Stability analysis and optimization algorithms for the set-up of infeed centerless grinding

•Infeed centerless optimization requires to configure a stable process first.•Frequency and time domain analysis of characteristic instabilities play this role.•Multi-stage infeed grinding cycle definition is the second step for optimization.•Simulation and time domain continuity equation supports solving this problem.•Grinding cycle optimization is still an open field for researchers.

This paper introduces new algorithms for analysis and optimization of infeed centerless grinding, based on high-level integration of grinding models into a web-based simulation. This holistic approach to simulation facilitates system-level simulation and solvers for several interlinked problems associated with the process mechanics. Emphasis is on structuring the model-based simulation as well as adapting and incorporating the underlying models into the algorithms. Geometric lobing-, chatter- and spinning-related process stability, as well as a time domain continuity equation, are integrated into the simulation to analyze the main quality-related limitations of the process. Once the process stability is assured for the process set-up, optimization strategies and a new infeed cycle definition function are proposed to achieve a minimal or target cycle time. An example of experimental optimization is provided to compare a high-quality process with a target cycle time to an optimized high-productivity process – demonstrating a 70% reduction in cycle time.