A High Material Removal Rate Grinding Process for the Production of Automotive Crankshafts

In this paper the application of high efficiency deep grinding to cylindrical plunge grinding is demonstrated and thermal modelling used to optimise the grinding cycle for an automotive steel and cast iron. The benefits associated with the high work speed achievable in cylindrical grinding are highlighted and both thermal modelling and experimental measurements have established that low workpiece temperatures are possible even when specific material removal rates of 2000 mm3/mm.s are achieved. Surface integrity studies based on microstructural analysis and Barkhausen noise have also demonstrated the effectiveness of the process.