A study on chatter boundaries of cylindrical plunge grinding with process condition-dependent dynamics

This paper presents a systematic study on the chatter characteristics of cylindrical plunge grinding processes. Chatter occurrence under a wide range of operating conditions is experimentally identified. The unique transient chatter behaviors during spark-in and spark-out of plunge grinding are also studied; and the transient chatter occurrence is separated from the steady-state chatter occurrence, which is used to define the chatter boundaries.It is shown that the measured structure dynamics of the wheel/workpiece exhibit strong dependency on grinding conditions. The dynamic/chatter model of cylindrical plunge grinding [H. Li, Y.C. Shin, A time-domain dynamic model for chatter prediction of cylindrical plunge grinding processes, ASME Journal of Manufacturing Science and Engineering 128(2) (2006) 404–415] is improved to handle the grinding force-dependent structure dynamics, and the modified model is validated by comparing the predicted chatter boundaries with experimental chatter conditions.