Multi-regenerative dynamic modeling and chatter analysis in through-feed centerless grinding for high aspect ratio ceramic tubes

Grinding chatter is the critical factor limiting high-efficiency and high-quality machining in the centerless grinding of ceramic tubes with high aspect ratio. To suppress chatter in through-feed centerless grinding, a multi-modal dynamic model of the centerless grinding system is established, incorporating multiple regenerative mechanisms, such as workpiece regeneration, grinding wheel regeneration, and geometric layout effect. The stability boundaries of the grinding system are predicted. Multi-sensor experiments integrating vibration, acoustic emission, and grinding power were conducted to investigate the dynamic stability characteristics of the complex grinding system. The results demonstrate that the proposed model effectively predicts grinding stability. Stability lobe diagrams indicate that 60–80 μm represents the critical stability threshold. A dynamic parameter identification method for the workpiece-support system based on follow-up support was proposed in this study. Increasing the feed distances of the regulating wheel reduces the amplitude of the frequency response function, achieving an average suppression rate exceeding 60 %. Considering the stiffness improvement, the optimal range for feed distances of the regulating wheel is 0.4 mm∼0.8 mm. Batch machining of silicon carbide ceramic tubes with a high aspect ratio (L/D≈50) and a wall thickness of 0.395 mm was achieved by the grinding strategy based on stability analysis. Compared with the conventional process, grinding efficiency increased by 62.5 %, while outer diameter fluctuation decreased by approximately 97 %. This study provides theoretical and technical support for the precision centerless grinding of ceramic tubes with high aspect ratio.