Adaptive Grinding Process (AGriPro) – Prevention of Thermal Damage using OPC UA Technique and in-Situ Metrology

Matthias Steffan, Franz Haas, Alexander Pierer, Jens Gentzen

Research output: Contribution to journalArticlepeer-review


The production process grinding deals with finishing of hardened workpieces and is one of the last stages of the value-added production chain. Up to this process step, considerable costs and energy have been spent on the workpieces. In order to avoid production rejects, significant safety reserves are calculated according to the present state of the art. The authors introduce two approaches to minimize the safety margin, thus optimizing the process’ economic efficiency. Both control concepts use the feed rate override of the machining operation as regulating variable to eliminate thermal damage of the edge zone. The first control concept is developed to avoid thermal damage in cylindrical plunge grinding by controlling the cutting forces. Therefore, the industrial standard Open Platform Communications Unified Architecture (OPC-UA) is used for the communication between a proportional–integral–derivative (PID) controller and the SINUMERIK grinding machine tool control system. For noncircular workpieces, grinding conditions change over the circumference. Therefore, thermal damage cannot be ruled out at any time during the grinding process. The authors introduce a second novel control approach, which uses a micromagnetic measure that correlates with thermal damage as the main control variable. Hence, the cutting ability of the grinding wheel and thermal damage to the workpiece edge zone is quantified in the process. The result is a control concept for grinding of noncircular workpieces, which opens up fields for major efficiency enhancement. With these two approaches, grinding processes are raised on higher economic level, independently of circular and noncircular workpiece geometries.
Translated title of the contributionAdaptive Grinding Process (AGriPro) - Prävention von thermischer Randzonenschädigung durch Verwendung von OPC UA und in-Situ Messtechnik
Original languageEnglish
Article number121008
JournalJournal of Manufacturing Science and Engineering
Issue number12
Publication statusPublished - 30 Aug 2017

Fields of Expertise

  • Mobility & Production


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