Stability-based optimization of grinding parameters to increase material removal rate in non-circular high-speed grinding

Abstract

The selection of grinding process parameters is of paramount importance for enhancing the productivity of high-speed grinding. To augment the material removal rate in the high-speed grinding of non-circular components, an optimization strategy for grinding process parameters, aimed at achieving stable grinding, has been proposed. Initially, a dynamic model of the high-speed grinding process system for non-circular profiles was established, integrating the geometric kinematic characteristics of non-circular grinding with the time-delay regenerative effect, and its grinding stability was analyzed. Subsequently, a multi-dimensional nonlinear mapping relationship between grinding process parameters and the system’s chatter behavior as well as surface quality was constructed. The machining stability and surface quality of the workpiece were taken into consideration to propose an optimization strategy for grinding process parameters oriented toward stable grinding. With the chatter stability boundary and surface roughness as constraints, and the maximum material removal rate as the objective, the spindle speed and grinding depth were optimized. This methodology was implemented in the context of grinding an automotive camshaft component, culminating in the attainment of an optimal grinding depth and spindle speed. This enhancement in machining efficiency was found to be approximately 100%.