Modelling and simulation of the NC grinding process for the controlled generation of workpiece surfaces under consideration of tool topography and wear

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The aim of this research is a simulation-based analysis and prediction of workpiece topographies taking the tool topography and the tool wear in NC shape grinding into account. The prediction of the workpiece topographies allows for the controlled manufacturing of functional surface properties, e.g. friction behavior, depending on the tool topography and the process parameter values. With respect to the machining of free formed surfaces and the difficult-to-machine workpiece materials used for dies and molds, the wear behavior of the small grinding tools results in shape and quality errors. The forming process of high strength steel, which becomes more and more important for the weight reduction of automobiles, decreases the lifetime of the forming tools due to the properties of those materials. By applying thermally sprayed, wear resistant coatings, the wear behavior of the forming tools can be improved. In order to structure the surface of the coated forming tools for controlling the material flow during the forming process, the simulation system has to be extended by a new workpiece model for the representation of inhomogeneous workpiece materials. This extension will be used to analyze the grinding process of arc-sprayed coatings. The developed simulation system can be used to optimize process strategies and parameter values during the process planning as well as the planning of the dressing processes for compensating tool wear. The developed models for the surface structuring and the tool wear will be validated by experiments.