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Fig. 8. Five-level architecture of the CPS pyramid [167].

Figure 8 Five-level architecture of the CPS pyramid [167].

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Fig. 1. Role of grinding research in the process chain. K. Wegener et al./CIRP Annals - Manufacturing Technology xxx (2017) xxx-xxx
Fig. 1. Role of grinding research in the process chain. K. Wegener et al./CIRP Annals - Manufacturing Technology xxx (2017) xxx-xxx
Fig. 2. Different grinding processes. according DIN 8589, 11-13, defining grinding machines.
Fig. 2. Different grinding processes. according DIN 8589, 11-13, defining grinding machines.
Fig. 4. Schematic representation of contact ratio and resulting chips from standard corundum grain and the Cubitron II grain [1,218]. Fig. 3. Microcrystalline sintered corundum abrasive grains: a) grain structure with elongate shape, b) grains with dimension proportion 4:1 c) wheel structure with elongated shape of grains [216].
Fig. 4. Schematic representation of contact ratio and resulting chips from standard corundum grain and the Cubitron II grain [1,218]. Fig. 3. Microcrystalline sintered corundum abrasive grains: a) grain structure with elongate shape, b) grains with dimension proportion 4:1 c) wheel structure with elongated shape of grains [216].
Fig. 5. Influence of lubricant coolant types on the surface roughness of titanium- nickel-nitride coated steel [113].
Fig. 5. Influence of lubricant coolant types on the surface roughness of titanium- nickel-nitride coated steel [113].
Fig. 6. Reduction of manufacturing times (Courtesy Reishauer). Besides all demands from customers, the overall productivity increase is the superordinated and omnipresent requirement. Drastic increase of productivity is indicated in Fig. 6 for the example of a gear grinding machine, due to increase of manufacturing speed and also due to automation and reduction of secondary times. This trend is still continuing.
Fig. 6. Reduction of manufacturing times (Courtesy Reishauer). Besides all demands from customers, the overall productivity increase is the superordinated and omnipresent requirement. Drastic increase of productivity is indicated in Fig. 6 for the example of a gear grinding machine, due to increase of manufacturing speed and also due to automation and reduction of secondary times. This trend is still continuing.
Fig. 7. Business aura of grinding machine tools as CPPS.
Fig. 7. Business aura of grinding machine tools as CPPS.
Fig. 9. Left: Massy design of grinding machine bed of polymer concrete with
Fig. 9. Left: Massy design of grinding machine bed of polymer concrete with
Fig. 10. Effects of machine drive concepts on grinding cycle time.
Fig. 10. Effects of machine drive concepts on grinding cycle time.
Fig. 12. Direct linear drive system left, Guideways for combined hydrostatic hydrodynamic support right [95].
Fig. 12. Direct linear drive system left, Guideways for combined hydrostatic hydrodynamic support right [95].
Fig. 11. Composite drive arrangement and Polar plot of circular motion of X-Y hydrostatic slides driven by linear motors [120].
Fig. 11. Composite drive arrangement and Polar plot of circular motion of X-Y hydrostatic slides driven by linear motors [120].
Fig. 13. Planar model of an isolated machine [168]. By understanding the machine as an integrated mechatronic system [213], an analysis of the system with regard to its characteristics, significantly given by the drives, can be carried- out on the rigid-body level. In Ref. [168], a vibration insulation system is analysed using 2D-models as shown in Fig. 13. The design rule here is to align the isolators’ locations with the centre of gravity (CG) [16,223,231].
Fig. 13. Planar model of an isolated machine [168]. By understanding the machine as an integrated mechatronic system [213], an analysis of the system with regard to its characteristics, significantly given by the drives, can be carried- out on the rigid-body level. In Ref. [168], a vibration insulation system is analysed using 2D-models as shown in Fig. 13. The design rule here is to align the isolators’ locations with the centre of gravity (CG) [16,223,231].
In order to obtain the model parameters of the grinding system, a variety of identification procedures has been proposed.
In order to obtain the model parameters of the grinding system, a variety of identification procedures has been proposed.
Fig. 15. Improvement of form deviations based on on-machine measurements [143]; left: PV before compensation: 22.2 wm, right: PV after compensation: 6.5 wm.
