Entwicklung und Erprobung sensorintegrierter Schleifwerkzeuge

Grinding is an important manufacturing technique widely used in industry. Despite their great significance, grinding processes still lack in sensoring, monitoring and assessment qualities. The main obstacle in realizing full in-process control of grinding in industry today is principally the lack of sufficient and reliable information obtained directly from the grinding zone. This is clearly caused by the difficult accessibility for conventional measuring techniques.A new approach to get information about temperatures and forces is the wheel based measurement of these process parameters, followed by telemetric data transfer. This concept offers an efficient monitoring of the grinding process, which constitutes the basis for the generation of new control strategies. Within this doctoral thesis macroscopical demonstrators have been built to prove the suitability of the sensor-equipped approach. For this purpose, conventional sensors such as a three-dimensional force sensor and wire thermocouples were implemented into the grinding layer. A telemetric unit attached to the wheel core contained the signal conditioning and performed the data transfer to a stationary receiver. By this way, observance of the key parameters within different grinding operations as closely as possible to the machining point was enabled and so observance of process efficiency and tool status was realized. In detail, the demonstrators were used for contact detection, monitoring of dressing and grinding and detection of tool fracture. After the feasibility study using macroscopic sensors the miniaturisation of the sensors was taken into consideration.