Productivity increase in tool grinding with the help of a "sensing" spindle

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Currently, axial slots in cemented carbide milling cutters and drills are machined using creep grinding operations (peripheral longitudinal grinding). As a result of the process forces and limited stiffness of the workpiece, significant displacement occurs between the workpiece and the grinding wheel. Minimizing the displacement requires a time-consuming set-up process with and without the use of a steady rest. The aim of the proposed project is to minimise the displacement and shorten the set-up time by eliminating the steady rest. Therefore, a displacement compensation is developed, which compensates the displacement occurring in the process. For this purpose, a force sensor system is developed which is installed in the workpiece spindle and measures the acting process forces. Rigidity models and automated measuring cycles are used to calculate the displacements caused by the process forces to compensate them by use of machine axes as part of online compensation. Thus, the productivity is significantly maximized, especially for small batch sizes. Furthermore, raw material is saved by minimizing rejects.