiece in a single horizontal feed cycle
Data Source
AI summary
The present invention relates to a method for grinding of a workpiece with a grinding tool, wherein an axis of rotation of the grinding tool is oriented perpendicular to a feed plane of the grinding tool, comprising the following steps: a) Movement of the grinding tool at a first velocity into a machining region of the workpiece, b) Establishment of contact between the grinding tool and a first entry region of the workpiece at a second velocity, c) First traverse of the grinding tool at the second velocity through the workpiece along a predefined contour located in the feed plane, d) First extraction of the grinding tool at the second velocity from a first exit region of the workpiece, e) Establishment of contact between the grinding tool and a second entry region of the workpiece at a third velocity, f) Second traverse of the grinding tool at the third velocity through the workpiece along a horizontal traverse direction located in the feed plane, g) Second extraction of the grinding tool at the third velocity from a second exit region of the workpiece.