An integrated model of tool grinding: challenges, chances and limits of predicting process dynamics

Payrebrune, Kristin M. de; Kröger, Matthias

doi:10.1007/s11740-016-0687-2

Cited by 7 publications

(2 citation statements)

References 19 publications

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“…The results feed into a model of the overall grinding process, developed by the authors [20,21]. This model includes a description of the dynamics of the workpiece [22], contact and material removal [17], empirical cutting forces, and grinding wheel topography and wear.…”

Section: Resultsmentioning

confidence: 99%

“…The investigations of grinding wheel surface and wear underline the significance of the macroscopic topography (eccentricity and waviness) on the dynamic excitation of the workpiece and machine structure in grinding. The results feed into a model of the overall grinding process, developed by the authors [20,21]. This model includes a description of the dynamics of the workpiece [22], contact and material removal [17], empirical cutting forces, and grinding wheel topography and wear.…”

Section: Resultsmentioning

confidence: 99%

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Effects of the Grinding Wheel Eccentricity and Waviness on the Dynamics of Tool Grinding

Payrebrune

Kröger

2017

AMM

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Abstract. The complex dynamics of grinding repeatedly cause critical or unstable process conditions. For a better understanding and prediction of such occurrences, the dominant excitation phenomena need to be identified and their interrelation with the system dynamics have to be analyzed.Based on measurements of the excited frequencies in several operation modes of the grinding machine, the grinding wheel rotation is identified as a major excitation source. Further analysis of the grinding wheel surface displays three main components that define the excitation frequencies of the system; these are the eccentricity, waviness and roughness (also named wheel topography). Moreover, the wheel topography and thus the excitation frequencies can change over time due to excessive wear.Following the experimental results, a grinding wheel topography and wear model are developed and included in an integrated simulation of tool grinding. The analysis of the calculated cutting forces in the frequency domain confirm the excitation due to the grinding wheel topography.Firstly, this work has extracted the grinding wheel as a prominent excitation mechanism and reproduced it with the developed grinding model. Secondly, we have evidence that a complete description of the complex grinding process is only possible when considering the interdependence between system dynamics, wheel kinematics and the grinding process.

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Section: Resultsmentioning

confidence: 99%

Section: Resultsmentioning

confidence: 99%

Effects of the Grinding Wheel Eccentricity and Waviness on the Dynamics of Tool Grinding

Payrebrune

Kröger

2017

AMM

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A predictive model on surface roughness during internal traverse grinding of small holes

Yang

Gao

et al. 2019

Int J Adv Manuf Technol

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Modeling the wetting behavior of grinding wheels

Wichmann¹,

Eden

Zvegincev³

et al. 2023

Int J Adv Manuf Technol

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Helical flute grinding is an important process step in the manufacturing of cylindrical cemented carbide tools where the use of cooling lubricants is a defining factor determining process performance. Finding optimal parameters and cooling conditions for the efficient use of lubricant is essential in reducing energy consumption and in controlling properties of the boundary zone like residual stresses. Any mathematical model describing the interactions between grinding wheel, lubricant and workpiece during the process has to account for the complex microstructure of the wheel; however, this renders the identification of parameters like slip or heat exchange coefficients numerically prohibitively expensive. In this paper, results from grinding oil droplet experiments are compared with simulation results for the wetting behavior of grinding wheels. More specifically, finite element simulations of the thin-film equation are used to identify slip parameters for different grinding wheel specifications (grain size, bonding structure, wetting status). Our results show that both the bonding and the grain size have an influence on the wetting behavior. The slip parameters that we identified account for the fluid-microstructure interactions and will be used to effectively model those interactions in more complex 3D fluid-dynamic simulations via the Beavers-Joseph condition.

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An integrated model of tool grinding: challenges, chances and limits of predicting process dynamics

Cited by 7 publications

References 19 publications

Effects of the Grinding Wheel Eccentricity and Waviness on the Dynamics of Tool Grinding

Effects of the Grinding Wheel Eccentricity and Waviness on the Dynamics of Tool Grinding

A predictive model on surface roughness during internal traverse grinding of small holes

Modeling the wetting behavior of grinding wheels

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