Effective planning of tool grinding processes considering process machine interactions

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Grinding wheel and machine tool manufacturers offer their customers not only their hardware products but also complete applications of grinding processes for high quality components to be manufactured. This includes the selection of suitable grinding wheels, which differ in terms of shape, material and specification of bonding and grain size. The process design also includes planning of tool paths and the process parameters, e.g. feed rate and cutting speed. The avoidance of shape deviations due to process machine interactions is an important quality criterion of process design. Process forces, material properties and the changing shape of the workpiece mainly characterize the mechanical compliance of the workpiece. Due to complex interdependences, currently a large number of experiments with different abrasive grinding wheel specifications and process parameters is required for design of grinding processes. This issue is particularly relevant in the interpretation of tool grinding processes. The aim of this project is to improve the design of tool grinding processes by development and implementation of a model-based approach. The user will be enabled to shorten the time for designing a new tool grinding process and significantly reduce the number of required grinding tests. The research approach consists of analyzing grinding processes, which already ran successfully, and transmits the derived relationships to the design of new processes.Base of this project will be the results of the research project for Tool Grinding within the Priority Programme 1180 "Process-Machine Interactions". In this research project in particular the influence of the engagement conditions during tool grinding on the forces and deformations has been investigated. Furthermore, methods have been developed to compensate for the resulting geometry errors by adjusting the tool path.