By Zulal Ayture-Scheele

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For operation of a reasonably comprehensive advisory system, a grinding data base within the system ideally contains grinding data for parts that have been previously ground on the machine. 26 A concept for intelligent grinding process control including an advisory system for selection of initial grinding conditions. the system must be able to employ data derived from other parts that have been ground or from other sources. Details of previously ground parts and relevant associated data can be stored in the system and incorporating this feature allows grinding conditions that were previously employed to be retrieved.

Intelligent process control systems are most successful when the techniques are absolutely essential to achieve the required size or shape control. A particular area where process requirements drive the need for innovation is in the control of shape in ultra-precision grinding of large surfaces. For ultra-precision applications, all process variables must be brought under control if a successful process is to be achieved at all. For example, temperature is a key factor in ultra-precision grinding that must be controlled throughout the grinding system including the grinding fluid system, the grinding machine structure and within the grinding process.

25 for a cylindrical plunge grinding process. The model based on many research experiments assumes there are several process limits as shown. For example, there is an upper feed-rate limit that leads to infringement of the constraints on available power or on maximum acceptable part roughness or on a minimum value of acceptable re-dress life. Another process limit is the minimum work speed that can be employed without causing excessive grinding temperatures. It is also assumed that there is a maximum work-speed above which grinding chatter vibration becomes highly probable.

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