Effective planning of tool grinding processes considering process machine interactions

砂轮和机床制造商不仅为他们的客户提供硬件产品，还为他们提供完整的磨削工艺应用，以制造高质量的部件。这包括选择合适的砂轮，这些砂轮在形状、材料、结合规格和晶粒度方面都有所不同。工艺设计还包括刀具路径和工艺参数的规划，如进给速度和切割速度。避免因工艺机器相互作用而产生的形状偏差是工艺设计的重要质量标准。加工力、材料性能和工件形状的变化主要表征了工件的机械柔度。由于复杂的相互依赖关系，目前需要对不同磨料砂轮规格和工艺参数进行大量的实验来设计磨削工艺。这一问题在解释工具磨削过程时尤其相关。该项目的目的是通过开发和实施基于模型的方法来改进工具磨削过程的设计。用户将能够缩短设计新工具磨削工艺的时间，并显著减少所需的磨削试验次数。研究方法包括分析已经成功运行的磨削工艺，并将推导出的关系传输到新工艺的设计中。本项目的基础将是优先计划1180“工艺-机床交互作用”中刀具磨削研究项目的结果。在本研究项目中，特别研究了刀具磨削过程中的啮合条件对力和变形的影响。此外，已经开发了通过调整刀具路径来补偿所产生的几何误差的方法。

Grinding wheel and machine tool manufacturers offer their customers not only their hardware products but also complete applications of grinding processes for high quality components to be manufactured. This includes the selection of suitable grinding wheels, which differ in terms of shape, material and specification of bonding and grain size. The process design also includes planning of tool paths and the process parameters, e.g. feed rate and cutting speed. The avoidance of shape deviations due to process machine interactions is an important quality criterion of process design. Process forces, material properties and the changing shape of the workpiece mainly characterize the mechanical compliance of the workpiece. Due to complex interdependences, currently a large number of experiments with different abrasive grinding wheel specifications and process parameters is required for design of grinding processes. This issue is particularly relevant in the interpretation of tool grinding processes. The aim of this project is to improve the design of tool grinding processes by development and implementation of a model-based approach. The user will be enabled to shorten the time for designing a new tool grinding process and significantly reduce the number of required grinding tests. The research approach consists of analyzing grinding processes, which already ran successfully, and transmits the derived relationships to the design of new processes.Base of this project will be the results of the research project for Tool Grinding within the Priority Programme 1180 "Process-Machine Interactions". In this research project in particular the influence of the engagement conditions during tool grinding on the forces and deformations has been investigated. Furthermore, methods have been developed to compensate for the resulting geometry errors by adjusting the tool path.