Machining of large diameter plungers for special hydraulic cylinders is a challenging task. Large overall dimensions (diameter may exceed 1 m) require the use of special equipment. High surface finish using conventional machining methods can be achieved in three steps (preliminary and final grinding followed by polishing). For these purposes special grinding and polishing heads are used, which are installed on a lathe. Finishing operations are highly laboru and time cosuming. In this paper the design of a special grinding head is discussed as well as its mathematical model, which enabled the investigation of the influence of the head kinematics on the lay pattern of machined surface. This head allows combining final grinding and polishing and, thus, achieving significant savings.
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