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Intermittent chatter on crankshaft journal

Throughout wheel life ( 1066 mm to 750 mm) Occurs at all operational parameters On all the journals

PROBLEM: CHATTER ISSUE

R-120 Machine

System Inputs
Abrasive Product

Machine Tool
Machine Tool: Machine type: Wheel Speed: Work Speed: Motor rating (hp): Coolant: Type: Concentration: Pressure: Flow: Direction: Nozzle type Dressing (Device/ tool/ spec.): Water soluble 4 % dilution ratio 3 bar 120 Lpm aligned with direction of wheel rotation fixed Blade type (OC-2) : 2 needles 2 needles between centers, with Two steady rest Driving dog Micromatic Grinding Rhino-R120 CNC 60 mps 90/65/50 RPM 22 kW

Company Specification: Abrasive (type, size, shape, content): Grit Size: Grade: Bond (type, content, props.): Structure (porosity): Design: Wheel Surface speed: Size, shape, features:

GNO 38A54-3L8VS3 SB white (friable) Al2O3 Combination of 54, 60, 80 (diff %) L Vitrified (VS3) 8 Straight 60 mps 1066 x 38.5 x 304.8

Work Material
Component Type: Hardness: Case hardened depth: Size, shape, Geometry: Stock Incoming Part Quality: Input run-out Crankshaft SAE 1541 55 HRC 1 mm

1.0 -1.2 mm On dia 0.5-0.6 MM Hardness 2 Hrc , on grinding stock -0.050 mm

Cutting edges Work holding Driving

Consistency:

GRINDING LAYOUT

Chatter
Chatter, in grinding, is the undesirable vibration during the grinding process, which results in marks on the surface of the work-piece or wheel or both called chatter marks. Basically caused due to two types of vibration: Forced vibration Self Excited Vibration

Chatter Marks on a crankshaft journal

Ref.: Inasaki, Karpuschewski, Lee Grinding Chatter Origin and Suppression, CIRP Annals, 2001.

Measurement of chatter frequency

10 chatter marks

OD Chatter Impression (on sheet)


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Vibration Signals Captured


Motor Frequency=Motor RPM/60 =2553/60 =42.55 Hz 2x component= 2 x 42.55 =85.1 Hz Thus, 85 Hz peak corresponds to the motor 2x component. Free-running condition (on wheel head) peak at 85 Hz

Peak at 85 Hz observed on the work-head during grinding.

Peak at 85 Hz observed on the tailstock during grinding.


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Experiment to identify source of chatter


Work speed varied and Wheel speed constant: Work Wheel Trial Speed speed Chatter Chatter Motor 2x No. (rpm) (rpm) marks/rev. freq. (Hz) freq. (Hz) 2 90 1407 65.2 97.8 93.8 3 70 1407 83.7 97.7 93.8 6 50 1407 115.8 96.5 93.8 15 40 1407 146.6 97.7 93.8 Work speed constant and Wheel speed varied: Work Trial Speed Wheel Chatter Chatter Motor 2x No. (rpm) speed (rpm) marks/rev. freq. (Hz) freq. (Hz) 11 70 788 #N/A 9 70 959 53.1 61.9 63.9 7 70 1201 70 81.7 80.1 14 70 1323 74.4 86.7 88.2 3 70 1407 83.7 97.7 93.8

Chatter frequency is constant at around 97 Hz indicating source is not from workdrive side

Chatter frequency varies linearly with change in wheel speed indicating source is from wheel drive side. Chatter frequency matches motor 2x component. This shows that the motor is the source of chatter.

Conclusion and Action Taken


Conclusion:
The wheel-head motor 2x component of vibration is high, causing chatter on the component (internal forced vibration)

Causes of high motor 2x component:


2-pole motor inherent characteristics may give rise to high 2x component. High 2x component also may be due to soft-footing (weakness in mounting).

Action Planned:
Change the motor from 2-pole to 4-pole which will have lower inherent 2x and overall vibration levels Increase the rigidity of the motor mounting assembly.

Changes made on existing machine


Old Design New Design

Drive motor changed from 2-pole (3000 rpm motor base speed at 50 Hz) to 4-pole (1500 rpm motor base speed at 50 Hz) to decrease the vibration level (particularly the 2X component) of the motor. To maintain 60 mps throughout the wheel life (1066mm to 780mm) with 4-pole motor, pulleys were changed such that the 4-pole motor runs near its base speed to derive maximum power. The motor mounting bracket was strengthened and made more rigid.

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Signals captured after modification

Free-running condition on wheel head overall vibration amplitudes are much lower peak at 25 Hz corresponding to motor 1x (1500 rpm/60=25Hz) but amplitude is low.

Signal captured on work-head during grinding overall vibration levels are low - No chatter!

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Final Status
Chatter was eliminated. Grinding Process Parameters:
Wheel speed: 60 mps Wheel diameter: 760 mm Wheel rpm: 1510 rpm Work Speeds: 96 rpm, 88 rpm, 76 rpm Dressing feed: 130 mm/min on OD and 131 mm/min on radius. Dynamic Balancing: unbalance below 0.3 um.

Technical Outputs:
No chatter observed on the journal. Surface Finish = 0.5-0.6 um (Ra) Cycle Time: 17 min 05 sec Ovality: <= 3um Taper: < 3um Dimension: 83 .00 4 um Cpk: 1.66 on thrust journal

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