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Throughout wheel life ( 1066 mm to 750 mm) Occurs at all operational parameters On all the journals
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
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
Ref.: Inasaki, Karpuschewski, Lee Grinding Chatter Origin and Suppression, CIRP Annals, 2001.
10 chatter marks
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.
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.
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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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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