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

点击翻译按钮获取中文摘要

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.