MACHINING COSTS IN GRINDING

Ante Pavić, Borislav Josipović, Marijan Brozović

Prof.dr.sc. A. Pavić, Polytechnic of Karlovac, I. Meštrovića 10, 47000 Karlovac

M.Sc. B. Josipovic, lecturer, Polytechnic of Karlovac, I. Meštrovića 10, 47000 Karlovac
M. Brozović, lecturer, Polytechnic of Karlovac, I. Meštrovića 10, 47000 Karlovac

11th INTERNATIONAL SCIENTIFIC CONFERENCE ON PRODUCTION ENGINEERING –CIM2007

Croatian Association of Production Engineering, Zagreb 2007
Keywords: the grinding process where:
machining costs, optimisation the intent L – total machining (07)
grinding, dressing of is that machining costs length (mm),
where: Vs - total
grinding wheels will be lower, by no – workpiece rev. per
grinding wheel losst
correct choice of minute (rpm),
volume per tool life, i.e.
Abstract cutting data with fa – axial feed (mm/rev.
between two
Grinding is a very keeping required of workpiece),
dressings (mm3/tool
important and often machining quality. aeuk – total depth of cut
life), kw – costs per one
used fine machining Externally cylindrical for grinding (mm), mm3 of grind. wheel
operation of precise longitudinal grinding ae – depth of cut per volume (Kn/mm3), zT -
parts in production will be described. one stroke (mm), workpiece number per
engineering. Thus, the k – coefficent for spark one tool life.
machining costs are 2. MACHINING machine time.
an essential estimate COSTS IN GRINDING Grinding wheel
After a certain dressing costs per one
criterion for grinding Maschining costs
machining time it workpiece are
process applicability. per one workpiece (or
comes to wearing out calculated according
In this paper the one operation) in
of the grinding wheel to the formula [1]:
structure of the grinding, like in
which for this reason
grinding costs is given machining by cutting
and an aproach to tools with defined
loses one part of its KML  t ed  Vsd  k w K wd
volume Vst. Now, it is Kd  
their calculating as a cutting geometry,
necessary to dress the
zT zTd  zT
example of externally contain the workplace (08)
grinding wheel work
cylindrical longitudinal costs KPM and the tool
area, for example by where:
grinding is derived. (grinding wheel) costs
one point diamond KML - workplace work
KA, [1,2]:
dresser. In dressing the price per minute
1. INTRODUCTION
In modern K O  K PM  K A grinding wheel loses (grinding
(01) also one part of its machine +
automatized
volume Vsd. Therefore, operator costs),
production the fine The workplace costs total lost volume Vs of
machining operations Kn/min,
are determined by grinding wheel is:
application and NNST ted - grinding wheel
formula [3]:
technology principles Vs  Vst  Vsd dressing time based
are increasing. KPM  KML  tk on one
Besides an increasing workpiece
(05)
introduction of fine (min/dressing),
machining operations Therefore, tool costs Vsd - grinding wheel
like micromilling, fine (02) KA are contain the lost volume during one
hard machining etc., In previous the formula costs KV i. e. grinding dressing
machining by grinding it is: wheel lost volume costs (mm3/dressing) ,
will remain an in grinding process, and Kwd - cutting tool e.g.
KML – workplace work
important and often price per minute also the costs Kd of diamond dresser
irreplaceable fine (grinding machine + grinding wheel purchase
machining approach in operator costs), dressing in which the price (Kn),
future. This especially Kn/min. costs of grinding zTd - total number of
refers to workpieces tk – piece time (min): wheel lost volume and dressings which the
from materials which work costs in dressing, diamond
are difficult to tk  (t t  tp )(1  k d ) which makes: dresser can
machine. endure (total dresser
KA  KV Kd
The criteria for a life).
valuation of grinding (03)
(06) Specific volume of
process applicability tt – machining time removed material in
are: (1) workpiece ( min), Grinding wheel lost externally cylindrical
machined surface tp – auxiliary volume costs: KV longitudinal grinding
quality (roughnes, time( min), (Kn/piece) per one
is:
measure accuracy, workpiece are calculated
surface integrity), (2) 2  L aeuk by the formula: Qb  π  Do  ae  v fa
grinding wheel tool
tt   k
no  fa ae Vs  k w (mm3/s),
life, (3) machining KV  (09)
costs and (4) grinding
(04)
zT
process efficiency. In where:

