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1 Journal of Machine Engineering

1 2011

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The effects of process parameters on spindle power consumption in abrasive machining of CoCr alloy

Brazel E., Hanley R., O'Donell G. E.

Journal of Machine Engineering

2011

Vol. 11, No. 4

59--69

The production environment requires seamless integration, efficiency and robustness of process monitoring solutions. This research investigates data acquisition on the machine tool through the monitoring of NC kernel data. This approach provides many advantages, particularly in an industrial setting where it may be impractical to install additional sensors for process monitoring. The process investigated is abrasive machining of Cobalt Chrome alloy. Cobalt Chrome alloys are extensively used in the biomedical industry as both femoral and tibial components of prosthetic joints. Abrasive machining or grinding is widely employed as the main method for material removal for these components. Understanding the influence of key variables in such a process is necessary before optimization can be achieved. Significant information can be obtained by utilizing power consumption during machining as a process metric. Power consumption of a spindle during an abrasive machining process of Cobalt Chrome alloy is monitored under various conditions through a machine-NC-based application. The effects of changes in feed rate, wheel speed, depth of cut and tool condition are investigated here through Taguchi experimental design. Experimental results are presented with significant machining variables identified.