Fig. 15. Improvement of form deviations based on on-machine measurements [143]; left: PV before compensation: 22.2 wm, right: PV after compensation: 6.5 wm.
Fig. 17. Actuators and sensors for adaptive machines [249].
Fig. 17. Actuators and sensors for adaptive machines [249].
Fig. 16. Improvement of thermal location errors during an arbitrarily chosen load cycle of A- and C-axes, using a grey-box model for on-line compensation [102].
Fig. 16. Improvement of thermal location errors during an arbitrarily chosen load cycle of A- and C-axes, using a grey-box model for on-line compensation [102].
Fig. 18. Active wheel-holding module [37].
Fig. 18. Active wheel-holding module [37].
Fig. 19. Multi-channel power profile of a cylindrical grinding machine based on specific customer requirements in standard configuration according to Ref. [104].
Fig. 19. Multi-channel power profile of a cylindrical grinding machine based on specific customer requirements in standard configuration according to Ref. [104].
Fig. 21. Inner flow profile and with the help of CFD-simulations optimized profile of a new nozzle with equal flow distribution at exit [8]. 5.2. Dressing An optimized fluid supply remains a challenge in grinding as grinding wheels are reprofiled and also change their diameter dramatically. Heinzel et al. [121] proposed a measurement chain to maintain the most important factors for the coolant supply. To maintain the flow speed at different volume flow rates a nozzle with adaptive exit cross-section based on Rouse’s design is used as shown in Fig. 23. In a closed-loop control, the optimal supply
Fig. 21. Inner flow profile and with the help of CFD-simulations optimized profile of a new nozzle with equal flow distribution at exit [8]. 5.2. Dressing An optimized fluid supply remains a challenge in grinding as grinding wheels are reprofiled and also change their diameter dramatically. Heinzel et al. [121] proposed a measurement chain to maintain the most important factors for the coolant supply. To maintain the flow speed at different volume flow rates a nozzle with adaptive exit cross-section based on Rouse’s design is used as shown in Fig. 23. In a closed-loop control, the optimal supply
Fig. 20. Dedicated fluid supply for a single purpose application [84].
Fig. 20. Dedicated fluid supply for a single purpose application [84].
Fig. 22. Additively manufactured grinding nozzles and the resulting G-values fo1 coordinate grinding of ZrO2 dental implants.
Fig. 22. Additively manufactured grinding nozzles and the resulting G-values fo1 coordinate grinding of ZrO2 dental implants.
Fig. 23. Rouse shaped nozzle with adjustable exit orifice (left) and motor-driven height and angle adjustment for the nozzle (right) [121].
Fig. 23. Rouse shaped nozzle with adjustable exit orifice (left) and motor-driven height and angle adjustment for the nozzle (right) [121].
Fig. 25. Left: situation of wire guidance, electrical contact and coolant flushing system; right: WireDress™ unit [155].
Fig. 25. Left: situation of wire guidance, electrical contact and coolant flushing system; right: WireDress™ unit [155].
Fig. 24. SEDD by Agathon [241] called PowerGrind and patented in EP2072182 (B1) [89].
Fig. 24. SEDD by Agathon [241] called PowerGrind and patented in EP2072182 (B1) [89].
Fig. 26. Principle of the thermo-chemical dressing process.
Fig. 26. Principle of the thermo-chemical dressing process.
Fig. 27. Dressing methods with ultrasonic assisting [256].
Fig. 27. Dressing methods with ultrasonic assisting [256].
Fig. 28. Tool changer with 6 positions that simultaneously changes grinding wheel together with the associated nozzle [90].
Fig. 28. Tool changer with 6 positions that simultaneously changes grinding wheel together with the associated nozzle [90].
Fig. 30. Magerle grinding centre MFP100 [188]: left: chain magazine of pairs of grinding wheel and associated dressing tool; right: grinding and dressing spindles for continuous dressing with 2-axes-coolant-nozzle.
Fig. 30. Magerle grinding centre MFP100 [188]: left: chain magazine of pairs of grinding wheel and associated dressing tool; right: grinding and dressing spindles for continuous dressing with 2-axes-coolant-nozzle.
Fig. 29. Tool magazine for grinding tools [9].
Fig. 29. Tool magazine for grinding tools [9].
