Grinding Chatter Prediction Grinding Chatter Prediction
Accurate prediction of chatter in grinding processes is the focus of this project. Due to the complexity and difficulties associated with undefined cutting edges and process mechanics, no accurate grinding chatter prediction model is available.
In our work, a mechanistic modeling approach is used to develop a predictive model of grinding chatter. The models consider two dimensional aspects (wheel & work) of grinding processes, process non-linearity, nonlinear force, loss of wheel-workpiece contact, cross-coupling effect, spark in and out, wheel wear, and multiple d.o.f. structural dynamics of the grinding system.
This interactive software provides time domain stability prediction as well as grinding force and vibration. The models share the basic core engine with the Integrated Dynamics Machining Simulator (IDMS) that has been developed in the group over the years. The models for various grinding processes including cylindrical, surface and centerless grinding are being developed and added to the system.
Dynamic cutting forces and vibrations are generated by the developed mechanistic
time-domain process simulation
software. The software provides comprehensive cutting force and vibration
signatures or peak-to-peak amplitude values over a range of grinding conditions. The
generated results can be used to determine the stable regions of grinding by looking at
force and vibration amplitudes as shown below.
Since the simulation model keeps track of removal of materials from both the wheel and workpiece, it can not only predict regenerative chatter as the wheel wears out, but also can predict the undulations (or lobes) left on the workpiece and wheel.
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