Professional Documents
Culture Documents
Case Studies
1 CONFIDENTIAL
In-Process Diagnostics
Monitoring of the grinding process:
a) Wheel motor power (kW) b) Slide Position (mm)
Signals represent the grinding process as it is happening gives the real-time signature of the process.
Input Transformation Output
2 CONFIDENTIAL
Machine characterization
Axis behaviour Deformation shapes, etc.
3 CONFIDENTIAL
Power
Optimize dressing skip Feature Identify features process problems recognition Estimate grinding system stiffness Trending
Check axis behaviour Derived Position Identify deformation shapes of work analysis Monitor element deformation Trending Usage Aspects: Portable unit
Can be mounted on any grinding machine of any type
Modular:
Different sensor specs can be easily configured based on application
4
CONFIDENTIAL
CASE STUDIES
5 CONFIDENTIAL
2.5
2 6
1.5 8 1
0.5
10
0 0 1 2 3 4 5 6 Time (sec) 7 8 9 10 11 12
12
Displacement (mm) 7
Power (kW)
CONFIDENTIAL
Peak power = 4 kW
Power
Displacement
4.2
3.5
2.5
3.6
3.4
1.5
3.2
1 0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 Time (sec)
Dressing
Steady Journals
Dressing
Displacement (mm)
3 Power (kW)
3.8
Steady Journals
Dressing
10
1. Wheel Glazing
High Power in the finishing operation indicates glazing.
Wheel glazing causing power rise (though MRR is constant)
Grind-Trak shows portions of the grinding cycle where the glazing takes place. Remedial action may be taken to rectify the problem by attacking that portion of the grinding cycle.
11
2. Burn
Sudden spikes in power indicate potential for burning
Spike in power causing burn Crankshaft Journal Grinding
Remedial action may be taken to rectify the problem by attacking that portion of the grinding cycle
12
Benchmarking
Crankshaft Journal Grinding
Compare grinding cycle, system stiffness, cycle time and process behaviour.
14
Machine Characterization
Axis behaviour
Spikes generated when there is a change in feed-rate. These spikes were giving rise to step on the component. After Servo Motor tuning, the spikes were eliminated. No more step on the component
15
SUMMARY
16
Grind-Trak Sales
Grind-Trak is a useful tool that helps us to
Observe what is really happening in the grinding process Quantify parameters by measurement that were earlier not possible
18 CONFIDENTIAL
Operational factors
Grinding cycle Speed, feed Depth of cut
Grinding process
Power Displacement Vibration Acoustic emission Force Temperature
Quality
Form error Dimension accuracy Surface roughness Waviness Integrity
Work Material
Geometry Surface properties Material properties
Tooling/ Supplies
Abrasive Coolant Fixtures
Process quantities
Quality parameters
Ref: Subramanian K, The System Approach A strategy to survive and succeed in the Global Economy, 2000 - M Brij Bhushan, Prof. Ramesh Babu,, B.Tech Project Report - A Diagnostic Tool For In-process Monitoring Of Grinding 2012, IIT Madras.