Distortion containment during grinding by computer-assisted identification of compensation-strategies

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Due to the removal of material layers with residual stresses and the induction of residual stresses by high thermal and mechanical loads during the grinding process bending potentials are generated in the surface layer. These bending potentials may lead to shape and dimensional changes. To assure the required quality, with regard to shape and dimension, especially of thin-walled workpieces, which react very sensitive on changes of the bending potential, straightening process are needed. Using controlled straightening processes the implementation of defined compensation potentials is possible. Currently experience-based and manually carried out straightening-processes are primarily still in use in industrial practice. The models and simulations for the prediction of shape and dimension-accuracy in grind-hardening-processes, which the applicants developed and validated together, include the potential to be transferred to the conventional grinding processes. In the proposed research project controlled compensation-strategies will be simulated and experimentally validated. By high thermal influences during the grinding process, reproducible and significant shape changes of thin workpieces can be achieved. Furthermore the effect of controlled thermal and mechanical straightening-processes and their compensation-potential can be understood purposefully. Using the developed simulation the combination of different straightening-processes and -strategies will be designed and finally implemented in the experimental environment.