Modeling of Discontinuous Surfaces Intragrinding Processing Peculiarities

Abstract

The analysis of the technological features of internal grinding revealed that a majority of internal grinding operations in the automotive and machine-tool industries are related with the processing of the discontinuous surfaces, including splined and dowel holes, internal surfaces having different notches, grooves and holes. Grinding of these holes causes the greatest difficulties due to the high process instability, increased fluctuations of the cutting forces and elastic deformations; it leads to diminution of processing accuracy. Models of the metal removal process and calculation of the processing errors were proposed to consider the specifics of the internal grinding of the discontinuous surfaces when modeling the optimal grinding cycles; they allow calculating the changes of the current value of the cutting force, actual allowance removal, radii of the machinable holes and other parameters. The developed model of the metal removal process allows considering fluctuating processing conditions of batch of details (initial radial runout of the billet, spread of processing allowance, blunting the grains of the grinding circle, etc.). Based on the metal removal model the modeling technique of the optimal cycles in the multidimensional space of the control parameters and the technological limitations of the criterion function was developed.