Patent ID: 7645180

Claim:
A method of avoiding abrading tool fracture and maximizing abrading tool life in a machining operation, which is caused by the coarseness of the surface of a workpiece significantly reducing the effectiveness of the abrading tool when the abrading tool is first applied to a new workpiece surface, said method comprising the steps of: establishing a predetermined optimum force profile as a function of the surface finish of an incoming new workpiece; monitoring the startup torque of a tool spindle servomotor having a processing tool mounted therein, and the startup torque of a work spindle servomotor of said machining operation using a control unit; comparing each said monitored startup torque generated by said tool spindle servomotor and said work spindle servomotor with a pre-established torque limit; reducing said startup torque generated by one of said tool spindle servomotor and said work spindle servomotor by adjusting at least one of said tool spindle servomotor and said work spindle servomotor when said comparing step senses said startup torque above said pre-established torque limit to maintain an operating torque below said pre-established torque limit; monitoring the actual force applied by said processing tool against said workpiece with a control unit during the material removal operation; comparing said actual force applied by said processing tool with said established predetermined optimum force profile; and adjusting parameters of said machining operation based on said comparison step of said actual force with said predetermined optimum force profile, to minimize the deviation from said optimum force profile throughout said machining operation whereby abrading tool life is maximized during said machining operation.