Grinding Wheel Profile Maintenance via Automated Crushing Roller
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Solution Overview
Problem
Existing grinding methods for grooved workpieces, particularly helically grooved or threaded workpieces, face challenges in maintaining precision and sharpness of grinding wheels due to wear, leading to deviations from the nominal shape and requiring frequent profiling, which is time-consuming and prone to errors.
Innovation Solution
A method and grinding machine that integrates crushing of the grinding wheel into an automated process, using a driven crushing roller with controlled relative advancement and power management to maintain optimal crushing conditions, ensuring high precision and extended wheel life by monitoring speed and current consumption for efficient reshaping and profiling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the grinding wheel is used for an extended period, then productivity increases, but the profiling precision and sharpness of the grinding wheel deteriorate due to wear
Solution Approach 1:
The grinding wheel is pre-profiled using a crushing roller before actual grinding operations begin. This preliminary profiling action prepares the grinding wheel surface with the required geometric accuracy, allowing the wheel to maintain its functional profile throughout extended usage periods without frequent re-profiling interventions.
Solution Approach 2:
The system automatically monitors grinding wheel wear through sensors that detect changes in the ground surface quality. When wear thresholds are detected, the system autonomously triggers the profiling mechanism to re-profile the grinding wheel, eliminating the need for manual intervention and maintaining continuous operational readiness.
2Manufacturing precision
If frequent profiling of the grinding wheel is performed, then profiling precision is maintained, but time loss and operational interruptions increase
Solution Approach 1:
The profiling operation is integrated into the continuous grinding workflow through automated monitoring and triggering mechanisms. The profiling action occurs seamlessly during scheduled maintenance intervals or when wear thresholds are reached, eliminating idle time and ensuring the grinding wheel is always ready for production without interrupting the overall manufacturing continuity.
Solution Approach 2:
Sensors continuously monitor the quality of ground surfaces to detect wear-induced deviations. This real-time feedback triggers automated profiling only when necessary, based on actual wear conditions rather than fixed schedules, optimizing the balance between maintaining precision and minimizing time loss.
3Device complexity
If manual profiling methods are used, then equipment complexity is reduced, but profiling accuracy and consistency deteriorate
Solution Approach 1:
Traditional manual mechanical profiling methods are replaced with an automated crushing roller system driven by a motor. This mechanical substitution eliminates human error and variability, providing consistent and repeatable profiling accuracy while maintaining relatively simple mechanical architecture that integrates seamlessly with existing grinding machine structures.
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
This approach allows for high-quality grinding with extended grinding wheel life by maintaining stable crushing conditions and avoiding process deviations, such as rattling, while enabling flexible and efficient profiling and reshaping processes.
Implementation Method 1
crushing, which is frequently also called roll-in profiling, is a particular, accepted and appreciated method for rotational dressing for reproduction-precise profiling of metal or ceramic bonded diamond or CBN grinding wheels
Implementation Method 2
the grinding wheel is profiled so that during grinding of groove into the workpiece, the outer positive form of profiling of the grinding wheel is generated as a negative formed groove in the workpiece
Data Source
AI summary
A method is disclosed for grinding grooves on workpieces using a profiled grinding wheel, the profile of which is crushed. A reshaping crush process includes driven crush rollers, each being controlled on the basis of a rotational speed and current consumption. Thus, relative advancement between the grinding wheel and crush roller is controlled according to the speed and current consumption. A grinding machine is also disclosed for grinding a workpiece, wherein the workpiece is held by means of a workpiece spindle head. A crush device comprising a crush roller with a dedicated rotary drive is provided on the grinding machine. The grinding wheel is applied to the crush roller in order to dress the grinding wheel profile. The crush roller has a profile-crushing portion for profile-crushing the grinding wheel with a first dressing volume and a reshaping profile-crushing portion for profile-crushing the grinding wheel with a second dressing volume.