A Hybrid Approach to the Modelling and Simulation of Grinding Processes

• We present recent advances in the modelling and simulation of Internal Traverse Grinding, a high performance grinding process incorporating a high rate of material removal combined with a high surface quality. Due to a special grinding wheel geometry, the latter two goals are achieved in just one pass of the tool through the axisymmetric workpiece. The simulation framework we present generally consists of three components. The first one is a parametric plane strain, h-adaptive finite element model capturing the material penetration of a single cBN grain on a meso-scale during the machining process. Secondly, a topography analysis procedure as well as a kinematic simulation have been developed to measure and analyse the surface topography of an actual grinding wheel. We then use this information to model the grinding wheel surface in the latter kinematic simulation. This enables us to perform an exact calculation of the transient penetration history of every grain intersecting with the workpiece bulk. The superposition of these results is then used in the third component of the simulation framework, namely a process scale workpiece model currently under development which captures the effects of thermo-mechanical loads on the workpiece undergoing material removal and thus, in the near future, shall enable us to predict potential unwanted phase transformations of the bulk surface as well as size and shape errors of the finished part. In this contribution, we will focus on the first two parts of the simulation framework, namely the meso-scale as well as the kinematic simulation and the coupling between the two scales.

Subject headings

TEKNIK OCH TEKNOLOGIER  -- Maskinteknik (hsv//swe)

ENGINEERING AND TECHNOLOGY  -- Mechanical Engineering (hsv//eng)

Keyword

High performance grinding

100Cr6/AISI 52100

h-adaptive finite element

method

thermo-mechanical coupling

geometric-kinematic analysis

Publication and Content Type

kon (subject category)

ref (subject category)