CN114290127A - Grinding wheel dressing and grinding wheel replacing method - Google Patents

Grinding wheel dressing and grinding wheel replacing method Download PDF

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Publication number
CN114290127A
CN114290127A CN202111579176.3A CN202111579176A CN114290127A CN 114290127 A CN114290127 A CN 114290127A CN 202111579176 A CN202111579176 A CN 202111579176A CN 114290127 A CN114290127 A CN 114290127A
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grinding wheel
control system
numerical control
radius
roller
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CN114290127B (en
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贺行健
王大伟
杜长林
王绍奇
孙永杰
耿文剑
杨超
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Dalian Kede Numerical Control Co Ltd
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Abstract

The invention discloses a method for dressing a grinding wheel and replacing the grinding wheel, which comprises the following steps: step 1, detecting the radius of a grinding wheel by a numerical control system, and judging whether the radius of the grinding wheel is smaller than a set threshold value; if so, replacing the grinding wheel, and after the grinding wheel is replaced; if not, carrying out the next step; step 2, starting the grinding wheel by the numerical control system, and grinding the workpiece by the grinding wheel; the numerical control system judges whether the grinding amount of the workpiece in unit time is smaller than a first set value or not, if so, the grinding wheel is dressed, and after finishing dressing of the grinding wheel, the grinding wheel continues to grind the workpiece; and if not, the grinding wheel continues to grind the workpiece. According to the invention, the radius of the grinding wheel is detected, so that the grinding wheel replacement alarm is realized, the state of the grinding wheel protective cover is detected, when the grinding wheel protective cover is in an open state, the grinding wheel protective cover does not work, and when the grinding wheel protective cover is in a closed state, the current of the main shaft of the grinding wheel is detected, whether the work can be carried out or not is judged, and the safety problem caused by the negligence of workers is prevented.

Description

Grinding wheel dressing and grinding wheel replacing method
Technical Field
The invention relates to the field of grinding processing, in particular to a method for dressing a grinding wheel and replacing the grinding wheel.
Background
The grinding wheel is a common grinding tool in grinding processing, and has a large use amount in the industries of metallurgy, automobile and ship manufacturing, mechanical manufacturing and the like. After the grinding wheel is used for a period of time, air holes in the surface of the grinding wheel are blocked by grinding dust, so that heat cannot be effectively dissipated, and a machining accident is caused. The sharpness of the grinding wheel particles is not enough, and the grinding efficiency is reduced. The grinding wheel is continuously worn in machining or dressing, the radius of the grinding wheel is smaller and smaller, but the grinding wheel has the minimum use radius, and when the radius of the grinding wheel reaches the minimum use radius, the grinding wheel needs to be replaced, and the grinding wheel is collided by a person. If a person neglects to open the grinding wheel protective cover, the protective cover is closed when the person forgets to replace the grinding wheel, and the machine tool is operated to process, so that a processing accident is caused.
Disclosure of Invention
The invention provides a method for dressing a grinding wheel and replacing the grinding wheel, which aims to overcome the problems.
The invention comprises the following steps:
step 1, detecting the radius of a grinding wheel by a numerical control system, and judging whether the radius of the grinding wheel is smaller than a set threshold value; if yes, replacing the grinding wheel, and repeating the steps after the grinding wheel is replaced; if not, carrying out the next step; the set threshold is set according to experience;
step 2, starting the grinding wheel by the numerical control system, and grinding the workpiece by the grinding wheel; the numerical control system judges whether the grinding amount of the workpiece in unit time is smaller than a first set value or not, if so, the grinding machining is stopped and the grinding wheel dressing is carried out, and after the grinding wheel dressing is finished, the grinding wheel continues to grind the workpiece; if not, the grinding wheel continues to grind the workpiece; the first setting value is set empirically.
