Simulation based prediction of compliance induced shape deviations in internal traverse grinding
(2021) In Journal of Manufacturing and Materials Processing 5(2).- Abstract
Internal traverse grinding (ITG) using electroplated cBN tools in high-speed grinding conditions is a highly efficient manufacturing process for bore machining in a single axial stroke. However, process control is difficult. Due to the axial direction of feed, changes in process normal force and thus radial deflection of the tool and workpiece spindle system, lead to deviations in the workpiece contour along the length of the bore, especially at tool exit. Simulations including this effect could provide a tool to design processes which enhance shape accuracy of components. A geometrical physically-based simulation is herein developed to model the influence of system compliance on the resulting workpiece contour. Realistic tool... (More)
Internal traverse grinding (ITG) using electroplated cBN tools in high-speed grinding conditions is a highly efficient manufacturing process for bore machining in a single axial stroke. However, process control is difficult. Due to the axial direction of feed, changes in process normal force and thus radial deflection of the tool and workpiece spindle system, lead to deviations in the workpiece contour along the length of the bore, especially at tool exit. Simulations including this effect could provide a tool to design processes which enhance shape accuracy of components. A geometrical physically-based simulation is herein developed to model the influence of system compliance on the resulting workpiece contour. Realistic tool topographies, obtained from measurements, are combined with an FE-calibrated surrogate model for process forces and with an empirical compliance model. In quasistatic experimental investigations, the spindle deflection is determined in relation to the acting normal forces by using piezoelectric force measuring elements and eddy current sensors. In grinding tests with in-process force measurement technology and followed by measurement of the resulting workpiece contours, the simulation system is validated. The process forces and the resulting characteristic shape deviations are predicted in good qualitative accordance with the experimental results.
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- author
- Tsagkir Dereli, Tountzer ; Schmidt, Nils ; Furlan, Tim ; Holtermann, Raphael ; Biermann, Dirk and Menzel, Andreas LU
- organization
- publishing date
- 2021-06
- type
- Contribution to journal
- publication status
- published
- subject
- keywords
- Compliance, FEM, Geometric kinematic simulation, Internal traverse grinding, Process forces, Single grain
- in
- Journal of Manufacturing and Materials Processing
- volume
- 5
- issue
- 2
- article number
- 60
- publisher
- MDPI AG
- external identifiers
-
- scopus:85108704453
- ISSN
- 2504-4494
- DOI
- 10.3390/jmmp5020060
- language
- English
- LU publication?
- yes
- id
- edcac894-f0b3-4fc1-bee6-686a3230376e
- date added to LUP
- 2021-08-20 15:06:03
- date last changed
- 2022-04-27 03:20:30
@article{edcac894-f0b3-4fc1-bee6-686a3230376e,
abstract = {{<p>Internal traverse grinding (ITG) using electroplated cBN tools in high-speed grinding conditions is a highly efficient manufacturing process for bore machining in a single axial stroke. However, process control is difficult. Due to the axial direction of feed, changes in process normal force and thus radial deflection of the tool and workpiece spindle system, lead to deviations in the workpiece contour along the length of the bore, especially at tool exit. Simulations including this effect could provide a tool to design processes which enhance shape accuracy of components. A geometrical physically-based simulation is herein developed to model the influence of system compliance on the resulting workpiece contour. Realistic tool topographies, obtained from measurements, are combined with an FE-calibrated surrogate model for process forces and with an empirical compliance model. In quasistatic experimental investigations, the spindle deflection is determined in relation to the acting normal forces by using piezoelectric force measuring elements and eddy current sensors. In grinding tests with in-process force measurement technology and followed by measurement of the resulting workpiece contours, the simulation system is validated. The process forces and the resulting characteristic shape deviations are predicted in good qualitative accordance with the experimental results.</p>}},
author = {{Tsagkir Dereli, Tountzer and Schmidt, Nils and Furlan, Tim and Holtermann, Raphael and Biermann, Dirk and Menzel, Andreas}},
issn = {{2504-4494}},
keywords = {{Compliance; FEM; Geometric kinematic simulation; Internal traverse grinding; Process forces; Single grain}},
language = {{eng}},
number = {{2}},
publisher = {{MDPI AG}},
series = {{Journal of Manufacturing and Materials Processing}},
title = {{Simulation based prediction of compliance induced shape deviations in internal traverse grinding}},
url = {{http://dx.doi.org/10.3390/jmmp5020060}},
doi = {{10.3390/jmmp5020060}},
volume = {{5}},
year = {{2021}},
}