11th INTERNATIONAL SCIENTIFIC CONFERENCE ON PRODUCTION ENGINEERING –CIM2007

Croatian Association of Production Engineering, Zagreb 2007
June, 13-17, 2007 Biograd, Croatia CIM2007

Do – workpiece account of grinding Grinding wheel wheel is used up

diameter (mm), and dressing per one diameter after about 58 %. Grinding
ae – depth of cut per tool life, asb – depth of dressing is: wheel volume is:
one stroke (mm),
vfa – grinding wheel
grinding wheel worn
layer on account of
Db2 = Db1 - 2asp,
Db2 = Db - 2as
or
Vb  B 
π
4

 Db2  Do2 
rate of feed in the grinding, asp - depth of Grinding wheel radius
(mm3)
direction of grinding wheel worn is: Rb = 0.5·Db
(15)
workpiece axis out layer on account of It is known that the
(mm/s). dressing, B – grinding grinding wheel
3. GRINDING WHEEL
By increasing the wheel width, Db1 – minimal allowed radius
DRESSING
specific volume of the grinding wheel of wear is: Rmin =
Workpiece number
removed material in external diameter after 0.65·Rb
zT which can be
grinding, the following end wear in grinding, Grinding wheel total
machined in one tool
results: Db2 – grinding wheel number of dressings
life (workpieces/tool
 decreasing the external diameter after up to total wear is:
life):
cutting time tt, dressing.
 decreasing Rb  Rmin
Grinding wheel ip  Tb
number the as zT 
volume which was lost tt
workpieces mT in grinding is smaller
that can be and is usually: Vs = (12)
machined during (16)
(0.1 to 0.2)∙Vsd .
one tool life, The costs in Kn per 1 where:
Grinding wheel depth
 increasing the mm3 of grinding wheel Tb - tool (grinding
for dressing usually
dressing time per volume are given wheel) life (min),
ranges from asp = 0.05
one workpiece ted according to the tt - cutting time (min).
to 0.08 mm.
(s/workpiece), formula:
 increasing the Depth of grinding Grinding wheel tool life
wheel to worn out C depends on of the kind
dressing costs Kd kw  b
per one layer on account of Vbe grinding operation,
workpiece. grinding is: asb ≈ and is according to [4]:
0.15∙asp mm. - externally cylindrical
Grinding wheel (13)
Total depth which is long. grinding with
sketch for removed from grinding where: tool exit and
calculating the wheel is: as = Cb – grinding wheel externally radial
volume loss Vs is asp+asb ≈ purchase price (Kn), grinding: 40 min
given in Figure 1. 0.065+0.065∙0.15 ≈ Vbe – grinding wheel - externally long.
0.08 mm effective volume grinding without tool
Grinding wheel (mm3). exit: 30 min
volume lost in grinding - flat circumference
Grinding wheel
process is, in Figure 1: grinding:
effective volume is: Vbe
25 min
 D 2π D 2 π  = Vb - Vbmin.
- internally grinding,
Vs   b  b 1 B
 4 4   πDb πDmin 
2 2 flat face grinding
 
Vbe      B  and profile grinding:
 4 4 
 10 min
(10)  πDb2 π  0,65  Db2  Cutting data by
  B
Grinding wheel  4 4  dressing of grinding
  wheels [4,5,6]:
diameter after end
wear in grinding is: Using the relation Dbmin - cutting speed: vcd =
Figure 1. Grinding Db1 = Db - 2asb = 0,65·Db (at total
wheel sketch 15 do 20 m/s,
Grinding wheel worn out grinding - total depth of cut by
volume loss in wheel) it is finally: dresing:
Simbols in Figure 1: dressing is:
Db – grinding wheel 2 aed uk = asp = 0.05 do
πD b 2 0.1 mm
external diameter, Do -  Db21π Db2 2π  Vbe  (1  0,65 )  B  0,58  Vb
grinding wheel boring Vsd     B 4 - dresser axial feed
 4 4  speed:
diameter, as – total   (14)
depth of grinding (11) vfad = 150 do 300
Acordingly, volume mm/min
wheel lost layer on Vb of new grinding

