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.

由于磨削颗粒有效接触时间长、接触条件复杂、冷却液支撑难以处理等原因，内横磨的工艺布置仍然具有挑战性。由于高切屑空间及其侵略性的形貌，电镀cBN砂轮用于加工硬化钢时获得高生产率。砂轮速度大于80 m/s的高速工况显著提高了物料的实际去除率。在1480优先计划的基础项目中，通过对不同尺度的热机械载荷及其对加工误差的影响进行建模，建立了一个由三部分组成的整体仿真框架。在中尺度上，采用有限元模型模拟单粒接触实现热-机械载荷。通过几何物理模拟，根据模拟砂轮的形貌估计出晶粒啮合度，并将其转换为工艺尺度。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-机械耦合有限元模型。在此基础上，提出了将沿孔加工误差降低50%的补偿策略。在不考虑磨削主轴和工件主轴的情况下，工件出料区存在较大的尺寸误差。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，因为所有必要的建模方面都可以为工业环境生成原型解决方案。重点研究了内横磨仿真框架中不同部件的主轴投诉和与磨粒有关的磨损的实现。由于与工业应用伙伴Schaeffler Technologies和August rggeberg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。利用整体仿真框架，保证了砂轮的优化设计和补偿nc路径的生成，以减小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和在工艺应用之前通过改变工艺边界条件引起的工艺加速。