Digital technologies for assessment and prevention of vibration related quality issues in grinding applications.
ALEXANDRU AND ROXANA
The InterQ European project seeks to develop a digital platform for the generation and integrated management of data with the aim of ensuring the quality of products and processes under the zero-defect manufacturing paradigm. Module Work is actively developing CAM technologies that can pay the way to the use of digital twins and artificial intelligence. Module Works algorithms will increase the efficiency of grinding operations in the key sectors such as aeronautics, energy and automotive.
Grinding itself is an abrasive machining process that uses a grinding wheel as the cutting tool. Grinding operations are often used to obtain a high surface finish on the latest production stages. Therefore, it is very critical to ensure proper process, otherwise the quality can be compromised. This is why it is particularly important to avoid vibration, also known as grinding chatter, in grinding operations. Since grinding is considered an unpredictable process due to its complexity, digitalization seems to be a remedy to improve understanding of the grinding process performance via algorithmic analysis.
Module Works is committed to provide the link between processes and the virtual production chain. Module Works is integrating new process management into standard CAM Products as well as in state-of-the-art machine control hardware. The goal is to visualize and predict grinding chatter, one of the most critical sources of geometrical workpiece inaccuracies.
Figure 1. Workpiece colouring
The Module Works material removal simulation provides multi-axis simulation with gouge and deviation analysis as well as collision checking and manual or automatic refinement of the simulation result. Workpiece colouring according to different criteria such as the tool, cutting length and change in tool orientation provide enhanced visual analysis at a glance (Figure 1). On-screen statistical information and a feature for measuring distances add to the analysis.
Currently, in the InterQ European project, Module Works extends its engine to empower CAM software with the embedded calculation of the frequencies during the process provided by project partners. Multi-threaded algorithms simulate multi-axis machine setups for verification of toolpath quality before actual production (Figure 2).
Figure 2. Multi-axis grinding setup