3
CIM2007 June, 13-17, 2007 Biograd, Croatia

- dresser axial feed 1000  60  v cd Grinding wheel work Depth of cut per
per rev. of the grinding n bd  area roughness: stroke: ae = 0.02
wheel: π  Db 2 mm/hod
f ad
fad = 0.05 do 0.15 (rev/min) (18) Rzb  125  Diamond dresser
(max. 0.2) mm/rev. rd purchase price: Kwd =
Total time needed for
- dressing depth of cut (mm) 650,00 Kn
grinding wheel
per one double stroke (21) Total number of
dressing ted contains
of the dresser: dressings (4 edges):
grinding wheel where: rd (mm) –
aed = 0.02 do 0.03 zTd = 1600
dressing time td diamond dresser nose
mm/d.h. - in rough k – coefficent of spark
(cutting time) and radius.
dressing machine time: k = 1,2
auxiliary time tpd
aed = 0.005 do 0.010 In this example the
needed for one 3. PRACTICAL
mm/d.h. - in fine standard case of
dressing: EXAMPLE AND
dressing externally cylindrical
Remark: rough t ed  t d  t pd RESULTS grinding with tolerance
(min)
dressing is used at In machining operation measure is given.
coarse grain size and of externally Total depth of cut is
(19) cylindrical
fine dressing at fine 0.2 mm in diameter.
grain grinding wheels. Cutting time contains longitudinal grinding The values needed for
Dressing is performed grinding wheel of workpiece Ø calculating according
with 1 to 2 double dressing time with 60.2x145 to dimension to sources [5,6,7]
strokes at depth of cut longitudinal feed and Ø 60±0.01x145, it is were accepted, and
aed, and than 2 to 3 grinding wheel needed to calculate afterwards this by
double stokes are smoothing time, and it machining costs. using the given
added (on account of will be calculated by formula the requisted
Given data:
smoothing of the the formula: values were obtained.
Total depth of cut: aeuk
grinding wheel) The results are given
B  l1  l 2 = 0,1 mm (from
without radial feed i.e. in Tables 1. and 2.
td  i workpiece)
aed = 0. Total depth of nbd  fad Workpiece number in Workplace costs
the layer removed
(min) batch: zos = 100 calcul. data are given
from the grinding
(20) Workpiece material: in Table 1.
wheel is up to 0.08
42CrMo4, 264 HB
mm. where: Table 1. Workplace
Grinding wheel:
l1 = l2 ≈ 6 do 12 mm - costs calculate data
If are given the 2A46/2J6V35
entry / exit of the
dresser feed speed - dimensions: Ø Values
dresser,
vfad and grinding wheel DbxBxDo = Ø
ndb - grinding wheel Cutting speed: vc (m/s) 30
cutting speed in 500x40x203 mm
number during Workpiece speed:vo (m/min) 20
dressing vcd are given, Grinding wheel Workpiece diameter: Do (mm) 60.
dressing
giving the grinding purchase price: Cb = Axial feed of grinding wheel:fa
(rev/min), 16
wheel rotation 1686.00 Kn fa = 0.4·B (mm/rev)
fad - dresser axial feed
speed in dressing Grinding wheel tool Depth of cut: ae (mm/stroke) 0.0
(mm/rev. of grinding
nbd, it is possible to life: Tb = 40 min Total depth of cut:aeuk (mm) 0.1
wheel),
calculate the dresser Machine tool: Cutting time: tt (min) 1.0
i - total number of
longitudinal feed fad Externally cylindrical Piece time: tk (min/piece) 2.4
dresser passes. For
(mm/rev. wheel): grind. machine Workplace costs:
16.0
example, KPM (Kn/piece)
Workplace price per
v if dressing is
fad  f performed with 2
hour: KML = 400.00
nbd Kn/h Tool costs calculate
double strokes Set-up-end time: tpz = data are given in Table
(17) and 2 double 30 min/lot 2:
strokes for Auxiliary time: tp =
where: Table 2. Tool costs
smoothing (at 0.92 min calculate data
vf - feed speed the same feed fad) Coefficient of added
(m/min), are added, than it is: time: kd = 0.2 Values
nb - grinding wheel i = 22 + 22 = 8 Total machining Total depth of cut by grinding
0.0
rotation speed in strokes. length: L = 145 + 8 = wheel dresing: asp (mm)
dressing Smoothing time is 153 mm Depth of grinding wheel worn
0.10
(rev/min): included in added out layer: asb= 0,15·asp (mm)
strokes for smothing. Total depth removed from
0.08
grind. wheel:as= asb+asp (mm)

