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Modelling and simulation of Internal Traverse Grinding: bridging meso- and macro-scale simulations

Holtermann, Raphael; Menzel, Andreas LU ; Schumann, Sebastian; Biermann, Dirk; Siebrecht, Tobias and Kersting, Petra (2015) In Production Engineering 9(4). p.451-463
Abstract
In this work, we focus on the computational bridging between the meso- and macro-scale in the context of the hybrid modelling of Internal Traverse Grinding with electro-plated cBN wheels. This grinding process satisfies the manufacturing industry demands for a high rate of material removal along with a high surface quality while minimising the number of manufacturing processes invoked. To overcome the major problem of the present machining process, namely a highly concentrated thermal load which can result in micro-structural damage and dimension errors of the workpiece, a hybrid simulation framework is currently under development. The latter consists of three components. First, a kinematic simulation that models the grinding wheel surface... (More)
In this work, we focus on the computational bridging between the meso- and macro-scale in the context of the hybrid modelling of Internal Traverse Grinding with electro-plated cBN wheels. This grinding process satisfies the manufacturing industry demands for a high rate of material removal along with a high surface quality while minimising the number of manufacturing processes invoked. To overcome the major problem of the present machining process, namely a highly concentrated thermal load which can result in micro-structural damage and dimension errors of the workpiece, a hybrid simulation framework is currently under development. The latter consists of three components. First, a kinematic simulation that models the grinding wheel surface based on experimentally determined measurements is used to calculate the transient penetration history of every grain intersecting with the workpiece. Secondly, an h-adaptive, plane-strain finite element model incorporating elasto-plastic work hardening, thermal softening and ductile damage is used to simulate the proximity of one cBN grain during grinding and to capture the complex thermo-mechanical material response on a meso-scale. For the third component of the framework, the results from the preceding two simulation steps are combined into a macro-scale process model that shall in the future be used to improve manufacturing accuracy and to develop error compensation strategies accordingly. To achieve this objective, a regression analysis scheme is incorporated to approximate the influence of the several cutting mechanisms on the meso-scale and to transfer the homogenisation-based thermo-mechanical results to the macro-scale. (Less)
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author
organization
publishing date
type
Contribution to journal
publication status
published
subject
keywords
h-Adaptive remeshing, cBN, Grinding, 100Cr6(AISI 52100), Finite element method
in
Production Engineering
volume
9
issue
4
pages
451 - 463
publisher
Springer
external identifiers
  • scopus:84943664461
ISSN
0944-6524
DOI
10.1007/s11740-015-0613-z
language
English
LU publication?
yes
id
47eadad5-cd00-482d-ab93-796255315ecd (old id 8521506)
date added to LUP
2016-02-08 15:44:40
date last changed
2017-10-01 03:04:06
@article{47eadad5-cd00-482d-ab93-796255315ecd,
  abstract     = {In this work, we focus on the computational bridging between the meso- and macro-scale in the context of the hybrid modelling of Internal Traverse Grinding with electro-plated cBN wheels. This grinding process satisfies the manufacturing industry demands for a high rate of material removal along with a high surface quality while minimising the number of manufacturing processes invoked. To overcome the major problem of the present machining process, namely a highly concentrated thermal load which can result in micro-structural damage and dimension errors of the workpiece, a hybrid simulation framework is currently under development. The latter consists of three components. First, a kinematic simulation that models the grinding wheel surface based on experimentally determined measurements is used to calculate the transient penetration history of every grain intersecting with the workpiece. Secondly, an h-adaptive, plane-strain finite element model incorporating elasto-plastic work hardening, thermal softening and ductile damage is used to simulate the proximity of one cBN grain during grinding and to capture the complex thermo-mechanical material response on a meso-scale. For the third component of the framework, the results from the preceding two simulation steps are combined into a macro-scale process model that shall in the future be used to improve manufacturing accuracy and to develop error compensation strategies accordingly. To achieve this objective, a regression analysis scheme is incorporated to approximate the influence of the several cutting mechanisms on the meso-scale and to transfer the homogenisation-based thermo-mechanical results to the macro-scale.},
  author       = {Holtermann, Raphael and Menzel, Andreas and Schumann, Sebastian and Biermann, Dirk and Siebrecht, Tobias and Kersting, Petra},
  issn         = {0944-6524},
  keyword      = {h-Adaptive remeshing,cBN,Grinding,100Cr6(AISI 52100),Finite element method},
  language     = {eng},
  number       = {4},
  pages        = {451--463},
  publisher    = {Springer},
  series       = {Production Engineering},
  title        = {Modelling and simulation of Internal Traverse Grinding: bridging meso- and macro-scale simulations},
  url          = {http://dx.doi.org/10.1007/s11740-015-0613-z},
  volume       = {9},
  year         = {2015},
}