Model-based adaptive process control for surface finish improvement in traverse grinding

The paper presents a process controller aimed at improving the surface quality generated by traverse grinding, avoiding the surface defects caused by vibrations onset. The innovation provided by the pro- posed controller consists in suppressing vibration occurrence by means of a model-based and self- learning approach: a monitoring layer classifies occurring problems and a control logic exploits these indications to select the proper mitigation actions. Since wheel-regenerative chatter represents one of the most important problems during traverse grinding in terms of achievable productivity and finish- ing quality, the main control variable is the wheel velocity. This variable is tuned exploiting an adaptive Speed tuning Map computed by the controller using a heuristic approach and learning methodology. The control can manage also the other sources of vibration by means of proper identification and mitiga- tion strategies. Experimental tests are carried out on a roll grinder to validate the control system. Good performances are achieved after some training tests to allow controller learning.