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Numerical modeling of the thermo-mechanical contact in grinding

磨削中热机械接触的数值模拟

基本信息

批准号：
394846749
负责人：
Professor Dr.-Ing. Thomas Bergs, since 7/2019
金额：
--
依托单位：
Werkzeugmaschinenlabor - WZL
依托单位国家：
德国
项目类别：
Research Grants
财政年份：
2017
资助国家：
德国
起止时间：
2016-12-31 至 2020-12-31
项目状态：
已结题

来源：
https://gepris.dfg.de/gepris/projekt/394846749?language=en
关键词：
Numerical modeling thermo mechanical contact

项目摘要

During the grinding process mechanical and thermal loads occur which have a significant influence on the process result. They can lead to changes in the material structure and thus the residual stress state in the external zone of the workpiece, which can adversely affect the subsequent use behavior of the components. In addition, the grinding wheel wear is decisively determined by the forces acting on the abrasive grains. In the machine tool, the process forces during processing affect the elastic displacement of the machine structure. Furthermore, the heat flows also affect the thermo-elastic displacement of the machine structure. Both displacements result in variations in the generated workpiece geometry. Accordingly, in the past, a variety of studies on the analysis of the thermo-mechanical processes in the interaction of grains and the workpiece have been conducted. These can be divided into experimental and simulative studies based on numerical models. Compared to experimental studies in numerical studies the processes and state variables can be determined in higher spatial and temporal resolutions and in particular at each position. In addition, the numerical models allow factors independently to vary and to analyze even if this is not possible in reality. However, a sufficiently accurate representation of reality in the numerical models is a major challenge. Furthermore, experimental studies are also needed in numerical models in order to verify the developed models. Existing numerical models on thermo-mechanical contact of abrasive grains and workpiece are not close enough to reality. In particular the influences of grain shape on the contact conditions are not sufficiently accurate. Therefore, the overall objective of the project is to develop a numerical model for the grain-workpiece interaction in the grinding process, which includes the thermo-mechanical contact conditions sufficiently accurate in order to explore the effect interactions of the contact between grain and workpiece. Furthermore, the influences of the process parameters, in particular of grain shape, on the thermo-mechanical stress should be included. For this purpose, a thermo-mechanical finite element model of the single grain engagement for determining the process forces and heat flows will be developed. The model is verified by experimental single grain cutting tests using the forces and temperatures that occur. After verification of the model, the influence of the process parameters, in particular the grain shape, on the thermo-mechanical loads will be determined systematically and the effect relationships will be explained.

在研磨过程中，机械和热负荷会对加工结果产生重大影响。它们可能导致材料结构的变化，从而导致工件外部区域的残余应力状态发生变化，这可能对部件的后续使用行为产生不利影响。此外，砂轮磨损由作用在磨粒上的力决定。在机床中，加工过程中的过程力影响机床结构的弹性位移。此外，热流还影响机器结构的热弹性位移。这两种位移都会导致生成的工件几何形状发生变化。因此，在过去，在晶粒和工件的相互作用的热机械过程的分析进行了各种研究。这些研究可以分为基于数值模型的实验研究和模拟研究。与数值研究中的实验研究相比，可以以更高的空间和时间分辨率确定过程和状态变量，特别是在每个位置。此外，数值模型允许因素独立地变化和分析，即使这在现实中是不可能的。然而，在数值模型中充分准确地表示现实是一个重大挑战。此外，还需要在数值模式中进行实验研究，以验证所开发的模型。现有的磨粒与工件热机械接触的数值模型与实际情况不够接近。特别是晶粒形状对接触条件的影响不够精确。因此，该项目的总体目标是开发磨削过程中磨粒-工件相互作用的数值模型，该模型包括足够精确的热-机械接触条件，以探索磨粒和工件之间接触的相互作用。此外，还应考虑工艺参数，特别是晶粒形状对热机械应力的影响。为此，将开发用于确定过程力和热流的单个晶粒接合的热机械有限元模型。该模型是通过实验验证单粒切削试验中使用的力和温度发生。在验证模型之后，将系统地确定工艺参数，特别是晶粒形状对热机械载荷的影响，并解释影响关系。