High-Performance Machining by Centerless through Feed Grinding

 

In centerless grinding, the workpiece is positioned by contact with the regulating wheel, grinding wheel, and support rail in the grinding gap. There is no need to fix the workpiece between centers or by chucks, which simplifies the automation. Due to the machining and bearing of the component on the identical circumferential surface, centerless ground components have a polygonal shape. The technical literature names a reference value for conventional grinding wheels of a specific material removal rate of Q'_w = 0.5 mm³/mms. For external circumferential longitudinal grinding between centers, the reference values are higher by a factor of 8.

Due to its good automatability, centerless through-feed grinding is predestined for high-performance machining, while the maximum possible metal removal rates limit productivity, especially compared to external circumferential longitudinal grinding. Preliminary tests by an AKS member company have shown that stable process control is possible even at significantly higher metal removal rates, but very high grinding wheel wear was observed, which limited the process productivity.

The aim of the subproject is therefore to develop an optimized grinding strategy for high-performance machining by centerless through feed grinding. For this purpose, the systemic selection of suitable tools and coolant specifications based on the state of the art is carried out. Experimental investigations will identify the performance limits for the selected settings, taking into account component properties and grinding wheel wear. As a result, recommendations for the design of highly productive, centerless through feed grinding processes, e.g. as an alternative process for hard turning, are derived for industrial applications.