A Novel and More Efficient Way to Grind Punching Tools

• A simulation model of punch grinding has been developed which calculates the instantaneous material-removal rate, arc length of contact and temperature based on the kinematic relationships between wheel and workiece and determines the optimum machine parameters to reduce cycle time and achieve a constant-temperature no-burn situation. Two basic outputs of the simulation model include arc length of contact and specific material-removal rate. A thermal model is included in the simulation to calculate maximum grinding zone temperature rise. A novel method is developed to constrain this temperature rise in the simulation. The thermal model inputs a constant value of specific grinding energy and the energy partition, which represents the fraction of the grinding energy conducted as heat to the workpiece. The simulation-based optimization can lead to a drastic reduction of grinding cycle time. Moreover, the limitation of maximum grinding zone temperature rise below the transitional temperature can help to avoid generation of workpiece thermal damage, which includes thermal softening, residual tensile stress, and rehardening burn. The grindability of high speed steel (HSS) is also discussed in terms of power consumption, specific grinding energy and undeformed chip thickness.

Nyckelord

Grinding

Modeling

Simulation

Geometry

Thermal

TECHNOLOGY

TEKNIKVETENSKAP

SRA - Production

SRA - Produktion

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