Intelligent Centerless Grinding: Global Solution for Process Instabilities and Optimal Cycle Design

Centerless grinding productivity is largely limited by three types of instabilities: chatter, geometric lobing and workpiece rotation problems. Regardless of its negative effect in manufacturing plants, no functional tool has been developed to set up the process, because it involves the simultaneous resolution of several coupled problems. In this paper, new simulation techniques are described to determine instability-free configurations, making it possible to guarantee that the final workpiece profile is round. With this information and taking into account other process restrictions, like system static stiffness and workpiece tolerance, the optimal grinding cycle is designed. These results have been implemented into an intelligent tool to assist the application of this research in industrial environments.