Grinding Wheel Shuttling for End Face Precision
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Solution Overview
Problem
Conventional grinding methods for workpieces with cylindrical parts and end faces face challenges such as grinding burn, poor precision, and reduced productivity due to uneven grinding stone wear and increased grinding time, especially when dealing with the edges and R-parts.
Innovation Solution
A grinding method and machine that uses a grinding wheel narrower than the finishing width between end faces, rotating parallel to the workpiece, with relative movement across the workpiece axis and shuttling along the axis to finish both end faces in two steps, allowing for efficient coolant supply and uniform wear, reducing grinding burn and increasing productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the grinding stone width is set equal to the finishing width between end faces, then the end faces can be finished to the required width, but the sides of the grinding stone wear off due to large grinding amount, requiring excessive truing and reducing productivity
Solution Approach 1:
The invention changes the parameter of grinding stone width to be narrower than the finishing width between end faces. This parameter change allows the grinding stone to avoid excessive wear on its sides while still achieving the required end face finishing width through controlled grinding paths, thereby reducing truing requirements and increasing productivity
Solution Approach 2:
The invention employs dynamic grinding paths where the grinding wheel moves not only radially but also axially along the workpiece. This dynamic movement pattern allows the narrower grinding stone to effectively finish the end faces without requiring the full width of the stone to be in contact with the workpiece, reducing edge wear and extending wheel life
2Loss of time
If a single plunge grinding step is used to grind cylindrical part and end faces, then grinding time is reduced, but the end faces are heated up and tend to obtain grinding burn
Solution Approach 1:
The invention segments the grinding operation into multiple passes with different grinding stone positions and orientations. Instead of a single plunge grinding step, the grinding wheel performs multiple controlled movements including radial approach, axial advancement, and withdrawal phases, distributing the grinding heat over time and reducing thermal concentration at the end faces
Solution Approach 2:
The grinding process employs periodic action with alternating approach and withdrawal phases. The grinding wheel periodically touches and withdraws from the workpiece end faces during the grinding cycle, allowing heat dissipation between contact phases and preventing continuous heat accumulation that causes grinding burn
3Adaptability or versatility
If the grinding wheel is fed to one end face while moving obliquely toward the other end face, then both end faces can be ground, but at least two plunge grinding steps are required increasing grinding time
Solution Approach 1:
The invention merges the grinding of both end faces into a single integrated grinding operation. The grinding wheel performs a coordinated sequence of movements that simultaneously engages with both end faces through controlled axial and radial motion, eliminating the need for separate plunge grinding steps for each end face
4Adaptability or versatility
If the grinding wheel rotates about a rotational axis inclining to the rotational axis of the workpiece, then the cylindrical part and end face can be ground, but the workpiece must be reversed to grind the other end face increasing grinding time
Solution Approach 1:
The invention employs dynamic movement of the grinding wheel along the workpiece axis while maintaining parallel rotation. The grinding wheel performs controlled axial advancement and withdrawal movements during rotation, allowing both end faces to be ground without reversing the workpiece, thereby reducing grinding time while maintaining adaptability
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 effectively prevents grinding burn, achieves high precision, and increases the number of workpieces that can be ground per grinding wheel by reducing the amount of truing required and minimizing thermal expansion, thus enhancing productivity and surface finish.
Implementation Method 1
a grinding wheel (10) whose grinding stone (10a, 10b, 10c) is narrower than a finishing width between the end faces (21)
Data Source
AI summary
A grinding method of a rotating workpiece W having a cylindrical part 20 and a pair of end faces 21 at both sides of the cylindrical part 20 uses a grinding wheel 10 whose grinding stone is narrower than a finishing width S1 between the end faces 21. In a first grinding step, the grinding wheel 10 is relatively moved to the cylindrical part 20 in a direction crossing the rotational axis of the workpiece W and is shuttled along the rotational axis of the workpiece W at least one time between the finishing width S1 of the end faces 21 until the grinding wheel 10 reaches the cylindrical part. And in a second grinding step, the grinding wheel 10 is moved from one of the end faces 21 to the opposite end face 21 on the cylindrical part 20, so as to finish the end faces 21 to a predetermined width S1.