Knowledge based process layout in grinding taking the surface and subsurface impact on the workpiece into account

由于工件的预加工、热处理引起的变形(特别是在长线性齿廓的情况下)或磨削过程本身的运动学(例如，磨削渐开线齿廓)引起的不同的余量可能导致在第一次粗加工行程期间局部切割深度较高，从而导致局部热机械载荷较高。这导致了相对谨慎、不经济的工艺，以便将(局部)发生热材料损坏的风险降至最低。现有的工艺模型没有充分考虑到不同的库存量，并且仅限于对地面的评价。目前还没有关于这些基于模型的方法的系统研究，这些方法与表面和亚表面对工件的冲击有关。根据前期工作显示，该项目的中心科学挑战是找到取决于比功率Pc“和接触时间∆t的表面和亚表面深度效应之间的函数关系，并在粗加工和精加工的划分中考虑这一点。此外，还需要探讨如何在基于模型的办法内处理当地不同的津贴。在此基础上，将制定一种以知识为基础的方法，考虑到津贴差异。这将有助于将工艺设计中的安全裕度降至最低，从而实现尽可能优化时间的磨削工艺，从而经济地接近特定材料的工艺极限。

Varying stock allowances, caused by premachining of workpieces, by distortions due to heat treatment (especially in case of long linear profiles) or by the kinematics of the grinding process itself (e.g. grinding of involute profiles) can lead to high local depth of cuts during the first roughing strokes and thus to high local thermomechanical loads. This results in comparatively cautious, uneconomical processes in order to minimise the risk of (locally) occurring thermal material damage. Existing process models do not sufficiently consider varying stock allowances and are limited to the evaluation of the ground surface. Systematic studies on these model-based approaches in connection with the characterisation of the surface and subsurface impact on the workpiece are not yet available. According to the preliminary work shown, the central scientific challenge of this project is to find a functional correlation of the surface and subsurface depth effect depending on the specific power Pc" and the contact time ∆t and to take this into account in the partitioning of roughing and finishing. Besides the handling of locally varying allowances within model-based approaches still needs to be explored. Based on this, a knowledge-based approach is to be developed that takes allowance differences into account. This should help to reduce safety margins in the process design to a minimum and thus lead to a grinding process that is as time-optimal as possible and thus economical, close to the material-specific process limit.