Optimization of internal plunge grinding using collaboration of the air-grinding and the material removal model based on the power signal

  • Yulun ChiEmail author
  • Jiajian Gu
  • Haolin Li


This paper introduces a new optimum method for internal plunge grinding by using the material removal model based on the power signals that were extracted from machine wheel spindle. An automatic grinding cycle optimization functional module is proposed to improve the process grinding efficiency while ensuring component quality requirements. Aiming at the productivity, the functional module encompasses a more comprehensive set of realistic constraints and the manufacturing values. By combining both the air-grinding reduction method and the grinding process optimization method, the functional module has been integrated to provide a new algorithm for analysis and optimization of bearing grinding process. In the paper, an experimental optimization example demonstrates a 33.6% reduction in production cycle time for bearing grinding process. The results confirm that this functional module can be used to save the total grinding cost greatly in industrial implication.


Internal plunge grinding Process optimization Air-grinding Material removal model 



total stock removal


grinding depth


grinding wheel width


real stock removal


equivalent diameter of the wheel


wheel diameter


workpiece diameter


power signal deviation


grinding tangential force


mechanical equivalent of heat


grinding force coefficient


coefficient of power


proportionality coefficient


overall effective stiffness


contact length of the grinding contact zone


air-grinding process


size of workpiece blank irregular shape


proportionality coefficient


order of infeed stage in the grinding cycle


workpiece rotational speed


grinding power

\( {P}_{\mathrm{lim}}^{\prime } \)

limitation of maximum grinding power


maximum power


maximum limitation of the heat flux


surface roughness


additional residual out-of-roundness


roundness of workpiece

R0 and R

empirical constants


ratio of the heat flowing


maximum constrained grinding roundness


limited surface roughness

\( {r}_n^{grind} \)

real workpiece radius reduction of the nth infeed stage


the n stages infeed time


roughing infeed time


semi-finishing infeed time


finishing infeed time


spark-out time


grinding wheel speed


grinding workpiece speed


time constant

objective function of the shortest grinding cycle time


elastic deflection


grinding temperature of the workpiece


grinding burn limit temperature


coefficient of heat emission


temperature diffusivity of the workpiece

\( {\overset{.}{r}}_n \)

material removal rate

\( {\overset{.}{u}}_i \)

ith command infeed velocity


Funding information

This study was financially supported by the Science and Technology Commission of Shanghai Municipality (No. 17DZ2283300).


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Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2019

Authors and Affiliations

  1. 1.College of Mechanical EngineeringUniversity of Shanghai for Science and TechnologyShanghaiChina

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