Simulation Based Prediction of Compliance Induced Shape Deviations in Internal Traverse Grinding

Tountzer Tsagkir Dereli,Nils Schmidt,Dirk Biermann,Raphael Holtermann,Tim Furlan,Andreas Menzel

doi:10.3390/jmmp5020060

Tountzer Tsagkir Dereli, Nils Schmidt + Show 4 more

Open Access

https://doi.org/10.3390/jmmp5020060

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Abstract

Internal traverse grinding (ITG) using electroplated cBN tools in high-speed grinding conditions is a highly efficient manufacturing process for bore machining in a single axial stroke. However, process control is difficult. Due to the axial direction of feed, changes in process normal force and thus radial deflection of the tool and workpiece spindle system, lead to deviations in the workpiece contour along the length of the bore, especially at tool exit. Simulations including this effect could provide a tool to design processes which enhance shape accuracy of components. A geometrical physically-based simulation is herein developed to model the influence of system compliance on the resulting workpiece contour. Realistic tool topographies, obtained from measurements, are combined with an FE-calibrated surrogate model for process forces and with an empirical compliance model. In quasistatic experimental investigations, the spindle deflection is determined in relation to the acting normal forces by using piezoelectric force measuring elements and eddy current sensors. In grinding tests with in-process force measurement technology and followed by measurement of the resulting workpiece contours, the simulation system is validated. The process forces and the resulting characteristic shape deviations are predicted in good qualitative accordance with the experimental results.

Highlights

The results a static analogy test,on thethe linear model Whereas the other two sensors can be used to differentiate between the compliances of individual system components, the results presented in this work do not rely
The quality of the results obtained in the Geometric physically-based simulations (GPS) for process forces and shape deviations is tied to the models for the single grain forces and for the machine compliance
Some discrepancies remained between the forces predicted by the combined FEM/GPS

Summary

Introduction

In hard machining of chuck components, such as bearing rings, the manufacturers aim is a high productivity and efficiency on the one hand, while on the other hand a good surface quality as well as a high product quality in terms of shape and dimensional accuracy are required [1,3] The realisation of these demands, which partly contradict each other, is difficult to achieve with grinding processes widely used in industrial applications, such as internal plunge grinding (IPG) with vitrified-bonded grinding tools [3,4]. Workpiece bores can be machined productively in this way, and a high surface quality can be produced due to a high coverage ratio between grinding wheel and workpiece [4,5,6] This grinding process is limited in terms of maximal material removal rate. The tool-side spindle as well as the workpiece-side spindle, shift relative to each other during the grinding process, and dimensional as well as shape deviations of the workpiece are the result [6,8,9]

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