Adaptive Grinding Process (AGriPro) – Prevention of Thermal Damage using OPC UA Technique and in-Situ Metrology

Matthias Steffan, Franz Haas, Alexander Pierer, Jens Gentzen

Research output: Contribution to journalArticleResearchpeer-review

Abstract

The production process grinding deals with finishing of hardened workpieces and is one of the last stages of the value-added production chain. Up to this process step, considerable costs and energy have been spent on the workpieces. In order to avoid production rejects, significant safety reserves are calculated according to the present state of the art. The authors introduce two approaches to minimize the safety margin thus optimize the
process’ economic efficiency. Both control concepts use the feed rate override of the machining operation as regulating variable to eliminate thermal damage of the edge zone. The first control concept is developed to
avoid thermal damage in cylindrical plunge grinding by controlling the cutting forces. Therefore, the industrial standard OPC Unified Architecture (OPC UA) is used for the communication between a PID-controller and the SINUMERIK grinding machine tool control system. For non-circular workpieces, grinding conditions change over the circumference. Therefore, thermal damage cannot be ruled out at any time during the grinding process. The authors introduces a second novel control approach which uses a micro-magnetic measure that correlates with thermal damage as the main control variable. Hence, the cutting ability of the grinding wheel and thermal damage to the workpiece edge zone is quantified in the process. The result is a control concept for grinding of
non-circular workpieces, which opens up fields for major efficiency enhancement. With these two approaches, grinding processes are raised on higher economic level, independently of circular and non-circular workpiece
geometries.
Translated title of the contributionAdaptive Grinding Process (AGriPro) - Prävention von thermischer Randzonenschädigung durch Verwendung von OPC UA und in-Situ Messtechnik
LanguageEnglish
JournalJournal of Manufacturing Science and Engineering
Volume139
Issue number12
StatusPublished - 30 Aug 2017

Keywords

    Fields of Expertise

    • Mobility & Production

    Cite this

    Adaptive Grinding Process (AGriPro) – Prevention of Thermal Damage using OPC UA Technique and in-Situ Metrology. / Steffan, Matthias; Haas, Franz; Pierer, Alexander; Gentzen, Jens.

    In: Journal of Manufacturing Science and Engineering, Vol. 139, No. 12, 30.08.2017.

    Research output: Contribution to journalArticleResearchpeer-review

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    abstract = "The production process grinding deals with finishing of hardened workpieces and is one of the last stages of the value-added production chain. Up to this process step, considerable costs and energy have been spent on the workpieces. In order to avoid production rejects, significant safety reserves are calculated according to the present state of the art. The authors introduce two approaches to minimize the safety margin thus optimize the process’ economic efficiency. Both control concepts use the feed rate override of the machining operation as regulating variable to eliminate thermal damage of the edge zone. The first control concept is developed to avoid thermal damage in cylindrical plunge grinding by controlling the cutting forces. Therefore, the industrial standard OPC Unified Architecture (OPC UA) is used for the communication between a PID-controller and the SINUMERIK grinding machine tool control system. For non-circular workpieces, grinding conditions change over the circumference. Therefore, thermal damage cannot be ruled out at any time during the grinding process. The authors introduces a second novel control approach which uses a micro-magnetic measure that correlates with thermal damage as the main control variable. Hence, the cutting ability of the grinding wheel and thermal damage to the workpiece edge zone is quantified in the process. The result is a control concept for grinding of non-circular workpieces, which opens up fields for major efficiency enhancement. With these two approaches, grinding processes are raised on higher economic level, independently of circular and non-circular workpiece geometries.",
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    AB - The production process grinding deals with finishing of hardened workpieces and is one of the last stages of the value-added production chain. Up to this process step, considerable costs and energy have been spent on the workpieces. In order to avoid production rejects, significant safety reserves are calculated according to the present state of the art. The authors introduce two approaches to minimize the safety margin thus optimize the process’ economic efficiency. Both control concepts use the feed rate override of the machining operation as regulating variable to eliminate thermal damage of the edge zone. The first control concept is developed to avoid thermal damage in cylindrical plunge grinding by controlling the cutting forces. Therefore, the industrial standard OPC Unified Architecture (OPC UA) is used for the communication between a PID-controller and the SINUMERIK grinding machine tool control system. For non-circular workpieces, grinding conditions change over the circumference. Therefore, thermal damage cannot be ruled out at any time during the grinding process. The authors introduces a second novel control approach which uses a micro-magnetic measure that correlates with thermal damage as the main control variable. Hence, the cutting ability of the grinding wheel and thermal damage to the workpiece edge zone is quantified in the process. The result is a control concept for grinding of non-circular workpieces, which opens up fields for major efficiency enhancement. With these two approaches, grinding processes are raised on higher economic level, independently of circular and non-circular workpiece geometries.

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