Machine design for performance and sustainability

Machine design for performance and sustainability

Development of an Energy-efficient Cylindrical Grinding Machine

The Hahn Grinder, built by R.S. Hahn and kindly donated by Worcester Polytechnic Institute, MA, had been used in a previous life for research on force-feedback controlled grinding and dressing; and was utilized to minimize taper error induced by unwanted deflection in grinder spindles. It is an internal and external cylindrical grinder with rotary dressing. The grinder is being refurbished to perform sustainability studies on resource consumption (consumables, energy, labor, and equipment) and liability production (wastes, emissions, energy losses, and labor hazards). Leveling feet were kindly donated by Mason Industries. [1-4]

Photo of Hahn grinder machine   Photo of 2 students with the grinding machine A friction test stand is used to analyze guideway friction. Photo of a friction tester

Modular Hybrid Desktop Machine

The manufacturing industry is challenged by shorter product life-cycles and customized products. Modular, reconfigurable production systems are seen as potential enablers for cloud-based manufacturing to cope with these challenges. However to date, there has been little development of flexible and modular grinding machines. Driven by the vision of a cheap, modular machine for the DIY user or for rural, remote areas, a small foot-print grinding and 3D printing machine has been developed from programmable components, the Barobo Mobots. The first prototype can be switched from a cylindrical grinding setup for round parts to a gantry design for three-dimensional tool paths within minutes. The system has been improved for higher stiffness, torque, precision, and user friendliness. New motor modules with higher torque have been developed. The machine control has been based on NI LabVIEW. [5,6]

OD_grinding Freeform_grinding

Figure: Outer diameter grinding (left) and freeform grinding (right) configurations of multipurpose grinding machine.

Publications:

  1. Ian Garretson, Bernd Peukert, Barbara Linke, Eckart Uhlmann, Hypothetical Sustainability Axioms for Axiomatic Design with an Application in Grinding Machine Design, Proceedings of the ASME 12th International Manufacturing Science and Engineering Conference, MSEC2017, June 4-8, 2017, Los Angeles, CA, USA, doi:10.1115/MSEC2017-2874
  2. Voet, H., Garretson, I., Falk, B., Schmitt, R., Linke, B., Peak Power Load and Energy Costs Using the Example of the Startup and Idling of a Grinding Machine, Procedia CIRP, Volume 69, 2018, Pages 324-329, CIRP Conference on Life Cycle Engineering, Copenhagen, Denmark, 2018, https://www.sciencedirect.com/science/article/pii/S2212827117308132
  3. Garretson, I., Linke, B., Voet, H., Falk, B., Schmitt, R., Peak Power Load and Energy Costs Example of Startup and Idling of a Grinder, Poster at the RAMP workshop on June 21, 2018 at the NAMRC/MSEC 2018, College Station, TX, USA
  4. Garretson, IC, Guo, Q, & Linke, BS. “Designing a Stand for Machine Tool Energy Efficiency, With Pump Embodied Energy Tradeoff Case Study.” Proceedings of the ASME 2021 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference. Volume 5: 26th Design for Manufacturing and the Life Cycle Conference (DFMLC). Virtual, Online. August 17–19, 2021. V005T05A022. ASME. https://doi.org/10.1115/DETC2021-70939
  5. Ghadamli, F.; Linke, B.: Development of a Desktop Hybrid Multipurpose Grinding and 3D Printing Machine for Educational Purposes, 44th Proceedings of the North American Manufacturing Research NAMRI/SME, Blacksburg, VI, USA, June 27- July 1, 2016, https://doi.org/10.1016/j.promfg.2016.08.090
  6. Linke, B.; Harris, P.; Zhang, M.: Development of Desktop Multipurpose Grinding Machine for Educational Purposes, 43rd Proceedings of the North American Manufacturing Research NAMRI/SME, Charlotte, NC, USA, June 2015, https://www.sciencedirect.com/science/article/pii/S2351978916301020

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