Further, the grinding wheel replacement comprises the following steps:
step 11, opening a mechanical door lock on the grinding wheel shield, triggering an electronic switch, and sending a triggering signal to the numerical control system by the electronic switch;
step 12, after the numerical control system receives the trigger signal, the numerical control system prohibits the grinding wheel spindle from rotating, the workpiece spindle from rotating and all linear axes from feeding, and then the grinding wheel is replaced;
and step 13, after the grinding wheel is replaced, closing the mechanical door lock, releasing the trigger of the electronic switch, sending a release trigger signal to the numerical control system by the electronic switch, and releasing the prohibition of the grinding wheel spindle rotation, the workpiece spindle rotation and the linear shaft feeding by the numerical control system.
Further, in step 13, the numerical control system releases the inhibition on the rotation of the grinding wheel spindle, the rotation of the workpiece spindle and the feeding of the linear shaft, and is based on the following processing strategies:
the numerical control system firstly removes the prohibition of the rotation of the grinding wheel spindle and starts the grinding wheel spindle to obtain the starting current value of the grinding wheel spindle and judge whether the starting current value is greater than a second threshold value, if so, the numerical control system removes the prohibition of the rotation of the workpiece spindle and the feeding of all linear axes; if not, the numerical control system prohibits the grinding wheel spindle from rotating again and sends an alarm; the second threshold is set empirically.
Further, the numerical control system judges whether the grinding amount of the workpiece in unit time is less than a first set value or not, and the method comprises the following steps:
step 21, the numerical control system acquires the radius of the workpiece acquired by the laser measurement system in real time;
step 22, after each set processing time T, judging whether the grinding amount of the workpiece in unit time is smaller than a first set value by the numerical control system; the calculation formula of the grinding amount of the workpiece in unit time is as follows:
Figure BDA0003426463380000021
wherein F is the grinding amount of the grinding wheel in unit time; r1 is the workpiece diameter at the first time in the set machining time; r2 is the workpiece diameter at the last time in the set machining time; t is a set machining time, and T is set empirically.
Further, the dressing of the grinding wheel comprises the following steps:
step 23, the numerical control system acquires the position u of the roller center in real timeActual position
And 24, controlling the roller to move towards the grinding wheel by the numerical control system, and calculating the distance between the center of the roller and the center of the grinding wheel in real time, wherein the calculation formula of the distance between the center of the roller and the center of the grinding wheel is as follows:
Urelative position=R3+R4+(uActual position-u1) (2)
Wherein, URelative positionThe distance between the center of the roller and the center of the grinding wheel; r3 is the grinding wheel radius; r4 is the roller radius; roller radius R4 and grinding wheel radius R1 are both of known dimensions;
if the distance U between the center of the roller and the center of the grinding wheelRelative positionIf the radius is equal to the sum of the radius R4 of the roller and the radius R1 of the grinding wheel, the roller is judged to be in a contact state with the grinding wheel, and the next step is carried out;
otherwise, the numerical control system continuously controls the roller to continuously move towards the grinding wheel until the distance between the center of the roller and the center of the grinding wheel is equal to the sum of the radius of the roller and the radius of the grinding wheel;
and 25, controlling the roller to trim the grinding wheel by the numerical control system, and acquiring the radius of the grinding wheel by the numerical control system in real time until the radius of the grinding wheel meets a second set value, wherein the second set value is set according to experience.
Further, the grinding wheel dressing mode in step 25 includes: performing single inching dressing and simultaneous dressing and processing, and selecting a grinding wheel dressing mode according to experience when dressing the grinding wheel;
the grinding wheel dressing mode comprises the following steps:
1) single inching finishing:
when the grinding wheel is dressed, the grinding wheel stops processing, the linear shaft moves towards the grinding wheel according to the set speed, and the roller moves towards the grinding wheel according to the set rotating speed and is dressed; after finishing, the roller returns to the zero position, and the grinding wheel begins to process;
2) trimming and processing:
and when the grinding wheel is dressed, the grinding wheel is dressed in real time without stopping machining, and the grinding wheel feed shaft carries out real-time compensation according to the reduction value of the grinding wheel radius.
