• Transactions of the Korean Society of Mechanical Engineers A
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• v.28 no.7
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• pp.896-903
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• 2004

This paper proposes the structural characteristic analysis and evaluation on the hydrostatic guide way and feeding system of a high-precision centerless grinder for machining ferrules. In order to realize the required accuracy of ferrules with sub-micron order, the axial stiffness and motion accuracy of feeding system have to become higher level than those of existing centerless grinders. Under these points of view, the physical prototype of feeding system composed of steel bed, hydrostatic guide way and ballscrew feeding mechanism is designed and manufactured for trial. Experimental results show that the axial and vertical stiffnesses of the physical prototype are very low as compared with those design values. In this paper, to reveal the cause of these stiffness difference, the structural deformations on the virtual prototype of feeding system are analyzed based on the finite element method under experimental conditions. The simulated results illustrate that the deformation of front ballscrew support-bearing bracket is the main cause of reduction in the axial stiffness of feeding system, and the deflection of bed structure and the bending deformation of hydrostatic guide rails are the main causes of reduction in the vertical stiffness of feeding system.

• Journal of the Korean Society for Precision Engineering
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• v.22 no.11 s.176
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• pp.142-150
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• 2005

Design and performance evaluation of a spindle system which was composed of a grinding spindle and a regulating spindle for the centerless grinding of ferrule were performed in this paper. Layout and details of spindle system were designed and hydrostatic bearings for spindles were also designed. Prototype of spindle system was developed and its availabilities to machine the ferrule were discussed using the experimental results on the spindle stiffness of each spindle, loop stiffness, rotational accuracy and thermal characteristics. Loop stiffness of the spindle system was $130\;N/{\mu}m$, which was enough to machine the ferrule. Rotational accuracies of each spindle were about $0.2{\mu}m$ at the primary speed of 2,300 rpm(grinding spindle) and 300 rpm(regulating spindle). Temperature rises at the same speed were about $4.4\~4.7^{\circ}C$ in the case of grinding spindle and $1.8^{\circ}C$ in the case of regulating spindle, which agreed well with the designed value. From these results, it was estimated that the prototype of spindle system had enough performances for the centerless grinding machine to machine the ferrule.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.10a
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• pp.65-69
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• 2002

In order to practicalize high precision centerless grinder for machining the ferrule, its feeding system is designed and tested. For satisfying the desired diametric tolerance and cylindricity of the ferrule, the feeding system is designed to have relatively high axial stiffness of 600 N/$\mu\textrm{m}$, high angular motion accuracy of 0.5 arcsec/mm in yaw direction and minimum resolution of 0.05 $\mu\textrm{m}$. A prototype of feeding system is built up with hydrostatic guideway and ballscrew. A linear scale with 0.05 $\mu\textrm{m}$ of resolution is used for position feedback. Experimental results show that the feeding system has the infinity of axial stiffness within the range of 1000 N and 0.3 arcsec/mm of yawing error. Also the feeding system shows obvious step response against 0.05 $\mu\textrm{m}$/step command without the lost motion or backlash. Although the vertical stiffness is reduced to 440 N/$\mu\textrm{m}$ by the elastic deformation of rail, it is good enough to use for machining the ferrule. From above, it is confirmed that the feeding system is applicable to centerless grinder for machining the ferrule.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.6-9
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• 2005

In this study, the ultra precision centerless grinder for ferrule grinding was designed. As the good-qualified ferrule is required a precise and fine grinding, grinding machine for ferrule must have a high accuracy and a sufficient stiffness. The centerless grinder is composed of the high damping concrete bed, grinding wheel spindle unit, regulating wheel spindle unit, feeding table and dressing unit. For a newly developed centerless grinder, hydrostatic system with high precision feeding and high stiffness was proposed. The grinding and regulating wheel spindle units were composed of hydrostatic spindle and feeding table was hydrostatic table. The prototype of hydrostatic table was manufactured and tested.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2006.05a
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• pp.557-558
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• 2006

In this study, the ultra precision centerless grinder for ferrule grinding was designed. As the good-qualified ferrule is required a precise and fine grinding, grinding machine for ferrule must have a high accuracy and a sufficient stiffness. The centerless grinder is composed of the high damping concrete bed, grinding wheel spindle unit, regulating wheel spindle unit, feeding table and dressing unit. For a newly developed centerless grinder, hydrostatic system with high precision feeding and high stiffness was proposed.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.8
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• pp.19-26
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• 2004

정밀 공작기계에 있어 안내/이송계(이하, 이송시스템)의 중요성은 새삼스럽게 강조할 필요가 없을 정도로 꾸준히 강조되어 왔다. 또한, 최근 들어서는 광부품, 반도체, 디스플레이 등 초정밀 가공기술시장의 급격한 확대에 따라 이들 산업의 제조장비용 핵심기술로서 이송시스템의 역할 및 수요는 훨씬 확대되어가고 있으며, 오히려 요구정밀도 면에서는 공작기계상에서의 요구성능을 초월하여, 이들 산업에서 개발된 기술이 역으로 공작기계에 적용되어야하는 시점으로까지 진전되고 있다.(중략)

• Journal of the Korean Society for Precision Engineering
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• v.20 no.7
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• pp.70-77
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• 2003

The centerless through-feed grinding is performed by passing the workpiece between the grinding wheel and the regulating wheel. So, the amount of removed material around the leading end, of the workpiece is always more than that around the trailing end until the leading end leaves the grinding wheel. Because of this, there are differences in diameters along the workpiece axis during grinding, and workpiece axis is not parallel to the grinding wheel axis and the contact lines between the workpiece and wheels. Thus the ground workpiece shows tapering error inherently. To eliminate this error, the workpiece axis must be kept to be parallel to the grinding wheel axis. And, the direction of the workpiece axis can be controlled by the work-rest blade. Therefore, the effects of work-rest blade inclination angle on the through-feed centerless ground part are investigated in this study. As a result, it is found that there is a positive inclination angle of the work-rest blade for minimizing the tapering error of a ground workpiece.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.108-113
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• 2005

In this study, rotary type diamond dressing system for ultra-precision centerless grinding for ferrule was developed at the first time and experiments were conducted with AE sensor and hall sensor system to verify the optimum dressing condition for ultra-precision centerless grinding for ferrule. The correlations with the condition of dressing are evaluated by AE signal analysis with root mean square (RMS) and frequency analysis. And current signals from hall sensor are also studied as a factor of dressing optimum condition selection. Dressing process was conducted to investigate the effects of depth of cut, rotating speed, and the number of overlap to select the optimum condition of rotary dressing system of ultra-precision centerless grinding machine for ferrule fabrication. In order to verify the optimum condition of dressing, AE and current signals were compared with the surface quality of dressing wheel and grinding wheel for ultra-precision ferrule grinding. All of these experiments were completed by Taguchi Methodology to reduce experimental time. Hence, the optimum condition of rotary dressing system for ultra-precision centerless grinding for ferrule fabrication can be selected following to the experiment result from signals of AE and hall sensor.

• Proceedings of the KSME Conference
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• 2004.04a
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• pp.1087-1091
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• 2004

In this study, the ultra precision centerless grinder for ferrule grinding was designed. The centerless grinder is composed of the high damping concrete bed, grinding wheel spindle unit, regulating wheel spindle unit, feeding table and dressing unit. For a newly developed centerless grinder, hydrostatic system with high precision feeding and high stiffness was proposed. The grinding and regulating wheel spindle units were composed of hydrostatic spindle and feeding table was hydrostatic table. The prototype of hydrostatic table was manufactured and tested.