Simulation of process forces and topographical characteristics of single grains in microfinishing processes

Abstract

Honing operations, e.g. microfinishing, are resulting in high quality surfaces with a roughness values, e.g., average roughness Ra, of only a few micro- to nanometer [1]. The simulation of honing processes can be beneficial to reduce experimental effort in terms of determining suitable process parameters for such processes. Various aspects of the finishing process can be investigated with the aid of process models, such as tool wear, tool life, the resulting surface quality or shape deviation. In addition, process simulations can be used to assist in the design of components with regard to desired functional properties. In order to model processes with such high accuracy, it is necessary to be aware of process influences on a microscropic scale. Such influences can be analyzed separately, for instance, by means of analogy experiments to reduce the complexity and dependencies of the occurring effects. In this work, a process force model was developed based on single-grain scratch tests, which takes into account the process-inherent kinematic variations. The occurring single grain forces in dependence of the orientation of the grains and in relation to the cutting direction were analyzed and modeled. This is important for a further analysis of the influences on tool wear to increase the accuracy of corresponding models.