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.

由于磨粒有效接触时间长、接触条件复杂、冷却液支撑难处理等原因，内圆横向磨削的工艺布置仍具有挑战性。由于高切屑间距及其侵蚀性形貌，电镀cBN砂轮在加工淬硬钢时可用于实现高生产率。砂轮速度高于80 m/s的高速条件显著提高了实现的材料去除率。在优先计划1480背景下的基础项目中，通过模拟热机械负荷及其在不同尺度上对加工误差的影响，建立了一个由三个组成部分组成的整体模拟框架。在细观尺度下，采用有限元模型模拟了单颗粒啮合过程，实现了热机械载荷。由于几何物理模拟的颗粒啮合估计，根据地形的建模砂轮和转换到工艺规模。在此基础上，建立了考虑夹紧效应、热加工误差和材料去除的热力耦合有限元模型。在此基础上，提出了补偿策略，使内孔加工误差沿着减小50%。在不考虑磨削和工件主轴的主轴投诉的情况下，在工件的排出区域处仍然存在相对高的尺寸误差。所提出的知识转移项目的目标是增强已建立的整体仿真框架，由于所有必要的建模方面，以产生一个原型的解决方案，为工业环境。重点是实现主轴投诉和晶粒相关的磨损，在不同的组成部分的仿真框架内的横向磨削。通过与工业应用合作伙伴舍弗勒技术公司和August Rüggeberg的密切合作，定义了基于仿真的磨削工具和工艺布局的相关工业要求。整体仿真框架的使用保证了砂轮的优化设计以及补偿NC路径的生成，以减少尺寸和形状加工误差。因此，可以证明应用适用性测试可以进行基于模拟的磨损调查，并在过程应用之前通过改变过程边界条件引起过程斜升。