Modelling and simulation of internal traverse grinding - from micro-thermo-mechanical mechanisms to process models

内孔横动磨削的建模和仿真 - 从微热机械机制到工艺模型

• 批准号: 178696858
• 负责人: Professor Dr.-Ing. Dirk Biermann
• 金额: --
• 依托单位: Institut für Spanende Fertigung
• 依托单位国家: 德国
• 项目类别: Priority Programmes
• 财政年份: 2010
• 资助国家: 德国
• 起止时间: 2009-12-31 至 2017-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/178696858?language=en
• 关键词: Modelling; simulation; internal; traverse; grinding

Internal Traverse Grinding (ITG) with electroplated CBN wheels is a modern, highly efficient grinding process holding a great potential for industrial applications. This is enabled by a functionally graded geometry of the grinding wheel which is divided into a roughing as well as a finishing section. Due to this special geometry, the process is capable of generating superior surface qualities of internal work piece surfaces along with a high rate of material removal with just one single pass of the tool. This is applicable to e.g. the manufacturing of bearing rings or gears. The process is characteristic through its small contact zone between tool and work piece, thus resulting in a highly concentrated thermo-mechanical load on the latter. In turn, this can induce unwanted phase transformations of the work piece surface as well as errors in shape and dimension of the finished part.The present project aims at the development of a holistic simulation framework that is able to predict the above-mentioned errors within the manufacturing process and that supports the development of appropriate compensation strategies. This simulation framework mainly consists of three components. First, a finite-element-model on a meso-scale to capture the proximity of one single cBN grain. This is coupled to the second component, a macro-scale simulation by the third one, a statistical approximation model. This hybrid simulation approach enables the detailed thermo-mechanical investigation of the grinding process under consideration. For the desired prediction of phase transformations and thermally induced errors on both scales, appropriate material models are being developed.Apart from modelling, experiments will be carried out using an exemplary work piece geometry including three different material thicknesses. As work piece materials, hardened cold work steel 102Cr6 and case-hardened steel 16MnCr5 will be used.

电镀CBN砂轮内圆横向磨削（ITG）是一种现代高效的磨削工艺，具有很大的工业应用潜力。这是通过砂轮的功能梯度几何形状实现的，该功能梯度几何形状被分为粗加工部分和精加工部分。由于这种特殊的几何形状，该工艺能够产生上级表面质量的内部工件表面沿着与高速率的材料去除，只有一个单程的工具。这适用于例如轴承环或齿轮的制造。该工艺的特点是刀具和工件之间的接触区域小，从而导致后者上的高度集中的热机械载荷。反过来，这可能会导致不必要的工件表面的相变以及成品零件的形状和尺寸的错误。本项目旨在开发一个整体的仿真框架，能够预测上述制造过程中的错误，并支持开发适当的补偿策略。该仿真框架主要由三部分组成。首先，在中尺度上的有限元模型来捕获单个cBN颗粒的接近度。这是耦合到第二个组成部分，一个宏观规模的模拟由第三个，一个统计近似模型。这种混合模拟方法使详细的热机械研究的磨削过程中考虑。为了对两种尺度上的相变和热致误差进行预期的预测，正在开发适当的材料模型。除了建模之外，还将使用包括三种不同材料厚度的示例性工件几何形状进行实验。作为工件材料，将使用硬化冷作钢102Cr6和表面硬化钢16MnCr5。