A Study on Bistability Analysis and Chatter Suppression for Roll Grinding Process

As chatter vibration in roll grinding process is the largest limitation in surface quality of machined roll. In this paper, the bistability analysis and chatter suppression are performed for further discussion of patterns of the grinding chatter to reduce the cost of enterprises. A new three degrees of freedom dynamic model with both the regenerative effect and nonlinear stiffness of grindstone indicated by Duffing oscillator is presented, and its availability is validated by the experiment. By means of the DDE-BIFTOOL, a numerical calculation package, the effect of process parameters on grinding stability is studied extensively, proving that a large grinding width worsens the stability in roll grinding and the parameters locating in unsafe areas should be avoided for a stable grinding operation in practice. In addition, the control techniques involving both the nonlinear velocity feedback and the chaos perturbation are proposed for the suppression of chatter vibration in grinding operation to decrease the amplitude of its vibration. The results show that these techniques give a significant performance for reducing the amplitude of chatter vibration, namely, the stability of grinding process is augmented, which give a new idea for firms in chatter suppression.