Abstract
A large-scale crankshaft of internal-combustion engine is easy to bend and twist when clamped onto the grinding machine. The deviation of workpiece axis from its optimal machining axis has a significant influence on machining accuracy of angle, eccentric throw, and diameter and contour of the heavy crankshaft in non-circular grinding. To reduce the consumption of manual labor and setting-up time, an automatic alignment approach and apparatus is proposed and integrated into the non-circular grinder. The on-machine gauge senses X and Y components of deviation of crank journal axis and feed them back to the computerized numerical control system. The motor-driving steady rests based on slider-crank mechanism are controlled to compensate for the deviation. The algorithm with self-correcting ability for compensation value is employed to make up for the finite contact stiffness of workpiece and steady rest. The results of three alignment tests are compared, which demonstrates the better effect on alignment precision and efficiency of the self-correcting compensation.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Fujiwara T, Tsukamoto S, Miyagawa M (2005) Analysis of the grinding mechanism with wheel head oscillating type CNC crankshaft pin grinder. Key Eng Mater 291–292(8):163–168
Xu DH, Sun ZY, Zhou ZX, Mi HQ, Wu Y (2002) Research on motion model of tangential point grinding. Chin J Mech Eng 38(8):68–73
Möhring HC, Gümmer O, Fischer R (2011) Active error compensation in contour-controlled grinding. CIRP Annals-Manuf Technol 60:429–432
Zhou ZX, Luo HP, Xu DH, Sun ZY, Zhou ZX, Mi HQ (2003) Analysis and compensation of stiffness-error of crankshaft in tangential point tracing grinding. Chin J Mech Eng 39(6):98–101
Shen NY, He YY, Wu GH, Tian YZ (2006) Calculation model of the deformation due to grinding force in crank pin non-circular grinding. Int Tech Innov Conf: 1325 – 1330
Huan J, Ma WM (2010) Method for graphically evaluating the workpiece’s contour error in non-circular grinding process. Int J Adv Manuf Technol 46:117–121
Yu HX, Xu MC, Zhao J (2015) In-situ roundness measurement and correction for pin journals in oscillating grinding machines. Mech Syst Signal Process 50–51:548–562
Claus PK, Daniel H, Hugo T, Bernard G (2008) Process monitoring in non-circular grinding with optical sensor. CIRP Annals-Manuf Technol 57:533–536
Hagay B, Hong E, Reuven K, John SA, Susan MS (2012) Non-contact, in-line inspection of surface finish of crankshaft journals. Int J Adv Manuf Technol 60:1039–1047
Aaron W (2004) Mathematical modelling of the crankshaft pin grinding process. Dissertation, Deakin University
Denkenaa B, Gümmera O (2013) Active tailstock for precise alignment of precision forged crankshafts during grinding. 8th CIRP Conference on Intelligent Computation in. Manuf Eng 12:121–126
Cha KC, Wang N, Liao JY (2013) Stability analysis for the crankshaft grinding machine subjected to a variable-position worktable. Int J Adv Manuf Technol 67:501–516
Yu GZ, Yu HL, Duan SL (2011) Crankshaft dynamic strength analysis for marine diesel engine. Third Int Conf Meas Tech Mech Autom 1:795–799
Jia Z, Xu B, Sun MY, Li DZ, Deng JJ, He MJ (2013) Study on the metal flow of large marine full-fiber crankshaft processed by TR bending up setting method. 11th Int Conf Numer Methods Ind Form Process 1532:812–818
Altintas Y, Weck M (2004) Chatter stability of metal cutting and grinding. Ann CIRP 53(2):619–642
Jang RS, Sun KL (2002) Machining error compensation of extern cylindrical grinding using a thermally actuated rest. J Mater Proc Technol 127:280–285
PG_1106_en_en-US.pdf (2014) http://support.automation.siemens.com/WW/adsearch/resultset.aspx?region=WW&lang=en&netmode=internet&ui=NDAwMDAxNwAA&term=installation+guide+++sinumerik+810&ID=25023768&ehbid=25023768. Accessed 9 March 2014
IM8_en_en-US.pdf (2014) http://support.automation.siemens.com/WW/adsearch/resultset.aspx?region=WW&lang=en&netmode=internet&term=HMI&ID=54090527&ehbid=54090527. Accessed 9 March 2014
Shen NY, Li J, Wang XD, Ye J, Yu ZX (2014) Analysis and detection of elastic deformation of the large-scale crankshaft in non-circular grinding. Appl Mech Mater 532:285–290
Anand R, Shreyes NM (2004) Analysis of the effects of fixture clamping sequence on part location errors. Int J Mach Tools Manufact 44:373–382
Gao Y, Jones B (1994) Position motion control of workpiece steadies for compensation in the traverse grinding process. Proc IEEE Conf Control Appl 3:1493–1498
Gao Y, Jones B (1993) Control of the traverse grinding process using dynamically active workpiece steadies. Int J Mach Tools Manufact 33(2):231–244
Gao Y (1998) Experimental validation of a dynamic workpiece steady control method for traverse grinding. J Manufact Sci Eng 120:236–245
Tian XC, Huissoon JP, Xu Q, Peng B (2008) Dimensional error analysis and its intelligent pre-compensation in CNC grinding. Int J Adv Manuf Technol 36:28–33
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Shen, N., Li, J., Ye, J. et al. Precise alignment method of the large-scale crankshaft during non-circular grinding. Int J Adv Manuf Technol 80, 921–930 (2015). https://doi.org/10.1007/s00170-015-7073-7
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-015-7073-7