Error Compensation Through Analysis of Force and Deformation in Non-circular Grinding

With industrial advancement, the demand for precision parts is increasing. A crankshaft is the main part of an engine, which determines the life and quality of the engine, and is one of the precision parts whose demand is growing. Non-circular grinding is the grinding method used for crankshafts, and it is different from conventional grinding methods. In this study, the grinding force, considering the characteristics of the non-circular grinding, was obtained, and the bending and torsional deformation of the crankshaft caused by the grinding force was predicted. By applying the deformation to the grinding force, a real depth of the cut prediction model that can calculate the grinding force and predict the real depth of cut was proposed. A compensation model that can estimate the set depth of cut was proposed to obtain the desired real depth of cut. Various grinding characteristics related to force and deformation in non-circular grinding were analyzed. It was observed that the grinding force has different values at all grinding points, even if one pin is ground because the change in the workpiece velocity depends on the grinding point. Unlike in general grinding, the tangential force affects the depth of cut. The real depth of cut obtained through the prediction model proposed in this study differed from the set depth of cut by up to 45%. Comparing the compensation model of this study to the conventional method, the former showed approximately 20% improved compensation performance.