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In-Process Diagnostics for Grinding Process

Case Studies

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In-Process Diagnostics
Monitoring of the grinding process:
a) Wheel motor power (kW) b) Slide Position (mm)

Signals represent the grinding process as it is happening gives the real-time signature of the process.
Input Transformation Output

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How does it help?


Better asset utilization
Capacity Increase & Reduced cost per part
By optimizing grinding cycle Reduction of non-grinding time Increasing wheel life

Solving process related issues


Identify and resolve process problems
Burn, wheel loading, glazing, high wheel wear

Process benchmarking and machine characterization


Document the grinding process for future reference Comparison of in-process signals between two grinding systems
2 different cycles Same cycles, but different machine, operator, wheel, etc.

Machine characterization
Axis behaviour Deformation shapes, etc.
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How does it do it?


Signals What How Feature recognition Superimposition Why Optimize cycle time Variation of inputs to grinding process Verify the grinding program Power + Observe variations in the process Position Benchmark processes

Power

Optimize dressing skip Feature Identify features process problems recognition Estimate grinding system stiffness Trending

Increase wheel life Solve process issues Improve consistency


Machine characterization

Check axis behaviour Derived Position Identify deformation shapes of work analysis Monitor element deformation Trending Usage Aspects: Portable unit
Can be mounted on any grinding machine of any type

High Sampling rate:


Ensures real-time data capture of the grinding process

Short Setup time:


Can be setup on a grinding machine within 30 minutes

Modular:
Different sensor specs can be easily configured based on application
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CONFIDENTIAL

Examples of use of Grind-Trak

CASE STUDIES

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BETTER ASSET UTILIZATION

1. Reduction of non-value added time


OD Profile Grinding
3.5
Power (kW) Displacement (mm)

2.5

2 6

1.5 8 1

0.5

10

0 0 1 2 3 4 5 6 Time (sec) 7 8 9 10 11 12

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Displacement (mm) 7

Non-value added time

Power (kW)

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2. Reduction of grinding time (a)


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Peak power = 4 kW

Camshaft Journal Grinding Initial

Power

Displacement

4.2

3.5

2.5

3.6

3.4

1.5

3.2

1 0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 Time (sec)

Dressing

Steady Journals

Dressing

Motor Rating : 7.5 kW Machine Stiffness sufficient Increase feed-rates

Grinding Cycle Time = 700 sec


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Displacement (mm)

3 Power (kW)

3.8

2. Reduction of grinding time (b)


Camshaft Journal Grinding After increasing feed-rates
Peak power = 8 kW

Steady Journals

Dressing

Grinding Cycle Time = 560 sec


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SOLVING PROCESS RELATED ISSUES

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1. Wheel Glazing
High Power in the finishing operation indicates glazing.
Wheel glazing causing power rise (though MRR is constant)

OD profile grinding work-material with high hardness (62 HRC)

Grind-Trak shows portions of the grinding cycle where the glazing takes place. Remedial action may be taken to rectify the problem by attacking that portion of the grinding cycle.
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2. Burn
Sudden spikes in power indicate potential for burning
Spike in power causing burn Crankshaft Journal Grinding

Remedial action may be taken to rectify the problem by attacking that portion of the grinding cycle
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PROCESS DOCUMENTATION AND BENCHMARKING


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Benchmarking
Crankshaft Journal Grinding

Compare grinding cycle, system stiffness, cycle time and process behaviour.
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Machine Characterization
Axis behaviour
Spikes generated when there is a change in feed-rate. These spikes were giving rise to step on the component. After Servo Motor tuning, the spikes were eliminated. No more step on the component

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SUMMARY

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Grind-Trak Sales
Grind-Trak is a useful tool that helps us to
Observe what is really happening in the grinding process Quantify parameters by measurement that were earlier not possible

Such a tool is valuable for customer relations


Optimizing the grinding system to provide value to customer (e.g. KOEL, Bosch, Texmo, etc.) Attending to customer process related issues (BFL, HFL) As a development tool for process benchmarking (cBN OD grinding project, Rhino project, cBN ID grinding project)

The use of such tool and the associated efforts result in


Increased customer goodwill MGT seen as a systems solution provider than just a machine supplier Increased customer confidence
Faster customer process issue trouble shooting More scientific approach to application engineering Data driven approach increased customer confidence
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18 CONFIDENTIAL

Grinding process The System Approach


Machine tool
Structural Compliance Kinematic Design Bearings and spindles Finished Part In process monitoring Post process monitoring

Operational factors
Grinding cycle Speed, feed Depth of cut

Grinding process
Power Displacement Vibration Acoustic emission Force Temperature

Quality
Form error Dimension accuracy Surface roughness Waviness Integrity

Work Material
Geometry Surface properties Material properties

Tooling/ Supplies
Abrasive Coolant Fixtures

Process quantities

Control strategies The System Approach of looking at grinding

Quality parameters

Ref: Subramanian K, The System Approach A strategy to survive and succeed in the Global Economy, 2000 - M Brij Bhushan, Prof. Ramesh Babu,, B.Tech Project Report - A Diagnostic Tool For In-process Monitoring Of Grinding 2012, IIT Madras.

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