Grinding and fine finishing of future automotive powertrain components

Krajnik, Peter; Hashimoto, Fukuo; Karpuschewski, Bernhard; Silva, Eraldo Jannone da; Axinte, Dragoş

doi:10.1016/j.cirp.2021.05.002

Cited by 34 publications

(7 citation statements)

References 204 publications

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“…These processes often run over 10-20 years without significant improvement due to the high risks and costs involved with part and process re-certifications. Another notable example is the cost-intensive trend towards reducing noise generation in modern gearboxes for electric propulsion solutions by optimizing gear surfaces (Krajnik et al, 2021).…”

Section: Introductionmentioning

confidence: 99%

Towards a multi-abrasive grinding model for the material point method

Leroch

Grützmacher²,

Heckes

et al. 2023

Front. Manuf. Technol.

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An efficient optimization of surface finishing processes can save high amounts of energy and resources. Because of the large occurring deformations, grinding processes are notoriously difficult to model using standard (mesh-based) micro-scale modeling techniques. In this work, we use the meshless material point method to study the influence of abrasive shape, orientation, rake angle, and infeed depth on the grinding result. We discuss the chip morphology, the surface topography, cutting versus plowing mode, the material removal rate, and the chip temperature. A generalization of our model from a straightforward single-abrasive approach to a multiple-abrasive simulation with pseudo-periodical boundary conditions greatly increases the degree of realism and lays the foundation for comparison with real finishing processes. We finally compare our results for multiple abrasives to those obtained for a scaled-down molecular dynamics system and discuss similarities and differences.

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Section: Introductionmentioning

confidence: 99%

Towards a multi-abrasive grinding model for the material point method

Leroch

Grützmacher²,

Heckes

et al. 2023

Front. Manuf. Technol.

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“…AM is an industrialised and mature (high TRL) technology, implemented in real production lines, for example in manufacturing and remanufacturing of turbine parts (e.g., burners) in the energy and aerospace sectors. In other industries, such as the automotive industry, AM is primarily used for rapid tooling (i.e., using AM to produce tools and fixtures with short lead times), making spare parts and small-volume/near-net shape production [4]. This is a clear indicator that AM is currently more suited for high-value/small-volume manufacturing where higher production costs are compensated by added value, e.g., capability of forming complex 3D parts by addition of material.…”

Section: Introductionmentioning

confidence: 99%

Post-processing of additively manufactured metallic alloys – A review

Malakizadi

Mallipeddi

Dadbakhsh

et al. 2022

International Journal of Machine Tools and Manufacture

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“…The rapid development of high-end equipment that uses gears, such as vehicles, wind turbines and aircraft, puts stringent requirements for component geometry and surface integrity [1]. Towards the continuing industry need, many collaborative manufacturing technologies of structure shape and surface integrity including mass finishing have been employed [2].…”

Section: Introductionmentioning

confidence: 99%

Numerical investigation of a novel bidirectional composite vibratory finishing

Yang¹,

Wang³

et al. 2022

Preprint

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Given the poor accessibility of the current finishing process for parts with complicated geometries, a novel bidirectional composite vibratory finishing (BCVF) approach is presented, which combines the power actions on abrasive particles and processed workpieces. The discrete element method (DEM) was used to obtain a fundamental understanding of the BCVF process. By comparing different processes, it has been demonstrated that the BCVF promotes the mobility of abrasive particles to improve the finishing results and efficiency further. The characteristics of normal and tangential contact on the surface of the workpiece involved in the BCVF process were analyzed. Meanwhile, the effects of container size (or wall effects), media amount, workpiece position, and vibration parameters (including vibration amplitude and frequency) on the media-component interactions were systematically studied. The results show that the distance between the workpiece and the container wall in the y-direction can be reduced to 4d (d is the abrasive particle diameter) without affecting the finishing effect. In addition, with the enhancing vibration in the x-direction, particle impact and shear effects are subsequently strengthened. In contrast, the media amount above the workpiece and the z-directional vibration is mainly effective for the shear effect. Overall, the process can enhance the impact and shear effects simultaneously through composite vibration.

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Grinding and fine finishing of future automotive powertrain components

Cited by 34 publications

References 204 publications

Towards a multi-abrasive grinding model for the material point method

Towards a multi-abrasive grinding model for the material point method

Post-processing of additively manufactured metallic alloys – A review

Numerical investigation of a novel bidirectional composite vibratory finishing

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