Kinematic simulation of the uncut chip thickness and surface finish using a reduced set of 3D grinding wheel measurements
Kinematic simulation of the uncut chip thickness and surface finish using a reduced set of 3D grinding wheel measurements
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DOI：
10.1016/j.precisioneng.2017.02.005
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发表时间：
2017-07-01
影响因子：
3.6
通讯作者：
Bauer, Robert J.
中科院分区：
文献类型：
--
作者：
McDonald, Andrew;Mohamed, Al-Mokhtar O.;Bauer, Robert J.
本文将实验测量的砂轮全周形貌数据与磨削过程的运动仿真相结合。开发了几种新的方法，以创建结果的高保真和计算效率的模拟。首先，开发了一种新的峰值去除技术，并将其应用于有效去除原始车轮形貌数据中的错误峰值。其次，通过考虑磨削过程的运动学，找到了一种仅确定砂轮模型上的活动切削点的方法。这种新的方法能够将模拟时间从超过12小时减少到大约4秒，而不会丢失关于刃口与工件相互作用的任何信息。然后，通过使用用于开发砂轮计算机模型的相同砂轮进行磨削实验，然后测量得到的工件表面轮廓，对得到的预测的工件表面进行实验验证。模拟结果与实验结果吻合较好。最后，利用该仿真器开发了一种运动学上精确的计算最大未切削屑厚的方法，并对不同的切深、砂轮转速和进给量下的仿真结果进行了分析。(C)2017 Elsevier Inc.保留所有权利。
This paper combined experimentally-measured grinding wheel topography data taken around the entire circumference of the grinding wheel with a kinematic simulation of the grinding process. Several new methods were developed in order to create the resulting high-fidelity and computationally-efficient simulation. First a novel peak-removal technique was developed and applied to effectively remove erroneous peaks in the raw wheel topography data. Next a method was found to determine only the active cutting points on the wheel model by considering the kinematics of the grinding process. This new approach was able to reduce the simulation time from over twelve hours to about four seconds without losing any information about the cutting edge-workpiece interaction. The resulting predicted workpiece surface was then experimentally validated by carrying out a grinding experiment using the same grinding wheel used to develop the grinding wheel computer model and then measuring the resulting workpiece surface profile. Good agreement between simulated and experimental workpiece profiles was observed. Finally, the validated simulator was used to develop a kinematically-exact method to calculate the maximum uncut chip thickness and the simulation results were investigated for different depths of cut, wheel speeds and workpiece feeds. (C) 2017 Elsevier Inc. All rights reserved.