Development of portable power monitoring system and grinding analytical tool

Abstract Grinding is one of the most critical surface finishing processes to meet the demand of tight tolerance, good surface integrity, high productivity and low cost in manufacturing industries. However, grinding is considered to be a complex and highly non-stationary process owing to a huge number of irregular cutting edges in abrasive tools. The abrasive tool and process condition monitoring is a well-recognized approach to track process change and analyze tool condition. In this work, we developed a portable power monitoring system with specially designed grinding analytical software. The hardware architecture and software modules were introduced in detail. The main functions in the software module comprised of signals acquisition, feature extraction and data calculation, and data analytical toolkit. Knowledge-based analytical tool was established through the correlation between grinding power/energy and grinding conditions. The actual application of the portable power monitoring system for grinding process was further demonstrated with some case studies. The developed portable power monitoring system is easy and convenient to implement in production conditions for improvement and optimization of grinding process.

[1]  Wei Tian,et al.  Signature Analysis of OD Grinding Processes with Applications in Monitoring and Diagnosis , 2009 .

[2]  K. Wegener,et al.  Conditioning and monitoring of grinding wheels , 2011 .

[3]  Peter Hodgson,et al.  Cycle time reduction in crankshaft pin grinding , 2002 .

[4]  Zhaowei Zhong,et al.  Comparative study on grinding of thin-walled and honeycomb-structured components with two CBN wheels , 2015 .

[5]  Hans Kurt Tönshoff,et al.  Process Monitoring in Grinding , 2002 .

[6]  Garret E. O’Donnell,et al.  FPGA based Monitoring Platform for Condition Monitoring in Cylindrical Grinding , 2014 .

[7]  Amitava Ghosh,et al.  Effect of Cryogenic Cooling on Spindle Power and G-ratio in Grinding of Hardened Bearing Steel , 2014 .

[8]  Sami Kara,et al.  Unit process energy consumption models for material removal processes , 2011 .

[9]  K. Subramanian,et al.  Mechanisms of Material Removal in the Precision Production Grinding of Ceramics , 1997 .

[10]  Stephen Malkin,et al.  Grinding Technology: Theory and Applications of Machining with Abrasives , 1989 .

[11]  Ekkard Brinksmeier,et al.  Process Signatures – A New Approach to Solve the Inverse Surface Integrity Problem in Machining Processes☆ , 2014 .

[12]  Ekkard Brinksmeier,et al.  A Versatile Method to Determine Thermal Limits in Grinding , 2014 .

[13]  R. P. Lindsay,et al.  A systems approach for the use of vitrified bonded superabrasive wheels for precision production grinding , 1992 .

[14]  Carlos Henrique Lauro,et al.  Monitoring and processing signal applied in machining processes – A review , 2014 .

[15]  Jun Qu,et al.  A wavelet-based methodology for grinding wheel condition monitoring , 2007 .