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

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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.