Multistage centerless grinding setup via discrete mapping

This article introduces a multistage approach for the execution of plunge centerless grinding operations aimed at accelerating waviness cancellation from workpiece initial profile, while preventing the harmful consequences of geometrical process instability. It suggests decomposing the process into multiple phases characterized by different workpiece heights and/or blade angle. The best parameters combination is identified by computing and analyzing the transition matrix of the overall process after a discretization of the profile evolution equation. Choosing to apply a two stages process, a map is computed with the most critical amplification gain of the harmonic components on the workpiece profile, for different heights combination. The gain map can be used to identify the height combination that guarantees a given roundness reduction with the minimal process duration for any initial profile. The analysis result is demonstrated comparing the effectiveness of a 2-stages process with the usual single stage process of the same duration.