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Large shafts, such as metallurgical shafts, large motor rotors, and large curved rollers, are widely used in industry. Multi-pass grinding is employed to remove the excess material on the shaft to ensure the high requirements of dimensional accuracy and surface quality. Due to the influence of the grinding wheel width, there is a stepped dimensional error in the grinding process. In this paper, a grinding wheel profile optimization method is proposed to decrease the dimensional error caused by wheel width. An error calculation model is firstly established to describe the dimensional error caused by wheel width, and the gradient descent method is further developed to optimize the wheel profile to improve dimensional accuracy. The experimental results show that after optimization, the total error decreases from 16.9 mm to 11.1 mm and the mean error decreases from 11.2 mm to 6.3 mm, respectively, which proves that the proposed method is effective to reduce the dimensional error for complex large shaft curve grinding.
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