According to the invention, the radius of the grinding wheel is calculated in real time according to the distance between the wheel center and the grinding wheel center, the sum of the radius of the roller and the radius of the grinding wheel, so that the grinding wheel loss and the time loss caused by insufficient finishing degree or excessive finishing during finishing are reduced. The invention realizes the alarm of grinding wheel replacement by detecting the radius of the grinding wheel, and automatically stops the machine operation by monitoring the gravity of the grinding wheel when the grinding wheel is absent, thereby ensuring the safety of personnel replacing the grinding wheel; meanwhile, the state of the grinding wheel protective cover is detected, and when the grinding wheel protective cover is in an opening state, the grinding wheel protective cover does not work, so that the safety problem caused by negligence of workers is prevented.
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In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed to be used in the description of the embodiments or the prior art will be briefly introduced below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to these drawings without creative efforts.
FIG. 1 is a flow chart of a wheel dressing and replacement method disclosed herein;
FIG. 2 is a diagram of the relationship between the position of the grinding wheel and the roller disclosed in the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, but not all, embodiments of the present invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
As shown in fig. 1, the present embodiment includes:
step 1, detecting the radius of a grinding wheel by a numerical control system, and judging whether the radius of the grinding wheel is smaller than a set threshold value; if yes, replacing the grinding wheel, and repeating the steps after the grinding wheel is replaced; if not, carrying out the next step; the set threshold is set according to experience;
specifically, the grinding wheel radius is the grinding wheel to workpiece center distance-workpiece radius. The workpiece radius is detected from the laser measurement.
Step 2, starting the grinding wheel by the numerical control system, and grinding the workpiece by the grinding wheel; the numerical control system judges whether the grinding amount of the workpiece in unit time is smaller than a first set value or not, if so, the grinding machining is stopped and the grinding wheel dressing is carried out, and after the grinding wheel dressing is finished, the grinding wheel continues to grind the workpiece; if not, the grinding wheel continues to grind the workpiece; the first setting value is set empirically.
Preferably, the grinding wheel replacement comprises the steps of:
step 11, opening a mechanical door lock on the grinding wheel shield, triggering an electronic switch, and sending a triggering signal to the numerical control system by the electronic switch;
step 12, after the numerical control system receives the trigger signal, the numerical control system prohibits the grinding wheel spindle from rotating, the workpiece spindle from rotating and the linear shaft from feeding, and then the grinding wheel is replaced;
and step 13, after the grinding wheel is replaced, closing the mechanical door lock, releasing the trigger of the electronic switch, sending a release trigger signal to the numerical control system by the electronic switch, and releasing the prohibition of the grinding wheel spindle rotation, the workpiece spindle rotation and the linear shaft feeding by the numerical control system.
Specifically, the linear shaft includes: the X-axis linear shaft, the Y-axis linear shaft, the Z-axis linear shaft, the W-axis linear shaft, the A-axis linear shaft, the U-axis linear shaft and the C-axis linear shaft.
Preferably, in step 13, the numerical control system releases the inhibition on the rotation of the grinding wheel spindle, the rotation of the workpiece spindle and the feeding of the linear shaft, and is based on the following processing strategies:
the numerical control system firstly removes the prohibition of the rotation of the grinding wheel spindle and starts the grinding wheel spindle to obtain the starting current value of the grinding wheel spindle and judge whether the starting current value is greater than a second threshold value, if so, the numerical control system removes the prohibition of the rotation of the workpiece spindle and the feeding of the linear shaft; if not, the numerical control system prohibits the grinding wheel spindle from rotating again and sends an alarm; the second threshold is set empirically.
Specifically, the current of the grinding wheel spindle is detected:
1. when a grinding wheel is newly installed and the grinding wheel rotates at a high speed, the starting current of the grinding wheel spindle is large due to the large diameter and large inertia of the grinding wheel, and the starting current value of the grinding wheel spindle at the moment is set as the current value of the maximum diameter of the grinding wheel.
2. After the grinding wheel is replaced, when the grinding wheel rotates at a high speed, the inertia is increased due to the increase of the diameter of the grinding wheel, and the starting current of the grinding wheel spindle is increased.
