Modelling and simulation of the NC grinding process for the controlled generation of workpiece surfaces under consideration of tool topography and wear

本研究的目的是在数控成形磨削中，考虑刀具形貌和刀具磨损，对工件形貌进行基于仿真的分析和预测。工件形貌的预测允许根据工具形貌和工艺参数值来控制功能表面特性（例如摩擦行为）的制造。对于加工自由曲面和难加工的模具工件材料，小磨削工具的磨损行为会导致形状和质量误差。高强度钢的成形工艺对汽车的轻量化越来越重要，但由于这些材料的特性，成形工具的寿命降低。通过应用热喷涂耐磨涂层，可以改善成形工具的磨损性能。为了构造涂层成形工具的表面以控制成形过程中的材料流动，仿真系统必须通过一种新的工件模型来扩展，以表示不均匀的工件材料。该扩展将用于分析电弧喷涂涂层的磨削过程。开发的仿真系统可用于优化工艺策略和工艺规划过程中的参数值，以及规划的修整过程中补偿刀具磨损。所开发的表面结构和刀具磨损模型将通过实验进行验证。

The aim of this research is a simulation-based analysis and prediction of workpiece topographies taking the tool topography and the tool wear in NC shape grinding into account. The prediction of the workpiece topographies allows for the controlled manufacturing of functional surface properties, e.g. friction behavior, depending on the tool topography and the process parameter values. With respect to the machining of free formed surfaces and the difficult-to-machine workpiece materials used for dies and molds, the wear behavior of the small grinding tools results in shape and quality errors. The forming process of high strength steel, which becomes more and more important for the weight reduction of automobiles, decreases the lifetime of the forming tools due to the properties of those materials. By applying thermally sprayed, wear resistant coatings, the wear behavior of the forming tools can be improved. In order to structure the surface of the coated forming tools for controlling the material flow during the forming process, the simulation system has to be extended by a new workpiece model for the representation of inhomogeneous workpiece materials. This extension will be used to analyze the grinding process of arc-sprayed coatings. The developed simulation system can be used to optimize process strategies and parameter values during the process planning as well as the planning of the dressing processes for compensating tool wear. The developed models for the surface structuring and the tool wear will be validated by experiments.