Modelling and simulation of Internal Traverse Grinding: bridging meso- and macro-scale simulations
(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)
Please use this url to cite or link to this publication:
https://lup.lub.lu.se/record/8521506
- author
- Holtermann, Raphael ; Menzel, Andreas LU ; Schumann, Sebastian ; Biermann, Dirk ; Siebrecht, Tobias and Kersting, Petra
- organization
- publishing date
- 2015
- 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
- wos:000420262700003
- 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
- 2016-04-01 09:58:15
- date last changed
- 2022-01-25 18:32:23
@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}},
keywords = {{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}},
doi = {{10.1007/s11740-015-0613-z}},
volume = {{9}},
year = {{2015}},
}