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Error Compensation Through Analysis of Force and Deformation in Non-circular Grinding

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Abstract

With industrial advancement, the demand for precision parts is increasing. A crankshaft is the main part of an engine, which determines the life and quality of the engine, and is one of the precision parts whose demand is growing. Non-circular grinding is the grinding method used for crankshafts, and it is different from conventional grinding methods. In this study, the grinding force, considering the characteristics of the non-circular grinding, was obtained, and the bending and torsional deformation of the crankshaft caused by the grinding force was predicted. By applying the deformation to the grinding force, a real depth of the cut prediction model that can calculate the grinding force and predict the real depth of cut was proposed. A compensation model that can estimate the set depth of cut was proposed to obtain the desired real depth of cut. Various grinding characteristics related to force and deformation in non-circular grinding were analyzed. It was observed that the grinding force has different values at all grinding points, even if one pin is ground because the change in the workpiece velocity depends on the grinding point. Unlike in general grinding, the tangential force affects the depth of cut. The real depth of cut obtained through the prediction model proposed in this study differed from the set depth of cut by up to 45%. Comparing the compensation model of this study to the conventional method, the former showed approximately 20% improved compensation performance.

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Abbreviations

v s :

Wheel velocity

v w :

Workpiece velocity

a :

Depth of cut

F t ′ :

Tangential forces per unit width

F n ′ :

Normal forces per unit width

R :

Distance between the pin and journal

R w :

Radius of pin

R s :

Radius of grinding wheel

P :

Grinding point

ω :

Rotation speed of the crankshaft

φ :

Rotation angle

v x :

Movement velocity of wheel in the x-axis direction

v si :

Wheel velocity due to rotation of the wheel

n :

Crankshaft rotation speed

θ g :

Grinding position angle

φ :

Angle error

E :

Elastic modulus of the crankshaft

L :

Length of the crankshaft

O J :

Center of the journal

O G :

Center of the grinding wheel

O P :

Center of the pin

O P ′ :

Center of the pin changed by angle error

L PG :

Distance between the pin and the grinding wheel

L PG ′ :

Distance between the changed pin and the grinding wheel

L JG :

Distance between the journal and the grinding wheel

δ b :

Bending deformation error

δ t :

Depth of cut error due to the torsional deformation

δ :

Total depth of cut error

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Authors and Affiliations

  1. Graduate School of Mechanical Engineering, Korea University, 145, Anam-ro, Seongbuk-gu, Seoul, 02841, South Korea

    Joon Jang

  2. School of Mechanical Engineering, Korea University, 145, Anam-ro, Seongbuk-gu, Seoul, 02841, South Korea

    Woo Chun Choi

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Jang, J., Choi, W.C. Error Compensation Through Analysis of Force and Deformation in Non-circular Grinding. Int. J. Precis. Eng. Manuf. 23, 627–638 (2022). https://doi.org/10.1007/s12541-022-00649-8

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  • DOI: https://doi.org/10.1007/s12541-022-00649-8

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