The effect of the relative vibrations of the abrasive tool and the workpiece on the probability of material removing during finishing grinding

Bratan, Sergey; Roshchupkin, Stanislav; Chasovitina, Anastasia; Gupta, Kapil

doi:10.17212/1994-6309-2022-24.1-33-47

Cited by 4 publications

(2 citation statements)

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“…ботки. Одним из самых распространенных видов финишной обработки является шлифование, которое в процессе формообразования обеспечивает получение поверхности с требуемыми качественными параметрами и представляет собой доступный и производительный способ обработки высокопрочных и труднообрабатываемых материалов [1][2][3][4][5][6].…”

Section: а н н о та ц и яunclassified

Design simulation of modular abrasive tool

Lobanov,

Skeeba,

Golyushov

et al. 2024

Metal Working and Material Science

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Introduction. Grinding is one of the most common types of finishing. It allows the production of surfaces with the required quality parameters and is one of the most available and productive methods for machining high-strength and difficult-to-machine materials. Grinding wheels represent the most prevalent application of grinding technology in mechanical engineering. The use of this abrasive tool helps to increase processing productivity by ensuring the removal of a significant layer of material. In addition, grinding wheels have a longer service life and are widely used in the implementation of hybrid technologies based on the combination of mechanical (abrasive), electrical, chemical, and thermal effects in various combinations. A variety of tool body shapes and types of abrasives allow the use of wheels in a wide variety of production areas. One of the ways to analyze and design a new tool is numerical simulation. In this research, graphic modeling was selected as the most appropriate method for representing the future design of the tool. This approach allows for a more straightforward conceptualization process compared to other modeling techniques. The purpose of the work is to simulate a modular abrasive tool in order to analyze and synthesize structures to increase the efficiency of tool support for the manufacture of products made of high-strength and difficult-to-process materials using traditional or hybrid processing technologies. Research methodology. Theoretical studies are carried out using the basic principles of system analysis, geometric theory of surface formation, cutting tool design, graph theory, mathematical and computer simulation. To solve the problem, we have studied the available designs of modular grinding wheels. There has also been the analysis of the types of abrasive parts, methods of fastening of the abrasive cutting part on the wheel’s body, the materials used for the manufacture of the body, the characteristics of the body of the wheel, and fastening schemes. Results and discussions. A simulation technique based on graphic modelling theory has been developed. A comprehensive investigation of the existing design of the grinding wheel has enabled the identification of the key structural elements that define its design. The data obtained has been used to create a generalized graphic simulation of a modular abrasive tool. This simulation integrates all the components and displays a conditional constructive relationship between them. The developed design methodology was tested on an example of two designs of modular grinding wheels. The theoretical studies established that the design efficiency of modular abrasive tools can be increased by 2–4 times by using the developed simulation technique.

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Section: а н н о та ц и яunclassified

Design simulation of modular abrasive tool

Lobanov,

Skeeba,

Golyushov

et al. 2024

Metal Working and Material Science

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“…В соответствии с размерной схемой процесса внутреннего шлифования, изображенной на рис. 1, уравнение баланса перемещений принимает вид При внутреннем шлифовании наблюдается неравномерный съем припуска, на поверхности заготовки формируется волнистость [25,26]. На основании этого можно предположить, что не только съем припуска будет изменяться по гармоническому закону, но и другие параметры, входящие в уравнение баланса перемещений.…”

Section: схема процесса внутреннего шлифованияunclassified

Simulation of the relationship between input factors and output indicators of the internal grinding process, considering the mutual vibrations of the tool and the workpiece

Bratan¹,

Chasovitina²

2023

Metal Working and Material Science

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Introduction. In real production conditions, the technological modes recommended in the scientific literature do not reflect the declared qualities, due to the fact that it does not take into account many factors inherent in the process of finishing grinding, for example, its stochastic nature, changes in its dynamic properties, an increase in mutual vibrations of the tool and the workpiece that appear due to changes in the state of the technological system, for example, an increase in vibrations machine tool due to uneven tool wear, etc. All previously developed models have a limited scope of application, it does not take into account the fact that the appearance of vibrations leads to fluctuations in the depth of grinding, with accidental contact of grains with the material being processed, where one group of grains cuts off the material, the other gets into the trace of scratches left by previous grains, etc. This leads to changes in the values of material removal, surface roughness and other parameters of the technological system, which directly affects the accuracy of processing and the quality of the machined surfaces. The purpose of the work is to develop mathematical models that establish the relationship between the processing modes and the current parameters of the contact zone during the fine grinding of pinholes, taking into account the mutual vibrations of the tool and the workpiece. The research methods are mathematical simulation using the basic provisions of the theory of abrasive-diamond processing. Results and discussion. The interrelations between the cutting modes and the current input parameters of the contact zone when grinding pinholes are established, taking into account the mutual vibrations of the tool and the workpiece, which make it possible to determine the parameters of the system at the output to avoid cost losses, including reducing the number of defective products and time costs. Non-stationary mathematical dependences are constructed that allow determining the cutting modes during the implementation of the grinding cycle, taking into account the magnitude of relative vibrations and the initial phase. It is established that instead of a steady process, harmonic oscillations are observed caused by deviations in the shape of the circle, the intensity of tool wear and other factors, all of the above has a significant impact on the quality of the machined surface. The obtained models are universal for various characteristics of the tool, however, for a more adequate description of the process, mathematical dependencies are needed that take into account the wear of the tool on various binders, which is the task of further research.

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