When the grinding wheel protective cover is closed, the rotation of the grinding wheel spindle, the rotation of the workpiece spindle and the feeding of the linear shaft are forbidden, a machining program is started, and when the grinding wheel spindle rotates, if a new grinding wheel is replaced, the starting current value of the grinding wheel spindle is increased due to the inertia of the grinding wheel. If the grinding wheel is not replaced, the starting current value of the grinding wheel spindle is below a second threshold value due to the inertia of the grinding wheel, the grinding wheel is judged not to be replaced, the grinding wheel spindle stops rotating, the system gives an alarm, the rotation of the grinding wheel spindle and the rotation of the workpiece spindle are forbidden, and all linear axes are forbidden to execute the automatic program.
Preferably, the numerical control system judges whether the grinding amount of the workpiece in unit time is less than a first set value, and the method comprises the following steps:
step 21, the numerical control system acquires the radius of the workpiece acquired by the laser measurement system in real time;
step 22, after each set processing time T, judging whether the grinding amount of the workpiece in unit time is smaller than a first set value by the numerical control system; the calculation formula of the grinding amount of the workpiece in unit time is as follows:
Figure BDA0003426463380000051
wherein F is the grinding amount of the grinding wheel in unit time; r1 is the workpiece diameter at the first time in the set machining time; r2 is the workpiece diameter at the last time in the set machining time; t is a set machining time, and T is set empirically.
Specifically, the machining time T is set to a time period [ T ]1,t2],R1-R2=t1The diameter of the workpiece at the moment of time minus t2The diameter of the workpiece at the moment.
Preferably, the dressing of the grinding wheel comprises the following steps:
step 23, the numerical control system acquires the position u of the roller center in real timeActual position
And 24, controlling the roller to move towards the grinding wheel by the numerical control system, and calculating the distance between the center of the roller and the center of the grinding wheel in real time, wherein the calculation formula of the distance between the center of the roller and the center of the grinding wheel is as follows:
Urelative position=R3+R4+(uActual position-u1) (2)
Wherein, URelative positionThe distance between the center of the roller and the center of the grinding wheel; r3 is the grinding wheel radius; r4 is the roller radius; roller radius R4 and grinding wheel radius R1 are both of known dimensions;
if the distance U between the center of the roller and the center of the grinding wheelRelative positionIf the radius is equal to the sum of the radius R4 of the roller and the radius R1 of the grinding wheel, the roller is judged to be in a contact state with the grinding wheel, and the next step is carried out;
otherwise, the numerical control system continuously controls the roller to continuously move towards the grinding wheel until the distance between the center of the roller and the center of the grinding wheel is equal to the sum of the radius of the roller and the radius of the grinding wheel;
and 25, controlling the roller to trim the grinding wheel by the numerical control system, and acquiring the radius of the grinding wheel by the numerical control system in real time until the radius of the grinding wheel meets a second set value, wherein the second set value is set according to experience.
Specifically, in the present embodiment, two grinding wheels, one roller is taken as an example, and as shown in fig. 2, the position of the feed axis (U/C axis) is dressed by the grinding wheel:
in the G54 coordinate system, the U-axis shows the distance between the centerlines of grinding wheel S2 and dressing S4, and the C-axis shows the distance between the centerlines of grinding wheel S3 and dressing S5. When the dresser is in contact with the maximum outer diameter of the grinding wheel, the distance between the two axes is equal to the sum of the radii. When the U/C axis shows less than the sum of the minimum wheel radius and the roller radius, i.e., the U/C axis shows less than 335mm, the wheel needs to be replaced. The roller radius is of known dimension R4 and is set, without regard to wear, according to the following steps:
1. the accurate installation of the diamond roller is ensured in the early stage.
2. The U-axis is moved forward toward the grinding wheel until the two contact at the maximum outer diameter position, and the position U1 of the U-axis in the machine coordinate system is recorded.
3. The C-axis is moved forward toward the wheel until the two contact at the maximum outer diameter, and the C-axis position C1 in the machine coordinate system is recorded.
