Condition monitoring of grinding wheels

Potential of internal control signals

authored by: B. Denkena, H. Klemme, D. Stoppel
Abstract: Monitoring of grinding wheel wear is a crucial task to ensure adequate quality of the manufactured workpiece. While external sensors, such as acoustic emission sensors, are commonly used for this task, the use of internal control signals has been neglected. Consequently, the extent to which degree these signals can be utilized to monitor the grinding process remains uncertain. Therefore, this work focuses on monitoring grinding wheel wear based on internal control signals in the case of surface grinding of 100Cr6. It is shown, that the novel approach can estimate tool life volume with a R² value of 0.98. The results are compared to models using force measurements of a dynamometer as well as sensor fusion approaches relying on both signal sources. Despite its low resolution in the frequency domain, drive signals can be used for grinding wheel wear monitoring. Nevertheless, dynamometer measurements enable more accurate estimations with a R² value of 0.99. The differences have to be considered when scheduling the grinding wheels redressing based on the estimated tool life volume.
Organisation(s): Institute of Production Engineering and Machine Tools
Type: Article
Journal: Production Engineering
ISSN: 0944-6524
Publication date: 20.06.2024
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: Mechanical Engineering, Industrial and Manufacturing Engineering
Electronic version(s): https://doi.org/10.1007/s11740-024-01295-x (Access: Open)

BibTeX

@article{8e56537fdf594f53bf395149b7b1ed6d,
title = "Condition monitoring of grinding wheels: Potential of internal control signals",
abstract = "Monitoring of grinding wheel wear is a crucial task to ensure adequate quality of the manufactured workpiece. While external sensors, such as acoustic emission sensors, are commonly used for this task, the use of internal control signals has been neglected. Consequently, the extent to which degree these signals can be utilized to monitor the grinding process remains uncertain. Therefore, this work focuses on monitoring grinding wheel wear based on internal control signals in the case of surface grinding of 100Cr6. It is shown, that the novel approach can estimate tool life volume with a R² value of 0.98. The results are compared to models using force measurements of a dynamometer as well as sensor fusion approaches relying on both signal sources. Despite its low resolution in the frequency domain, drive signals can be used for grinding wheel wear monitoring. Nevertheless, dynamometer measurements enable more accurate estimations with a R² value of 0.99. The differences have to be considered when scheduling the grinding wheels redressing based on the estimated tool life volume.",
keywords = "Grinding, Tool condition monitoring, Tool wear",
author = "B. Denkena and H. Klemme and D. Stoppel",
note = "Publisher Copyright: {\textcopyright} The Author(s) 2024.",
year = "2024",
month = jun,
day = "20",
doi = "10.1007/s11740-024-01295-x",
language = "English",
journal = "Production Engineering",
issn = "0944-6524",
publisher = "Springer Verlag",
}