Optimization of conditions for small-rigid prismatic workpieces flat grinding by elastic deformations controlling

The authors propose the technique of optimization the conditions for small-rigid prismatic workpieces side surfaces flat grinding that guarantees obtaining the predefined quality requirements of the machined surface while ensuring the maximum process efficiency. The input factors (grinding wheel hardness, depth of grinding, table feed speed and run, etc.) are considered as the grinding process optimization parameters. Mathematical models of the output factors (surface roughness parameter Ra, absence of grinding burns, required flatness tolerance of surface) are used to limit the range of optimization parameters allowable values. The resulted efficiency is an objective function. The optimization of parameters in the range of allowable values is carried out with the view of ensuring the maximum process efficiency. The required flatness admission is provided at the second optimization stage of the workpieces by controlling the elastic deformation extent. The varied parameters at controlling the maximum elastic deformation are cutting forces, the attraction of the magnetic field of the machine table and rigidity of workpiece at a bend. The terms for providing of the required side surface flatness tolerance are determined for workpieces taking into account elastic deformation of the small-rigid workpieces under the magnetic field effect on the machine table and the radial component of the grinding force. Keywords: elastic deformations; small-rigid prismatic workpieces; flat grinding; quality of machined surface; process optimization.