4. And calculating the relative position U/C of the U/C axis, and inputting the relative position U/C into the numerical control system.
Relative position U ═ R3+ R4+ (U actual position-U1) (1)
Relative position C ═ R3+ R4+ (C actual position-u 2) (2)
Preferably, the grinding wheel dressing mode in the step 25 comprises the following steps: performing single inching dressing and simultaneous dressing and processing, and selecting a grinding wheel dressing mode according to experience when dressing the grinding wheel;
the grinding wheel dressing mode comprises the following steps:
1) single inching finishing:
when the grinding wheel is dressed, the grinding wheel stops processing, the linear shaft moves towards the grinding wheel according to the set speed, and the roller moves towards the grinding wheel according to the set rotating speed and is dressed; after finishing, the roller returns to the zero position, and the grinding wheel begins to process;
2) trimming and processing:
and when the grinding wheel is dressed, the grinding wheel is dressed in real time without stopping machining, and the grinding wheel feed shaft carries out real-time compensation according to the reduction value of the grinding wheel radius.
Has the advantages that:
according to the invention, the radius of the grinding wheel is calculated in real time according to the distance between the wheel center and the grinding wheel center, the sum of the radius of the roller and the radius of the grinding wheel, so that the grinding wheel loss and the time loss caused by insufficient finishing degree or excessive finishing during finishing are reduced. The invention realizes the alarm of grinding wheel replacement by detecting the radius of the grinding wheel, and automatically stops the machine operation by monitoring the gravity of the grinding wheel when the grinding wheel is absent, thereby ensuring the safety of personnel replacing the grinding wheel; meanwhile, the state of the grinding wheel protective cover is detected, and when the grinding wheel protective cover is in an opening state, the grinding wheel protective cover does not work, so that the safety problem caused by negligence of workers is prevented.
Finally, it should be noted that: the above embodiments are only used to illustrate the technical solution of the present invention, and not to limit the same; while the invention has been described in detail and with reference to the foregoing embodiments, it will be understood by those skilled in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; and the modifications or the substitutions do not make the essence of the corresponding technical solutions depart from the scope of the technical solutions of the embodiments of the present invention.

Claims (6)

1. A method for dressing a grinding wheel and replacing the grinding wheel is characterized by comprising the following steps:
step 1, detecting the radius of a grinding wheel by a numerical control system, and judging whether the radius of the grinding wheel is smaller than a set threshold value; if yes, replacing the grinding wheel, and repeating the steps after the grinding wheel is replaced; if not, carrying out the next step; the set threshold is set according to experience;
step 2, starting the grinding wheel by the numerical control system, and grinding the workpiece by the grinding wheel; the numerical control system judges whether the grinding amount of the workpiece in unit time is smaller than a first set value or not, if so, the grinding machining is stopped and the grinding wheel dressing is carried out, and after the grinding wheel dressing is finished, the grinding wheel continues to grind the workpiece; if not, the grinding wheel continues to grind the workpiece; the first setting value is set empirically.
2. A method of dressing a grinding wheel and changing the grinding wheel according to claim 1, wherein the grinding wheel changing comprises the steps of:
step 11, opening a mechanical door lock on the grinding wheel shield, triggering an electronic switch, and sending a triggering signal to the numerical control system by the electronic switch;
step 12, after the numerical control system receives the trigger signal, the numerical control system prohibits the grinding wheel spindle from rotating, the workpiece spindle from rotating and all linear axes from feeding, and then the grinding wheel is replaced;
and step 13, after the grinding wheel is replaced, closing the mechanical door lock, releasing the trigger of the electronic switch, sending a release trigger signal to the numerical control system by the electronic switch, and releasing the prohibition of the grinding wheel spindle rotation, the workpiece spindle rotation and the linear shaft feeding by the numerical control system.
