This paper presents new simulation models and global stability charts that have been developed to analyze the principal instabilities and constraints involved in the throughfeed centerless grinding process. In addition to a frequency domain stability analysis of the three characteristic instabilities of the process (geometric lobing, chatter and spinning), new models have been developed and implemented to analyze the other main restrictions, namely, process power, temperature and burning power, roughness, and final part geometrical tolerance due to machine compliance. As a result, new global stability charts have been devised where instabilities are plotted against different productivity rates by combining the two principal variables in the throughfeed process: regulating wheel speed and feed angle. The use of such charts has led to the development of new optimization strategies for throughfeed operation mode and their implementation in a web based SET-UP ASSISTANT software tool developed to improve machining accuracy and productivity in centerless grinding.

Recent advances in process modeling allow for more accurate prediction of complex phenomena. A combination of different modeling approaches makes it possible to develop new products to set up, control and optimize machining operations. In the near future, a continuous improvement strategy should be adopted, as improvements to advanced models open up new opportunities for industrial applications. In particular, the efforts made by different research groups on grinding have given rise to significant developments in this area, some of which have recently been made into applied software. As an example of the necessity for process modeling and the viability of industrialized tools based on it, this article presents the work carried out on the development of an assistant tool for the setting up and optimization of the centerless grinding process, focusing on avoiding the main limitations of this process and optimizing productivity.

Workpiece rejection originated by thermal damage is of great concern in high added-value industries, such as automotive or aerospace. Surface temperature control is vital to avoid this kind of damage. Difficulties in empirical measurement of surface temperatures in-process imply the measurement in points other than the ground surface. Indirect estimation of temperatures demands the use of thermal models. Among the numerous temperature measuring techniques, infra-red measurement devices excel for their speed and accurate measurements. With all of this in mind, the current work presents a novel temperature estimation system, capable of accurate measurements below the surface as well as correct interpretation and estimation of temperatures. The estimation system was validated by using a series of tests in different grinding conditions that confirm the hypotheses of the error made when measuring temperatures in the workpiece below the surface in grinding. This method provides a flexible and precise way of estimating surface temperatures in grinding processes and has shown to reduce measurement error by up to 60%.