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A Hybrid Approach to the Modelling and Simulation of Grinding Processes

Holtermann, R.; Schumann, S.; Menzel, Andreas LU and Biermann, D. (2014) 11th World Congress on Computational Mechanics (WCCM) / 5th European Conference on Computational Mechanics (ECCM) / 6th European Conference on Computational Fluid Dynamics (ECFD) In Proceedings of the 11th World Congress on Computational Mechanics (WCCM XI); 5th European Conference on Computational Mechanics (ECCM V); 6th European Conference on Computational Fluid Dynamics (ECFD VI) p.1932-1937
Abstract
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... (More)
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. (Less)
Please use this url to cite or link to this publication:
author
organization
publishing date
type
Chapter in Book/Report/Conference proceeding
publication status
published
subject
keywords
High performance grinding, 100Cr6/AISI 52100, h-adaptive finite element, method, thermo-mechanical coupling, geometric-kinematic analysis
in
Proceedings of the 11th World Congress on Computational Mechanics (WCCM XI); 5th European Conference on Computational Mechanics (ECCM V); 6th European Conference on Computational Fluid Dynamics (ECFD VI)
pages
1932 - 1937
publisher
CIMNE
conference name
11th World Congress on Computational Mechanics (WCCM) / 5th European Conference on Computational Mechanics (ECCM) / 6th European Conference on Computational Fluid Dynamics (ECFD)
external identifiers
  • WOS:000353626502044
  • Scopus:84923963520
ISBN
978-84-942844-7-2
language
English
LU publication?
yes
id
b2eb67e8-acc5-4a2a-892e-a295186452cb (old id 7432851)
date added to LUP
2015-06-25 08:22:38
date last changed
2016-10-13 04:36:42
@misc{b2eb67e8-acc5-4a2a-892e-a295186452cb,
  abstract     = {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.},
  author       = {Holtermann, R. and Schumann, S. and Menzel, Andreas and Biermann, D.},
  isbn         = {978-84-942844-7-2},
  keyword      = {High performance grinding,100Cr6/AISI 52100,h-adaptive finite element,method,thermo-mechanical coupling,geometric-kinematic analysis},
  language     = {eng},
  pages        = {1932--1937},
  publisher    = {ARRAY(0xa0ccbf0)},
  series       = {Proceedings of the 11th World Congress on Computational Mechanics (WCCM XI); 5th European Conference on Computational Mechanics (ECCM V); 6th European Conference on Computational Fluid Dynamics (ECFD VI)},
  title        = {A Hybrid Approach to the Modelling and Simulation of Grinding Processes},
  year         = {2014},
}