Simulation-based design of high performance internal grinding processes

基于仿真的高性能内圆磨削工艺设计

• 批准号: 403857741
• 负责人: Professor Dr.-Ing. Dirk Biermann
• 金额: --
• 依托单位: Institut für Spanende Fertigung
• 依托单位国家: 德国
• 项目类别: Research Grants (Transfer Project)
• 财政年份: 2019
• 资助国家: 德国
• 起止时间: 2018-12-31 至 2021-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/403857741?language=en
• 关键词: Simulation; based; design; performance; internal

Due to the long effective contact time of the grinding grains, complex contact conditions and the difficult-to-handle coolant support, the process layout of internal traverse grinding is still challenging. Because of the high chip space and its aggressive topography, electroplated cBN grinding wheels are used to achieve high productivity when machining hardened steels. High-speed-conditions with grinding wheel velocities higher than 80 m/s significantly raise the realised material removal rate. In the fundamental project in the context of the Priority Programme 1480, a holistic simulation framework with three components was established by modelling the thermo-mechanical loads and their effects of the machining errors in different scales. At the mesoscale, a finite element model was used to model the single grain engagement achieving the thermo-mechanical loads. Due to a geometric-physical simulation the grain engagements were estimated according to the topography of the modelled grinding wheel and transformed to the process scale. On this scale, a thermomechanical coupled finite element model – considering the clamping effect, the thermal induced machining error as well as the material removal – was developed. Based on this, compensation strategies were achieved reducing the machining error along the bore by 50 percent. Without regarding the spindle complaints of grinding and workpiece spindle, a relatively high dimension error remains at the discharge area of the workpiece. The objective of the presented knowledge transfer project is the enhancement of the established holistic simulation framework due to all necessary modelling aspects to generate a prototypical solution for the industrial environment. In the focus are the implementation of the spindle complaints and the grain related wear in the different components of the simulation framework of internal traverse grinding. Due to the close cooperation with industrial application partners, Schaeffler Technologies and August Rüggeberg, the relevant industrials requirements to a simulation based layout of grinding tools and processes are defined. The usage of the holistic simulation framework secures the optimal design of the grinding wheels as well as the generation of the compensation NC-path to reduce the dimensional and form machining errors. Therefore, the application suitability test can be proven to conduct simulation based wear investigations and process ramp-ups provoked by changing the process boundary conditions prior to the process application.

由于磨粒的有效接触时间长，接触条件复杂，冷却液支承难于处理，内横磨的工艺布局仍然具有挑战性。由于高的切屑空间和侵蚀性的表面形貌，电镀CBN砂轮被用来在加工淬火钢时获得高生产率。在砂轮转速高于80m/S的高速条件下，显著提高了实现的材料去除速度。在优先方案1480的基础项目中，通过对不同尺度的机械加工误差的热机械载荷及其影响进行建模，建立了一个由三个组成部分组成的整体模拟框架。在细观尺度上，用有限元模型模拟实现热机械载荷的单颗粒啮合。通过几何物理模拟，根据所建模型砂轮的表面形貌对磨粒啮合进行了估算，并将其转化为工艺尺度。在此基础上，建立了考虑夹紧效应、热致加工误差和材料去除的热力耦合有限元模型。在此基础上，提出了减小内孔加工误差50%的补偿策略。在不考虑磨削和工件主轴的主轴抱怨的情况下，在工件的卸料区域仍然存在相对较高的尺寸误差。本知识转让项目的目标是加强已建立的整体模拟框架，这是由于所有必要的建模方面，以便为工业环境产生一个原型解决方案。重点是实现了主轴的投诉和与磨粒磨损相关的不同部件的内横移磨削仿真框架。由于与工业应用合作伙伴舍弗勒技术公司和奥古斯特·吕格贝格公司密切合作，定义了基于模拟的磨具和工艺布局的相关工业要求。整体仿真框架的使用确保了砂轮的优化设计以及补偿NC轨迹的生成，以减少尺寸和形状加工误差。因此，可以证明应用适宜性测试可以进行基于模拟的磨损调查和在工艺应用之前改变工艺边界条件所引起的工艺提升。