Optimising the grinding wheel design for flute grinding processes utilising numerical analysis of the complex contact conditions
Optimising the grinding wheel design for flute grinding processes utilising numerical analysis of the complex contact conditions
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DOI：
10.36897/jme/119641
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发表时间：
2020-09
影响因子：
--
通讯作者：
E. Uhlmann;B. Gülzow;A. Muthulingam
中科院分区：
文献类型：
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作者：
E. Uhlmann;B. Gülzow;A. Muthulingam
资源效率在生产的各个方面都越来越重要。因此，切削刀具面临着生产率和质量方面的高要求。考虑到刀具制造中的各种磨削操作，排屑槽磨削是最重要的工艺步骤，因为它定义了外周切削刃和前刀面。因此，它对例如铣削工具的加工行为具有实质性影响。对于螺旋槽，多轴磨削过程中砂轮与刀具毛坯之间的复杂接触条件特别难以确定。由于缺乏对这些接触条件的了解，通常用于长笛磨削的砂轮不能完全满足实际工艺要求。为了优化砂轮的设计，开发了一个数值模型。在此基础上，实现了一个仿真工具，分析了复杂的接触条件，在长笛磨削过程中取决于工艺参数和工具/工件的几何形状。利用该模型分析了不同磨削参数对有效接触长度、比材料去除率和等效切屑厚度的影响。生成的结果用于开发新的优化工具概念，以实现更高效的长笛磨削工艺。
Resource efficiency is gaining relevance in every aspect of production. Hence, cutting tools are exposed to high demands regarding productivity and quality. Considering the various grinding operations in tool manufacturing, flute grinding is the most significant process step as it defines the peripheral cutting edge and the rake face. Therefore, it has a substantial influence on the machining behaviour of, for example, milling tools. When it comes to helical flutes, the complex contact conditions between grinding wheel and tool blank during the multiaxial grinding process are particularly difficult to determine. Due to the lack of knowledge about those contact conditions, the grinding wheels typically used for flute grinding cannot wholly meet the actual process requirements. In order to optimise the design of the grinding wheels, a numerical model was developed. Based on that, a simulation tool was implemented to analyse the complex contact conditions during flute grinding depending on the process parameters and tool/workpiece geometry. The influence of different grinding parameters on the effective contact length, the specific material removal rate and the equivalent chip thickness was evaluated by employing the computer-based model. The generated results were then used to develop a new optimised tool concept for a more efficient flute grinding process.