Modeling of Process Machine Interactions in Tool Grinding

Deichmueller, Manuel; Denkena, Berend; Payrebrune, Kristin M. de; Kröger, Matthias; Wiedemann, Sebastian; Schröder, Jörg; Carstensen, Carsten

doi:10.1007/978-3-642-32448-2_7

Cited by 11 publications

(4 citation statements)

References 9 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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“…The following four wear mechanisms occur during grinding: grain attening or blunting, grain chipping, grain breakage and chip space clogging. Due to the twisted groove geometry of common end mills and the process kinematics required to manufacture these geometries, the local material removal rate varies signi cantly along the width of the grinding wheel [3,4,10]. This variation leads to locally different types of wear on the grinding wheel.…”

Section: Introductionmentioning

confidence: 99%

Process Related Characteristic-Based Topography Evaluation of Wear Conditions On Grinding Wheels

Strug

Denkena²,

Breidenstein³

et al. 2021

Preprint

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Non-productive auxiliary processes affect the single part and small badge production of milling tools. The key production process grinding is inevitably linked to the auxiliary conditioning process. The time demand of those process steps decreases the overall productivity of the manufacturing process. However, today the machine operator decides on conditioning cycles individually by the use of experience. Until today, there is no objective data based approach available that supports the initiation of these conditioning processes or the adaption of the grinding process itself in order to improve its process efficiency. For this purpose, a process related topography evaluation method of the grinding wheel surface is developed within this study. For the measurement an optical method based on laser triangulation is used. The measurement system is implemented into a common tool grinding machine tool. In addition, characteristic topography values are defined that show the wear conditions of the grinding tool. Moreover, the data is summarized in a database of wear conditions. The developed measurement method can save grinding and dressing tool resources, process times and minimizes scrap parts. In addition, an adaptation of the process and a targeted launch of auxiliary processes can be enabled. The novel characteristic-based topography measurement creates the opportunity to enhance the tool life of the grinding wheels up to 30 % without losing productivity.

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“…In order to improve the quality of the workpiece and to optimize grinding time by infeed control, several simulation results of the material removal processes have been presented in the past [4][5][6]. Different models have been developed to predict dynamic deformation of the grinding machine and its interaction with the grinding process [7][8][9]. Process errors like grinding chatter and externally excited vibration, e.g.…”

Section: Introductionmentioning

confidence: 99%

Theoretical and Experimental Determination of Geometry Deviation in Continuous Path Controlled OD Grinding Processes

Denkena

Fischer

2011

AMR

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A simulation method for the continuous path controlled grinding process is described in this paper. The process model allows a virtual analysis of the process parameters, different input conditions and their influence concerning workpiece geometry. The machine structure is represented by a structural dynamic system. The dynamic influence of the machine axes is considered by its control system parameters. In this machine model, the positioning error of the axes can be calculated in relation to the reference position. This is used to compute the local engagement numerically. The process force is estimated by means of an empirical grinding force model. Hence, the overall process force can be calculated and fed back into the dynamic model. Closed-loop modeling allows to rate the influence of different parameters with respect to process errors. Finally, a parameter study and the model verification under real conditions are presented on the basis of the wheel head oscillating pin grinding process of crankshafts.

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Modeling of Process Machine Interactions in Tool Grinding

Cited by 11 publications

References 9 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

Process Related Characteristic-Based Topography Evaluation of Wear Conditions On Grinding Wheels

Theoretical and Experimental Determination of Geometry Deviation in Continuous Path Controlled OD Grinding Processes

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