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

Abstract

The objective of manufacturing technology, to reduce machining costs, increase product quality and optimize process setups, is only achievable by considering the entire manufacturing process and its interrelations. Especially in tool grinding, strong interactions exist between workpiece dynamics, grinding wheel engagement, structure deformations and cutting process conditions, which makes an integrated model necessary. This paper introduces a tool grinding model that combines time-dependent dynamical aspects of the grinding wheel and workpiece with local varying contact conditions to predict the final workpiece geometry and cutting forces with a high resolution in space and time. The model is capable to reproduce systemic effects on cutting forces and ground geometries which only occurs in the interplay of all system components. The model is also positively tested in representing influences of process parameters and in optimizing the machining. The excellent agreement of simulations and experimental data shows the model’s potential in manufacturing technology, but also in investigating grinding aspects, which are not fully understood yet.