3. The method of claim 2, wherein the numerical control system removes the inhibition of the rotation of the grinding wheel spindle, the rotation of the workpiece spindle and the linear axis feed in step 13 based on the following processing strategy:
the numerical control system firstly removes the prohibition of the rotation of the grinding wheel spindle and starts the grinding wheel spindle to obtain the starting current value of the grinding wheel spindle and judge whether the starting current value is greater than a second threshold value, if so, the numerical control system removes the prohibition of the rotation of the workpiece spindle and the feeding of all linear axes; if not, the numerical control system prohibits the grinding wheel spindle from rotating again and sends an alarm; the second threshold is set empirically.
4. The method of claim 1, wherein the numerical control system determines whether the grinding amount per unit time of the workpiece is less than a first set value, and comprises the steps of:
step 21, the numerical control system acquires the radius of the workpiece acquired by the laser measurement system in real time;
step 22, after each set processing time T, judging whether the grinding amount of the workpiece in unit time is smaller than a first set value by the numerical control system; the calculation formula of the grinding amount of the workpiece in unit time is as follows:
Figure FDA0003426463370000021
wherein F is the grinding amount of the grinding wheel in unit time; r1 is the workpiece diameter at the first time in the set machining time; r2 is the workpiece diameter at the last time in the set machining time; t is a set machining time, and T is set empirically.
5. The method of claim 1, wherein the dressing comprises the steps of:
step 23, the numerical control system acquires the position u of the roller center in real timeActual position
And 24, controlling the roller to move towards the grinding wheel by the numerical control system, and calculating the distance between the center of the roller and the center of the grinding wheel in real time, wherein the calculation formula of the distance between the center of the roller and the center of the grinding wheel is as follows:
Urelative position=R3+R4+(uActual position-u1) (2)
Wherein, URelative positionThe distance between the center of the roller and the center of the grinding wheel; r3 is the grinding wheel radius; r4 is the roller radius; roller radius R4 and grinding wheel radius R1 are both of known dimensions;
if the distance U between the center of the roller and the center of the grinding wheelRelative positionIf the radius is equal to the sum of the radius R4 of the roller and the radius R1 of the grinding wheel, the roller is judged to be in a contact state with the grinding wheel, and the next step is carried out;
otherwise, the numerical control system continuously controls the roller to continuously move towards the grinding wheel until the distance between the center of the roller and the center of the grinding wheel is equal to the sum of the radius of the roller and the radius of the grinding wheel;
and 25, controlling the roller to trim the grinding wheel by the numerical control system, and acquiring the radius of the grinding wheel by the numerical control system in real time until the radius of the grinding wheel meets a second set value, wherein the second set value is set according to experience.
6. The method of claim 5, wherein the dressing of the grinding wheel in step 25 comprises: performing single inching dressing and simultaneous dressing and processing, and selecting a grinding wheel dressing mode according to experience when dressing the grinding wheel;
the grinding wheel dressing mode comprises the following steps:
1) single inching finishing:
when the grinding wheel is dressed, the grinding wheel stops processing, the linear shaft moves towards the grinding wheel according to the set speed, and the roller moves towards the grinding wheel according to the set rotating speed and is dressed; after finishing, the roller returns to the zero position, and the grinding wheel begins to process;
2) trimming and processing:
and when the grinding wheel is dressed, the grinding wheel is dressed in real time without stopping machining, and the grinding wheel feed shaft carries out real-time compensation according to the reduction value of the grinding wheel radius.
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CN116352607A (en) * 2023-03-30 2023-06-30 无锡市明鑫机床有限公司 Centerless grinder compensation control system and method based on numerical control analysis
CN117260408A (en) * 2023-11-21 2023-12-22 江苏京创先进电子科技有限公司 Grinding wheel dressing method, grinding wheel dressing or not identification system and thinning equipment

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JP2007083351A (en) * 2005-09-22 2007-04-05 Jtekt Corp Grinder
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CN115609361A (en) * 2022-12-01 2023-01-17 成都和鸿科技股份有限公司 Machining method of multi-groove part
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CN117260408B (en) * 2023-11-21 2024-02-02 江苏京创先进电子科技有限公司 Grinding wheel dressing method, grinding wheel dressing or not identification system and thinning equipment

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