4
June, 13-17, 2007 Biograd, Croatia CIM2007

Total lost volume of grinding It is possible to čestica, own

wheel per tool life: Vs (mm3) sum up that the edition.
Total number of dresings to [3] König, W.;
total grinding wheel wear: ip
calculation of the
Klocke, F., 1981,
Grinding wheel volume loss in grinding machining Fertigungsverfahr
dressing: Vsd (mm3) costs is very difficult.
en – Band 1,
Costs per one mm3 of grind. The reason for this
wheel volume: kw (Kn/mm3) is specific grinding Drehen, Fräsen,
Grinding wheel vol.: Vb (mm Bohren, VDI
process affected by Verlag.
Grinding wheel effective vol:
Vbe = 0,58·Vb (mm3) lot of influencing [4] Velikanov, K.M.,
Workpiece number machined factors. 1989, Rasčeti
in one tool life: zT (pieces) The shares of ekonomičeskoj
Grinding wheel dressing individuel cost are efektivnosti novoj
speed: vcd (m/s) similer to those in the tehniki,
Number of strokes in dressing machining methods Mašinostroenie.
i = 8 (4 rough + 4 fine) performed with a [5] Lochmann, K.:
Dressing time: td (min) geometrically defined Fertigungstechnik
Total dressing time: ted (min) edge, where share of (Formeln),
Dressing costs: Kd (Kn/piece) the cutting tool costs is 2001, Hanser
Grinding wheel lost volume
about 3 to 5 % in the Fachbuchverlag.
costs: KV (Kn/piece)
Total tool costs KA (Kn/piece)
total machining costs. [6] Tschätsch, H.:
Praxiswissen
4. CONCLUSION Zerspantechnik,
Total machining
Based on obtained 1997, Vieweg
costs of the
results, it is possible to Verlag.
grinding:
conclude the folloving: [7] Schönherr, H.:
KO = KPM + KA = - in cutting tool Spanende
16.00+0.8586 = 16.86 costs the part of Fertigung, 2002,
Kn/piece grinding wheel Oldenburg
dressing costs are 99 Verlag.
Total machining
% and grinding wheel
costs for batch:
lost volume costs are
KOU = KOּzos = about 1 %.
16.86ּ100 = 1686.00 - in total machining
(Kn/batch) costs of grinding
operation, the
The histogram of the workplace costs are
obtained results of about 95 %, and
machining costs is cutting tool costs
presented in Figure 2. about 5 %.
- for the practical
calculating of
Machining costs machining costs in
grinding, it is needed
20 to have many exact
16
input data about
Ko (Kn/workpiece)

15 grinding process,
grinding wheel and
10 diamond dresser.
5
5. REFERENCES
0,8586
[1] Fritz, A. H.;
0
Schulze, G.,
Costs: KPM KA
1998,
Figure 2. Histogram of Fertigungstechnik
machining costs , Springer Verlag.
KPM – workplace costs, [2] Cebalo, R., 2000,
KA – tool costs Obrada
odvajanjem