Fig. 32. BoX five axis grinding machine [64].
Fig. 32. BoX five axis grinding machine [64].
Fig. 31. Part sizes and their accuracies in micro-processing and ultra-precision machining [47].
Fig. 31. Part sizes and their accuracies in micro-processing and ultra-precision machining [47].
Fig. 34. Angular positioning of the grinding wheel by the use of B-axis based on a flexure hinge [1].
Fig. 34. Angular positioning of the grinding wheel by the use of B-axis based on a flexure hinge [1].
Fig. 33. On-machine measurement for diamond grinding [42].
Fig. 33. On-machine measurement for diamond grinding [42].
Fig. 35. 3 different methods of US assisted grinding. US-assistance reduces cutting forces, reduces wear of the grinding tool and enhances the surface quality. US-assisted grinding according to Ref. [41] turns out to strongly reduce feed forces up to 50%. These excitation systems are integrated within the spindles [281] for internal grinding. In Ref. [115] a system is reported with high rotational speed up to 60,000 rpm to reach real cutting speeds for grinding and suitably increase of the US- frequency up to 70 kHz.
Fig. 35. 3 different methods of US assisted grinding. US-assistance reduces cutting forces, reduces wear of the grinding tool and enhances the surface quality. US-assisted grinding according to Ref. [41] turns out to strongly reduce feed forces up to 50%. These excitation systems are integrated within the spindles [281] for internal grinding. In Ref. [115] a system is reported with high rotational speed up to 60,000 rpm to reach real cutting speeds for grinding and suitably increase of the US- frequency up to 70 kHz.
Fig. 36. Left: tool revolver for grinding turning machine [95]; right: grinding— turning benchmark [73].
Fig. 36. Left: tool revolver for grinding turning machine [95]; right: grinding— turning benchmark [73].
Fig. 37. Large combined coordinate grinding and milling machine.
Fig. 37. Large combined coordinate grinding and milling machine.
Fig. 38. Desktop machine with path and force control option [77]. 7.2. Databases
Fig. 38. Desktop machine with path and force control option [77]. 7.2. Databases
Fig. 39. Micro grinding machine from Ref. [267].
Fig. 39. Micro grinding machine from Ref. [267].
Fig. 42. Simulation of centreless grinding geometric stability [24]. The simulation-based setup assistant (SUA) included models for grinding power, forces and roughness. Besides the identification of stability, a time-domain simulation was developed to predict the roundness deviations. The SUA shown in Fig. 43 allows the user to
Fig. 42. Simulation of centreless grinding geometric stability [24]. The simulation-based setup assistant (SUA) included models for grinding power, forces and roughness. Besides the identification of stability, a time-domain simulation was developed to predict the roundness deviations. The SUA shown in Fig. 43 allows the user to
Fig. 44. Comparison of state of the art in industry and research. The review of the state of the art in grinding machines shows a clear difference between scientific state of the art or understanding and industrial readiness on machines. The expert-based assess- ment supported by market research, patents and scientific literature is shown in Fig. 44. The blue outer circumference of the diagram outlines the expected requirements, namely those extrapolated into the future for high end machines. Measured relative to these requirements, the current state of research and understanding is shown in red, where the difference to the blue line is indicating the research gap. Drawn in black is the current state of technology in high end commercialized machines, where the gap to the red line signifies the deficiencies in application of existing research results and to the blue line the development potential. Naturally machine tools fulfill actual market require- ments, which makes a gap to the blue line system immanent. No technology is really finalized from the research point of view either.
Fig. 44. Comparison of state of the art in industry and research. The review of the state of the art in grinding machines shows a clear difference between scientific state of the art or understanding and industrial readiness on machines. The expert-based assess- ment supported by market research, patents and scientific literature is shown in Fig. 44. The blue outer circumference of the diagram outlines the expected requirements, namely those extrapolated into the future for high end machines. Measured relative to these requirements, the current state of research and understanding is shown in red, where the difference to the blue line is indicating the research gap. Drawn in black is the current state of technology in high end commercialized machines, where the gap to the red line signifies the deficiencies in application of existing research results and to the blue line the development potential. Naturally machine tools fulfill actual market require- ments, which makes a gap to the blue line system immanent. No technology is really finalized from the research point of view either.
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